Models: 8042, 10042, 10054 S/N 13198 thru 19987 and 0160002332 thru 0160029592 OH2462 SERVICE MANUAL 8990396 C Printed in U.S.A.
SECTION CONTENTS Section Subject Section 1 Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 Page 1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Owners/Operators Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Training Mechanics as Operators . . . . . . . . . .
Section Subject Page Section 4 Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.1 Operator’s Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Open Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section Subject Page Section 7B Engine: Cummins QSB4.5T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.1 7B.1 7B.2 7B.3 7B.4 7B.5 7B.6 7B.7 7B.8 7B.9 7B.10 7B.11 7B.12 7B.13 7B.14 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Serial Number . . .
Section Subject Page Section 10 Stabil-TRAK™ System and Boom Interlock System . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10 10.11 10.12 10.13 Section 11 Index Stabil-TRAK™ System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Extend Interlock System Component Terminology (10054 Only) . . . . . . . . . . . . Stabil-TRAK™ Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1 Safety Practices Contents PARAGRAPH 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 TITLE Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Owners/Operators Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Training Mechanics as Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Practices 1.1 INTRODUCTION JLG Industries, Inc. (hereafter, JLG) products meet all applicable industry safety standards. JLG actively promotes safe practices in the use and maintenance of its products through training programs, instructional manuals and the pro-active efforts of all employees involved in engineering, design, manufacture, marketing and service.
Safety Practices 1.3 TRAINING MECHANICS AS OPERATORS Because it is necessary to move the vehicle to service or maintain the vehicle, it is necessary that all mechanics are OSHA trained and certified as operators. A mechanic trained in the proper operation of the vehicle can better determine whether all functions are operating correctly. At the time of original purchase, the purchaser of this vehicle was instructed by the seller on its proper use.
Safety Practices 1.4.2 Hazard Statements 1.5 ACCIDENT PREVENTION TAGS Signal words and messages are used in conjunction with the safety alert symbol to create hazard statements. These hazard statements convey important information about SAFETY. Four types of hazard statements are used within this manual. Each statement indicates the existence and degree of relative risk of the hazard described within the statement that follows a signal word.
Safety Practices 1.6 SAFETY INSTRUCTIONS Following are general safety statements to consider before performing maintenance procedures on a vehicle. Additional statements related to specific tasks and procedures are located throughout this manual and are listed prior to any work instructions to provide safety information before the potential of a hazard occurs. For all safety messages, carefully read, understand and follow the instructions before proceeding. 1.6.
Safety Practices 1.6.3 General Hazards SOLVENTS: Only use approved solvents, and solvents that are known to be safe for use. HOUSEKEEPING: Keep the work area and operator’s cab clean, and remove all hazards (debris, oil, tools, etc.). FIRST AID: Immediately clean, dress and report all injuries (cuts, abrasions, burns, etc.), no matter how minor the injury may seem. Know the location of a First Aid Kit, and know how to use it.
Safety Practices This Page Intentionally Left Blank Model 8042, 10042, 10054 Legacy Rev. 10/03 1.
Safety Practices 1.8 HAZARD/EMERGENCY INFORMATION DECAL LOCATIONS Locations of vehicle hazard and other emergency information decals are shown on this page and the following pages. As part of routine maintenance, check that ALL hazard and emergency information decals on the vehicle are present and readable. Keep all decals clean.
Safety Practices 9 12 13 8 10 11 MH4180 8. 9. 10. 11. 12. 13. Model 8042, 10042, 10054 Legacy 4110184 Moving Parts Warning (2) 4110172 Explosive Gases Warning (1) 4110389 Carrying Personnel Warning (1) 4107442 Boom Extend Letters (1) 4105262 Boom Angle Indicator (1) 4109791 Emergency Exit - Enclosed Cab Only (1) Rev. 10/03 1.
Safety Practices Model 10042 (S/N 13198 thru 19030) 5 3 7 1. Read operator's manual before operating. 3. Allow no riders. 2. Fasten seat belt. 4. Use a compliant work platform to lift or lower personnel. DANGER AVOID CRUSHING if vehicle tips. Jumping can result in death or serious injury. 2 6 DO NOT JUMP. Brace yourself. Stay in cab. Keep seat belt on.
Safety Practices 10 13 14 9 11 12 MH4190 9. 10. 11. 12. 13. 14. Model 8042, 10042, 10054 Legacy 4110184 Moving Parts Warning (2) 4110172 Explosive Gases Warning (1) 4110389 Carrying Personnel Warning (1) 4107442 Boom Extend Letters (1) 4105262 Boom Angle Indicator (1) 4109791 Emergency Exit - Enclosed Cab Only (1) Rev. 10/03 1.
Safety Practices Model 10054 (S/N 13198 thru 19079) 3 5 7 6 1. Read operator's manual before operating. 3. Allow no riders. 2. Fasten seat belt. 4. Use a compliant work platform to lift or lower personnel. DANGER AVOID CRUSHING if vehicle tips. Jumping can result in death or serious injury. 2 4 WARNING 1 DO NOT JUMP. Brace yourself. Stay in cab. Keep seat belt on.
Safety Practices 10 13 14 9 11 12 MH4190 9. 10. 11. 12. 13. 14. Model 8042, 10042, 10054 Legacy 4110184 Moving Parts Warning (2) 4110172 Explosive Gases Warning (1) 4110389 Carrying Personnel Warning (1) 4107442 Boom Extend Letters (1) 4105262 Boom Angle Indicator (1) 4109791 Emergency Exit - Enclosed Cab Only (1) Rev. 10/03 1.
Safety Practices Model 8042 (S/N 18991 & After) 5 3 7 6 2 1. Read operator's manual before operating. 3. Allow no riders. 2. Fasten seat belt. 4. Use a compliant work platform to lift or lower personnel. DANGER AVOID CRUSHING if vehicle tips. Jumping can result in death or serious injury. WARNING DO NOT JUMP. Brace yourself. Stay in cab. Keep seat belt on. 4 AVOID CRUSHING, falling off vehicle can cause death or serious injury 1 OH17431 Allow no riders 1. 2. 3. 4. 5. 6. 7. 1.
Safety Practices 14 9 12 8 10 8. 9. 10. 11. 12. 13. 14. Model 8042, 10042, 10054 Legacy 13 OH2894 11 4110184 Moving Parts Warning (2) 4110172 Explosive Gases Warning (1) 4110389 Carrying Personnel Warning (1) 4107442 Boom Extend Letters (1) 4105262 Boom Angle Indicator (1) 4109791 Emergency Exit - Enclosed Cab Only (1) 4110460 Ether Starting Warning (2) Rev. 10/03 1.
Safety Practices Model 10042 (S/N 19031 & After) 5 3 7 2 1. Read operator's manual before operating. 3. Allow no riders. 2. Fasten seat belt. 4. Use a compliant work platform to lift or lower personnel. DANGER AVOID CRUSHING if vehicle tips. Jumping can result in death or serious injury. WARNING DO NOT JUMP. Brace yourself. Stay in cab. Keep seat belt on.
Safety Practices 15 10 9 13 11 14 12 OH1754 9. 10. 11. 12. 13. 14. 15. Model 8042, 10042, 10054 Legacy 4110184 Moving Parts Warning (2) 4110172 Explosive Gases Warning (1) 4110389 Carrying Personnel Warning (1) 4107442 Boom Extend Letters (1) 4105262 Boom Angle Indicator (1) 4109791 Emergency Exit - Enclosed Cab Only (1) 4110460 Ether Starting Warning (2) Rev. 10/03 1.
Safety Practices Model 10054 (S/N 19080 & After) 5 3 7 2 1. Read operator's manual before operating. 3. Allow no riders. 2. Fasten seat belt. 4. Use a compliant work platform to lift or lower personnel. DANGER AVOID CRUSHING if vehicle tips. Jumping can result in death or serious injury. WARNING DO NOT JUMP. Brace yourself. Stay in cab. Keep seat belt on.
Safety Practices 15 10 9 13 11 14 12 OH1754 9. 10. 11. 12. 13. 14. 15. Model 8042, 10042, 10054 Legacy 4110184 Moving Parts Warning (2) 4110172 Explosive Gases Warning (1) 4110389 Carrying Personnel Warning (1) 4107442 Boom Extend Letters (1) 4105262 Boom Angle Indicator (1) 4109791 Emergency Exit - Enclosed Cab Only (1) 4110460 Ether Starting Warning (2) Rev. 10/03 1.
Safety Practices This Page Intentionally Left Blank 1.20 Model 8042, 10042, 10054 Legacy Rev.
Section 2 General Information and Specifications Contents PARAGRAPH 2.1 2.2 2.3 2.4 2.5 TITLE 8042, 10042, 10054 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.1 Service Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.2 The Owners/Operators Manual. . . . . . . . . . . . . . . . . . . . . . . . .
General Information and Specifications 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.2 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.1 Axle (Differential Housing). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.2 Axle Wheel Ends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.3 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information and Specifications 2.1 8042, 10042, 10054 COMPONENT TERMINOLOGY To understand the safety, operation and maintenance information presented in this manual, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies on this vehicle. The following illustration identifies the components that are referred to throughout this manual.
General Information and Specifications 2.2 2.2.1 INTRODUCTION The vehicle serial number plate (1) is located at the front of the vehicle, on the frame sway cylinder upright. Service Methods Appropriate service methods and proper repair procedures are essential for safe, reliable operation of this vehicle and the safety of the individual doing the work. This Service Manual provides general direction for accomplishing service and repair work with tested, effective techniques.
General Information and Specifications 2.3 2.3.1 TORQUES 3. Apply clean petroleum based oil to the male thread. 4. Place the flat surface of the female connector (2) in full contact with the o-ring (4) in the male connector. Fasteners All fasteners (nuts, bolts, washers, etc.) are equal to SAE Grade 5 (PC8.8) and are plated, unless otherwise specified. 2.3.2 Bolts and Nuts Unless otherwise specified, the following values apply for Grade 5 (PC8.8) nuts and bolts: Size Torque Size 5.
General Information and Specifications b. Straight O-Ring Boss Fittings To O-Ring Boss Ports c. Adjustable (Angle) O-Ring Boss Fittings To O-Ring Boss Ports Improper assembly of this joint will result in leaking joints. Under tightening of the fitting will result in the fitting loosening during normal operation and the joint leaking. Damaging the o-ring during assembly will result in immediate joint leakage. Improper assembly of this joint will result in a leaking joint.
General Information and Specifications d. Pipe Fittings to Pipe Ports Improper assembly of this joint will result in a leaking joint and possible damage to the port. 1. Inspect the port and fitting to insure that there are no burrs, nicks, or foreign material. If any thread damage is found the part must not be used. Clean off any foreign material. 2. Apply sealant/lubricant to male pipe thread. If Teflon tape is used it should be wrapped 1.
General Information and Specifications 2.3.4 SAE 37° Flare Hydraulic Fittings a. Assembly Procedure Follow these steps when tightening hose ends, tube ends and fitting swivel ends onto fitting male end connections Improper assembly of this type of joint will result in leaking joints. Over tightening can result in cracking of the female swivel seat or deformation of the male fitting tapered seat. Under tightening will result in the joint loosening during normal usage.
General Information and Specifications 2.4 METRIC CONVERSION FACTORS When this is known Multiply by To find VOLUME 2.4.1 Approximate American to Metric Conversions When this is known Multiply by To find TORQUE (moment of force) Pound/feet (lb-ft) 1.356 Newton meters (Nm) Pound/inches (lb-in) 0.113 Newton meters (Nm) POWER Horsepower (hp) 745.7 Watts SPEED (velocity) Miles per hour (mph) 1.
General Information and Specifications 2.4.
General Information and Specifications This Page Intentionally Left Blank Model 8042, 10042, 10054 Legacy Rev. 10/03 2.
General Information and Specifications 2.5 2.5.1 SPECIFICATIONS Vehicle Dimensions a. Model 8042 (With Standard 12-Ply, 13.00-24 Tires) Description (A) Length (Without Attachment) 225.25" (5.721 mm) (B) Width 98.25" (2.495 mm) (C) Height (Boom Lowered) 99.4" (2.525 mm) (D) Wheelbase 119.5" (3.035 mm) (E) Tread Center 84.0" (2.134 mm) (F) Ground Clearance 17.25" (438 mm) (G) Turning Radius, Curb to Curb 156.0" (3.962 mm) (H) Turning Radius, Clearance 158.3" (4.
General Information and Specifications I UM V J N 0.0 Q P C S R F 24.0" K T L O D A B E H G MH07802 Model 8042, 10042, 10054 Legacy Rev. 10/03 2.
General Information and Specifications b. Model 10042 (With Standard 12-ply, 17.5-25 Tires) Description (A) Length (Without Attachment) 225.25" (5.721 mm) (B) Width (Outriggers UP) 102.0" (2.591 mm) (C) Width (Outriggers DOWN) 156.75" (3.981 mm) (D) Height (Boom Lowered) 100.1" (2.542 mm) (E) Wheelbase 119.5" (3.035 mm) (F) Tread Center 84.25" (2.140 mm) (G) Ground Clearance 18.0" (457 mm) (H) Turning Radius, Curb to Curb 170.0" (4.318 mm) (I) Turning Radius, Clearance 182.0" (4.
General Information and Specifications J WN X K O 0.0 R Q D U S T G 24.0" L V M P E A C B F I H MH07902 Model 8042, 10042, 10054 Legacy Rev. 10/03 2.
General Information and Specifications c. Model 10054 (With Standard 12-Ply, 17.5-25 Tires) Description (A) Length (Without Attachment) 239.0" (6.071 mm) (B) Width (Outriggers UP) 102.0" (2.591 mm) (C) Width (Outriggers DOWN) 156.75" (3.981 mm) (D) Height (Boom Lowered) 101.0" (2.565 mm) (E) Wheelbase 119.5" (3.035 mm) (F) Tread Center 84.25" (2.140 mm) (G) Ground Clearance 18.0" (457 mm) (H) Turning Radius, Curb to Curb 170.0" (4.318 mm) (I) Turning Radius, Clearance 182.0" (4.
General Information and Specifications W N J X K O Q 0.0 R U D S G E A 24.0" L M T X P CBF I H MH08002 Model 8042, 10042, 10054 Legacy Rev. 10/03 2.
General Information and Specifications 2.5.2 Vehicle Weights Description 8042 10042 10054 Curb Weight (Open Cab) 25,356 lb (11.505 kg) 26,323 lb (11.940 kg) 27,323 lb (12.393 kg) Curb Weight (Enclosed Cab) 25,565 lb (11.596 kg) 26,523 lb (11.940 kg) 27,523 lb (12.523 kg) Operating Load 8,000 lb (3.629 kg) 10,000 lb (4.536 kg) 10,000 lb (4.536 kg) Working Weight (Machine working weight is figured with 48" [1.219 mm] carriage, two 48" (1.
General Information and Specifications 2.5.3 Attachment Weights Note: Attachments listed below are for all models, except where specified.
General Information and Specifications 2.5.4 Performance Specifications Note: Performance criteria is based on full throttle engine speed unless otherwise specified or not applicable. Travel Speed (Standard Tires, No Load) All Models First Gear 0-3.5 mph (0-5,6 km/hr) Second Gear 0-6 mph (0-9,7 km/hr) Third Gear 0-14 mph (0-21,7 km/hr) Fourth Gear 0-20 mph (0-32,2 km/hr) 2.5.
General Information and Specifications 2.5.6 Electrical System Battery: Type, Rating 12 VDC, Negative (-) Ground, Maintenance Free Quantity (Cummins 4BT3.9 & 4BTA3.9 Engine) 1 Quantity (Cummins QSB4.5T Engine) 2 Reserve Capacity (Cummins 4BT3.9 & 4BTA3.9 Engine) 1,000 Cold Cranking Amps @ 0° F (-18° C) Reserve Capacity (Cummins QSB4.5T Engine) 850 Cold Cranking Amps (Each Battery) Group/Series (Cummins 4BT3.9 & 4BTA3.9 Engine) C31XH Group/Series (Cummins QSB4.
General Information and Specifications Relays: Neutral Start Relay 12 Volt Park Brake Disengage Relay 12 Volt Optional Headlight Switch Relay 12 Volt Back-up Relay 12 Volt Light Switch Relay 12 Volt Stabil-TRAK Lock 12 Volt Boom Switch 12 Volt Park Brake Interlock (10054 Only) 12 Volt Boom Extend Interlock (10054 Only) 12 Volt Outrigger Lockout (10054 Only) (S/N 13198 thru 17984) 12 Volt Stabil-TRAK Interlock (10054 Only) 12 Volt Stabil-TRAK Lock Up (10054 Only) 12 Volt Boom Extend
General Information and Specifications 2.5.7 Engine Performance Specifications Note: Engine manufacturer's maximum “high idle” setting is lockwired and sealed. DO NOT disturb this setting Model 8042 (S/N 13198 thru 18990), 10042 (S/N 13198 thru 19030) & 10054 (S/N 13198 thru 19079). Description 8042 10042 10054 Engine Make/Model Cummins 4BT3.9 Turbo Cummins 4BTA3.9 Aftercooled Turbo Cummins 4BTA3.
General Information and Specifications 2.5.8 Fluid and Lubricant Capacities Engine Crankcase Oil: Capacity with Filter Change 11.0 qt (10,4 liters) Cummins 4BT3.9 & 4BTA3.9 Engine 10.5 qt (10 liters) Cummins QSB4.5T Engine Filter Capacity 1.0 qt (0,9 liters) Cummins 4BT3.9 & 4BTA3.9 Engine 0.85 qt (0,80 liters) Cummins QSB4.5T Engine Oil Type SAE 15W40 Diesel Engine Oil (Refer to Section 2.6.6, “Engine.”) Fuel Tank: Total Capacity 37.0 gal (140 liters) Usable Capacity 35.
General Information and Specifications Axle (Wheel Ends): Capacity Front Axle - 1.7 qt (1,6 liters) Rear Axle - 1.3 qt (1,2 liters) Type of Oil Universal Tractor Fluid. Refer to Section 2.6.1, “Axle (Differential Housing).” Hydraulic System: System Capacity (8042) 57.5 gal (218 liters) System Capacity (10042 and 10054) 64 gal (242 liters) Reservoir Capacity 32.2 gal (122 liters) Type of Oil ISO Grade 46 Anti-Wear Hydraulic Oil (Refer to Section 2.6.5, “Hydraulic System.”) 2.5.
General Information and Specifications 2.5.11 Tires Description 8042 10042 10054 Wheel Lug Nut Torque 430-470 lb-ft (583-637 Nm) 430-470 lb-ft (583-637 Nm) 430-470 lb-ft (583-637 Nm) Standard Tire Size 13.00-24, 12-ply 17.5-25, 12-ply 17.5-25, 12-ply Standard Tire Air Pressure (Minimum) 70 psi (483 kPa) 60 psi (414 kPa) 60 psi (414 kPa) Optional Tires 15.5-25, 12-ply 70 psi (483 kPa) — — 15.5-25, 12-ply Rock 70 psi (483 kPa) — — 15.5R25 One Star Radial 75 psi (517 kPa) — — 17.
General Information and Specifications 2.5.12 Miscellaneous Specifications (All Models) Steering Wheel: Maximum Number of Turns, Lock to Lock 3.75 turns Minimum Number of Turns, Lock to Lock 3.00 turns Breakout Force: Utility bucket (calculated at -24° lip angle, max. moment) 2.5.13 Tamper Proofing 24,500 lb (11.113 kg) 2.5.14 Fork Ratings A tamper-proof means is in place on the following adjustable components prior to machine shipment.
General Information and Specifications 2.6 FLUIDS, LUBRICANTS AND CAPACITIES 2.6.1 Axle (Differential Housing) a. Axle Differential Housing Lubricants In general, use a Universal Tractor Fluid that meets the following specifications: Nominal viscosity at 104° F (40° C)....................... 55 cSt Minimum viscosity at 212° F (100° C) .................. 9.1 cSt Pour point (Maximum) ..............................-32° F (-36° C) Flash point (Minimum) ............................
General Information and Specifications 2.6.4 Lubrication Points (Grease Fittings) SAE 10W MOTOR OIL • CASTROL/DEUSOL CRD a. Lubricants When lubricating any component via the grease fittings, use multi-purpose, lithium-based grease with EP additives that meets NLGI Grade-2 specifications.
General Information and Specifications 3. Fuel: In general, use #2 diesel fuel. From November 15 to March 15, when operating in cooler climates where ambient (outside air) temperatures are consistently at or below 32° F (0° C), use a 50/50 mix of #1 and #2 diesel fuels. Use a good quality diesel fuel and change the fuel filter regularly. Additives are not necessary. b. Engine Capacities 1. Engine Oil Capacity: Crankcase Capacity (4BT3.9 & 4BTA3.9 Engine) With filter change.................................
General Information and Specifications b. Fuse Ratings Optional Washer/Wipers ....................................10 Amp Model 8042: Outriggers (4BT3.9 & 4BTA3.9 Engine)............7.5 Amp Main................................................................... 40 Amp Outriggers & ECM Indicator Light (QSB4.5T Engine Only) ....................................7.5 Amp Light Switch Relay ............................................ 7.5 Amp Instrument Cluster .............................................
General Information and Specifications 2.6.10 Paint Unless otherwise specified, paint components as indicated in the following sections. a. Orange Paint Durable, premium Sky Trak Orange paint is available in both a convenient 16 ounce (480 ml) spray can for touchups and in a production size, one gallon (3,8 liter) container for extensive repainting. Consult the appropriate parts manual for the applicable part number and ordering information.
General Information and Specifications 2.8 REPLACEMENT 2.9.2 ALWAYS use the correct tool when removing or replacing any part or performing any service. Some procedures may require the use of specialized tools. If needed, many of these tools can be obtained through Snap-On® tool distributors. Contact: Snap-On Incorporated P.O. Box 1410 Kenosha, WI 53141-1410 USA Phone: (262)-656-5200 Internet: http://www.snapon.com Snap-On® is a registered trademark of Snap-On Technologies, Inc.
General Information and Specifications 2.10.3 Bearing Installation 2.12 1. Always install bearings carefully to help avoid damaging their delicate surfaces. 2. Install bearings using one of the following methods: • PRESS FIT for installation on rotating parts such as shafts and gears • PUSH FIT into static locations such as reduction gear housings. 3. Always install the bearing into the rotating part first, whenever possible. 4.
General Information and Specifications 2.12.3 After Hydraulic Component Service 1. Check the torque of all fasteners on replaced hydraulic components. 2. Check that the hoses and tubes are properly attached, properly positioned and that all the fittings are properly tightened. 3. If a hydraulic component failed and contaminated the system: • Drain the hydraulic oil reservoir • Flush the system using clean hydraulic oil • Prime the pump • Change the hydraulic oil filter 4.
General Information and Specifications 2.12.7 After Tire and Wheel Service 1. Check the air pressure in the tires. Maintain proper air pressure at all times. Refer to proper tire size as follows: Standard Tires • 8042 (13.00-24, 12 ply) 70 psi (483 kPa) • 10042/10054 (17.5-25, 12 ply) 60 psi (414 kPa) Optional Tires - 8042 4. Check for proper operation by operating all boom functions through their full range of motion several times. 2.12.10 After Axle Service 1.
Section 3 Boom Contents PARAGRAPH 3.1 3.2 3.3 3.4 3.5 3.6 TITLE PAGE Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 Boom System - Three Section Booms (8042 and 10042) . . . . . . . . . . . . . . . . . . 3.4 3.2.1 Boom System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 3.2.2 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.
Boom 3.7 3.8 3.9 3.10 3.11 3.2 Boom Chains - Four Section Boom (10054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.1 Boom Chain Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.2 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.3 Boom Chain Tension Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.4 Intermediate Boom Chains Tension Adjustment . . . . .
Boom 3.1 BOOM SYSTEM COMPONENT TERMINOLOGY To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the major assemblies of the boom system. The following illustration identifies the components that are referred to throughout this section.
Boom WARNING: DO NOT service the vehicle without following all safety precautions as outlined in the “Safety Practices” section of this manual. Failure to follow the safety practices may result in death or serious injury. 3.2 3.2.1 BOOM SYSTEM - THREE SECTION BOOMS (8042 AND 10042) Boom System Description The boom operates via an interchange among the electrical, hydraulic and mechanical systems.
Boom 3.3.1 Inner Boom Removal 1. Remove any attachment from the quick attach assembly. (Refer to Section 3.10.1, “Disconnecting from an Attachment.”) Note: If you are replacing the inner boom with a new inner boom, remove the quick attach from the inner boom. (Refer to Section 3.10.3, “Quick Attach Removal.”) WARNING: Wear protective footwear with reinforced toe caps and slip-resistant soles. Failure to comply can result in foot or other bodily injury from crushing, slipping or falling.
Boom 9. If your vehicle is equipped with optional auxiliary hydraulics, label and remove the two hoses (1) from the bulkhead fittings (2) inside the gooseneck (3). Plug the hose ends and cap the bulkhead fittings to prevent dirt and debris from entering the hydraulic system. 8 7 If you are replacing the inner boom with a new inner boom: Remove the female coupler, male nipple and bulkhead fittings from the bulkhead plate inside the gooseneck. 6 5 4 11.
Boom 13. Without optional auxiliary hydraulics: Inside the inner boom, remove the two capscrews (15) and two lockwashers (16) holding the stack clamps (17) to the left side wall of the inner boom. Remove the clamp cover plate (18) and all the clamps. 15. At the front of the intermediate boom (22), remove the capscrews (23) and lockwashers (24) holding the top wear pads (25) and spacers (26) to the inside of the intermediate boom. Label the wear pads and spacers as “Top Left” and “Top Right” sides.
Boom 17. At the rear of the boom, measure the amount of threads protruding beyond each elastic locknut (1) and record that measurement for reassembly. Remove the two elastic locknuts (1) and flat washers (2) holding both extend chain clevis’ (3) to the anchor plate (4) on the inner boom (5). Save the flat washers and discard the elastic locknuts. 2 1 Note: Record the location of the shoulder bolt (10) to ensure correct installation. 19.
Boom Note: The Attachment Tilt cylinder is heavy. Use a hoist and sling to support the Attachment Tilt cylinder when the base end pin is removed. 26. Remove the retaining ring (24) from one side of the base end pivot pin (25). Save the retaining ring. Use a brass punch and a rawhide hammer to remove the base end pivot pin from the inner boom gooseneck (26). 17 27. Inspect the pin for nicks or surface corrosion. Use fine emery cloth to repair minor nicks or corrosion.
Boom 30. At the rear of the inner boom (1), remove the capscrews (2) and lockwashers (3) holding the top wear pads (4), spacers (5) and shims (6) to the top of the inner boom. Label the wear pads, spacers and shims as “Top Left” and “Top Right” sides. Save the spacers, shims, capscrews, lockwashers and wear pad inserts (7). 31. Remove the capscrews (8), lockwashers (9) and flat washers (10) holding the side wear pads (11) and shims (12) to the sides of the inner boom.
Boom 3.3.2 Intermediate Boom Removal WARNING: Wear protective footwear with reinforced toe caps and slip-resistant soles. Failure to comply can result in foot or other bodily injury from crushing, slipping or falling. 3. At the front of the outer boom (25), remove the capscrews (26), lockwashers (27) and flat washers (28) holding the side wear pads (29) and shims (30) to the inside of the outer boom. Label the wear pads as “Left Side Upper/Lower” and “Right Side Upper/Lower.
Boom 5. If replacing the intermediate boom with a new boom section: Remove the lower wear pads at the front of the boom. Remove the capscrews (1) and lockwashers (2) holding the lower wear pads (3) and spacers (4) to the inside of the boom. Label the wear pads and spacers as “Left” or “Right” sides. Save the capscrews, lockwashers, spacers and wear pad inserts (5). 9.
Boom 11. Pull the hose reel, with hoses, out the back of the intermediate boom. Allow the hose reel assembly to slide down the hoses and rest it on the floor. 35 32 36 33 12. Label and remove the hoses from the hose reel. The center bolt (24) can remain in place to hold the hose reel and side plates together. a. Remove the elastic locknut (25) and flat washer (26) from the lower retaining shoulder bolt (27).
Boom 19. Pull the intermediate boom straight out of the outer boom. Reposition the slings as needed so the intermediate boom balances when removed from the outer boom. Set the intermediate boom down on blocks on a hard, level surface. WARNING: b. Remove the capscrews (7), lockwashers (8) and flat washers (9) holding the upper wear pads (10) and shims (11) to the intermediate boom. Label the wear pads and shims as “Top Left,” “Top Center” or “Top Right.
Boom d. At the front of the intermediate boom, remove the capscrew (19) and lockwasher (20) holding the extend chain sheave pin (21) to the mounting ears on the intermediate boom. Remove the pin from the mounting ears and the extend chain sheave (22). Remove the extend chain sheave and inspect the condition of the sheave bushings. Replace the bushings if showing any signs of wear. 3.3.3 Outer Boom Removal WARNING: Wear protective footwear with reinforced toe caps and slip-resistant soles.
Boom 5. At the underside of the outer boom, locate the retract chain locknut (1). Measure the amount of threads protruding beyond the elastic locknut and record that measurement for reassembly of the chain. Remove the elastic locknut and the flat washer (2). Save the flat washer and discard the locknut. 10. Without auxiliary hydraulics: Label and remove the Attachment Tilt retract (outer) hose (3) and the extend (inner) hose (4) from the bulkhead fittings on the mounting plate (5).
Boom 22 21 17 20 31 19 20 29 28 18 30 MH1180 MH1150 13. At the rear right side of the outer boom, label and remove the extend tube (23) and retract tube (24) from the bulkhead fittings (25). Plug the tube ends and cap the bulkhead fittings. 14. Remove the extend tube (23) and retract tube (24) from the 90° elbow fittings (26) on the rear of the Extend/Retract cylinder (27). Plug the tube ends and cap the 90° elbows. 24 23 24 25 17.
Boom 20. Label and remove the retract hoses (1) from the straight connectors on both Slave cylinders (2). 5 21. Label and remove the extend hoses (3) from the straight connectors on both Slave cylinders (2). Plug the hose ends and cap the straight connectors on the Slave cylinders. 6 10 7 1 4 2 9 2 8 3 1 3 MH1200 22. Remove the capscrew (1) and elastic locknut (2) holding the upper Slave cylinder pivot pin (3) to the outer boom. Use a hoist and a sling to hold the Slave cylinder in position.
Boom c. Discard the elastic locknuts and retain the capscrews, flat washers, cover plates, clamp, safety plate and stop plate. 29. Inspect the pivot pin (15) for nicks or damage. If the pin is damaged, it must be replaced. 30. Repeat Steps 28 and 29 to remove the other Lift/ Lower cylinder. 22 20 14 24 26 13 25 25 24 15 MH1230 31. Remove the capscrews (16) and elastic locknuts (17) holding the boom pivot pins (18) to the frame.
Boom 37. At the front of the outer boom, remove the elastic locknut (1) holding the rubber bumper (2) to the Extend/Retract cylinder retainer (3). Discard the elastic locknut. 38. Inspect the rubber bumper (2). If it is in good condition, the rubber bumper can be reused. If the rubber bumper is showing signs of cracking or deterioration, it should be replaced. 42. Remove the self-aligning bearings (10) from the Lift/ Lower cylinder mounts (8) and the Slave cylinder mounts (9). 43.
Boom 1. On the rear of the boom, assemble the extend and retract bulkhead fittings (17) to the mounting plate on the right side. Insert the fittings from the bottom up and secure in place with the bulkhead fitting nuts (18) on the top side. Tighten securely. 14 15 IMPORTANT: Keep the caps on the threaded ends of the fittings to protect the threads from damage and to keep dirt and debris out of the fittings. 16 MH1310 49. Inspect the boom and welds.
Boom 4. Assemble a new angle indicator decal (1) to the left side of the boom assembly. Place the hole in the decal around the weld stud (2) and line up the upper edge of the decal parallel with the top edge of the boom assembly. 8. Install grease fittings (13) into the Lift/Lower cylinder mounts (7) and the Slave cylinder mounts (12) on the outer boom. Tighten all the grease fittings. 12 7 1 11 6 13 8 13 10 2 MH1320 9 5. Place the two flat washers (3) and the angle indicator (4) onto the weld stud.
Boom Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening. 11. Lift the rod end of the Extend/Retract cylinder (19) far enough to insert the threaded stud on the rubber bumper (20) into the hole in the Extend/Retract cylinder retainer (21). Secure the rubber bumper in place with a new elastic locknut (22). Tighten securely. Lower the rod end of the Extend/Retract cylinder, and allow it to rest on the rubber bumper. 32 23 31 30 29 24 27 25 26 28 MH1250 13.
Boom 14. On the end of the boom pivot pin (1), closest to the capscrew hole, mark the capscrew mounting hole location. Coat the entire pin with anti-seize compound. 19. Coat the entire Lift/Lower cylinder pivot pin (8) with anti-seize compound. Insert the pin through the rod end of the cylinder and the self-aligning bearing. If necessary, use a rawhide hammer to install the pin. 15.
Boom Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening. 23 22 25. Coat the upper pivot pin (17) with anti-seize compound. Insert the pin through the rod end of the Slave cylinder. If necessary, use a rawhide hammer to install the upper pivot pin. Use a tapered punch to align the capscrew hole in the pin with the mounting tabs on the cylinder. Secure the upper pivot pin in place with the capscrew (18), saved, and a new elastic locknut (19).
Boom Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening. 31. Assemble the tube clamp halves (1) to the extend (2) and retract (3) tubes under the outer boom. Place one clamp half on top of the tubes and one on the underside of the tubes. Place a clamp cover (4) on the top and bottom of the clamps. Secure in place with the capscrew (5), saved, and a new elastic locknut (6).
Boom 41. With auxiliary hydraulics: Assemble the tube clamp halves, saved, to the underside of the outer boom. Place a upper clamp half (25) on each side of the Attachment Tilt (upper) tubes (26). Secure each set of clamp halves to the boom with a locking plate (27), saved, and a stacking bolt (28), saved. Tighten the stacking bolt securely to hold the upper tubes in place. 15 13 16 14 17 19 20 18 MH1440 42. Place a lower clamp half (29) on each side of the auxiliary hydraulic (lower) tubes (30).
Boom 44. Without auxiliary hydraulics: At the rear left side of the boom, connect the Attachment Tilt extend (inner) hose (1) to the inner bulkhead fitting (2). Remove all twists from the hose, and tighten the hose end securely to the bulkhead fitting. 8 7 6 45. Connect the Attachment Tilt retract (outer) hose (3) to the outer bulkhead fitting (4). Remove all twists from the hose, and tighten the hose end securely to the bulkhead fitting. Proceed to Step 49. 5 12 11 2 10 4 9 MH1130 3 1 49.
Boom 51. At the front of the outer boom, reassemble the lower outside wear pads (17) and wear pad spacers (18): a. Place the wear pad inserts (19) into the cavities in the wear pad. Be sure the inserts are seated completely in the cavities. b. Place a wear pad (17) and a spacer (18) into the outer boom with the hole offset of the wear pad toward the middle of the boom. Align the holes in the spacer and wear pads with the holes in the bottom of the boom. c.
Boom 3.3.5 Intermediate Boom Installation WARNING: Wear protective footwear with reinforced toe caps and slip-resistant soles. Failure to comply can result in foot or other bodily injury from crushing, slipping or falling. WARNING: NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist. Failure to comply can result in death or serious personal injury. 1.
Boom 10 Note: Shim ALL upper rear wear pads as needed to maintain a total maximum gap of .06" (1,5 mm) at the rear of the pads and maintain a total minimum gap of .07 to .13" (1,8 to 3,3 mm) in the vertical direction. 11 8 8 7 5. Assemble the top wear pads to the top of the intermediate boom. Position the wear pads so the outside pads are offset to the outside and the center pad is offset to the right: 6 9 a. Apply Loctite® 242 threadlocker to the threads of the capscrews (18), saved. b.
Boom 6. Spray the wear pad pathways on the inside of the outer boom, inside of the intermediate boom and the underside of the intermediate boom with LPS3 or equivalent. 7. Before installing the intermediate boom into the outer boom, place a string (heavy enough to pull the Attachment Tilt and auxiliary hydraulic hoses) down the inside of the outer boom. Allow the string to hang out the rear of the boom. Pull the other end out the opening on the left side of the boom where the hoses will exit the boom.
Boom 11. Assemble the top wear pads to the inside of the outer boom: a. Place the wear pad inserts (10), saved, into the cavities of the top wear pads (11), saved. b. Fill all wear pad cavities with a good grade of lithium-based EP grease. c. Apply Loctite® 242 threadlocker to the threads of the capscrews (12), saved. Slide the wear pad between the intermediate boom and the outer boom with the offset of each wear pad away from the center.
Boom 16. Install the intermediate boom front, bottom wear pads: a. Place the wear pad inserts (1), saved, into the cavities of the front bottom wear pads (2), saved. b. Place the wear pads and spacers (3), saved, into the intermediate boom with the offset of the wear pads toward the outside. c. Apply Loctite® 242 threadlocker to the threads of the capscrews (4), saved. Align the holes and secure in place with the capscrews (4) and lockwashers (5), saved.
Boom 3. With auxiliary hydraulics: Slide the elbow ends of the two Attachment Tilt hoses (10 and 11) down the inner boom and out to the gooseneck. Keep the hoses next to each other as they are being pushed down the inner boom. At the opening in the gooseneck, pull both hoses out. Be careful not to cross the hoses as you pull them out. Label the left side hose (10 ) as “Retract” and the right side hose (11) as “Extend.” Label the hoses the same on the male end of each hose. 4.
Boom 10. With auxiliary hydraulics: Keep the four hoses in line (left to right) as they come out of the rear of the inner boom. Place a lockwasher (1), saved, and a flat washer (2), saved, onto each capscrew (3), saved. Insert the capscrews through the hose clamp support bracket (4), saved. Insert the capscrews from the side as shown. 11. Place a 3/4" diameter hose clamp half (5), saved, onto the capscrews.
Boom 17. Assemble the wear pads to the rear of the inner boom. If your vehicle has optional auxiliary hydraulics, the upper left wear pad has been already assembled. Note: Shim ALL upper rear wear pads as needed to maintain a total maximum gap of .06" (1,5 mm) at the rear of the pads and maintain a total minimum gap of .07 to .13" (1,8 to 3,3 mm) in the vertical direction. Note: Shim ALL side wear pads as needed to maintain a total minimum gap of .07 to .13" (1,8 to 3,3 mm) in the horizontal direction. a.
Boom Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening. 18. Lay the two extend chains (1) on the top of the inner boom with the threaded clevis ends (2) toward the rear of the boom. Coat the threads on each clevis with multi-purpose grease, and insert the clevis’ through the holes in the anchor plate. Install a flat washer (3), saved, onto each clevis. Install a new elastic locknut (4) onto each clevis.
Boom a. Remove the elastic locknut (16) from the upper retaining capscrew (17). While pulling the capscrew out, catch the spacers (18) from between the plates as the capscrew is removed. Pull the capscrew out far enough to place the hoses around the hose reel. 22. Install the top wear pads to the inside of the intermediate boom: a. Place the wear pad inserts (11), saved, into the cavities of the top wear pads (12), saved. b. Apply Loctite® 242 threadlocker to the threads of the capscrews (13), saved.
Boom 25. With auxiliary hydraulics: Assemble the hoses to the hose reel at the back of the boom: 1 a. Remove the elastic locknut (1) from the upper retaining capscrew (2). While pulling the capscrew out, catch the spacers (3) from between the plates as the capscrew is removed. Pull the capscrew out far enough to place the hoses around the hose reel. 8 Place the left side auxiliary hydraulic hose (4) into the left position on the hose reel.
Boom 28. With auxiliary hydraulics: Tie the strings (positioned inside the outer boom) to the male end of each of the Attachment Tilt hoses and the auxiliary hydraulic hoses. IMPORTANT: Keep the hoses in the same order as they come off the hose reel. DO NOT allow the hoses to cross. 29. Working from the front of the boom, pull each hose through the boom assembly: a. Pull the right side auxiliary hydraulic hose (15) through the boom assembly.
Boom 32. With auxiliary hydraulics: At the front of the outer boom, assemble the hose assemblies and tube assemblies to the mounting plate: 7 1 4 Note: Where the hose assemblies come out of the outer boom, lubricate the radius in the outer boom with soap and water to allow proper tensioning of hoses. 10 Note: ALWAYS use new o-rings when servicing the vehicle. a. Install new o-rings into the fittings. Lubricate o-rings with clean hydraulic oil. 6 b.
Boom 35. Assemble the two extend chains to the outer boom mount if the yoke plates were removed from the extend chains. If the yoke plates were not replaced, proceed to Step 38. 24 23 Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening. 36. Assemble the yoke plates (17) to the mount on the front of the outer boom.
Boom 41. With auxiliary hydraulics: If the inner boom has been replaced with a new boom, the auxiliary hydraulic fittings need to be reassembled: a. Assemble the two bulkhead fittings (1) from the original boom to the bulkhead plate inside the gooseneck. Insert the bulkhead fittings from the top and secure in place with the bulkhead fitting nut (2) on the bottom side. Tighten securely. b. Assemble the two swivel straight connectors (3) to the two bulkhead fittings. c.
Boom 44. Coat the rod end pivot pin (17), saved, with antiseize compound. Swing the rod end (18) of the Attachment Tilt cylinder up and line up the rod end with the mounting holes in the quick attach (19). 22 24 Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening. 45. Insert the rod end pivot pin (17) through the lined-up holes. Use a tapered punch to line up the capscrew hole in the pivot pin and the mounting hole in the quick attach hub.
Boom 3.4 BOOM CHAINS - THREE SECTION BOOM (8042 AND 10042) This vehicle uses double extend chains to extend the boom and a single retract chain to retract the boom. The extend and retract chains are constructed of 3/4" pitch links with 6 x 6 leaf lacing. Note: DO NOT attempt to repair a chain. Replace a stretched or damaged chain with a new part. Always replace both the chain and the clevis. It is recommended that when any chain is replaced, that all the chains and clevis’ be replaced at the same time.
Boom a. Inspection Guidelines Edge Wear Expose the extend and retract chains (refer to Section 3.4.1, b. “Expose Extend Chain for Inspection,” or Section 3.4.1, c. “Expose Retract Chain for Inspection.”) and inspect the chains for the following conditions: Check the chain for wear on the link plate edges caused by running back and forth over the sheave. The maximum reduction of material must not exceed 5%.
Boom Turning or Protruding Pins Highly loaded chain, operating with inadequate lubrication, can generate abnormal frictional forces between pin and link plates. When chain is allowed to operate in this condition, a pin or series of pins, can begin to twist out of a chain, resulting in failure. Examine the pin head rivets to determine if the “VEE” flats are still in correct alignment (1). Chain with rotated/ displaced heads (2) or abnormal pin protrusion (3) must be replaced immediately. (Refer to Section 3.
Boom b. Expose Extend Chain for Inspection Other Modes of Failure • Ultimate Strength Failure - These types of failures are caused by overloads far in excess of the design load. Either fractured plates (6) or enlarged holes (7) can occur. If either of these failures occurs, the chain must be replaced immediately. (Refer to Section 3.4.5, “Boom Extend and Retract Chains Removal and Replacement.”) Note: The tight joints inspection must be done with the chain disconnected from the boom. (Refer to Section 3.4.
Boom c. Expose Retract Chain for Inspection The retract chain must be removed from the boom in order to be visually inspected. This must be done every 1000 hours or whenever the retract chain is removed from the boom. (If removal of the chain is required refer to Section 3.4.5, “Boom Extend and Retract Chains Removal and Replacement.”) 4. At the front underside of the boom, record the amount of threads extending beyond the elastic locknut (6).
Boom 6. If the chain clevis has a threaded hole on the end (9), a string or wire can be attached to the retract chain clevis using a threaded eye (10) or a flat washer tack welded to a capscrew (11). The outside diameter of the eye or flat washer must be smaller than the diameter of the threads on the clevis. The string or wire will be used to pull the chain back through the boom during the reassembly.
Boom 11. Measure the chain elongation. Measure across 17 pins (1), somewhere between the chain sheave and where the chain is laying in the pan or on the tarp. The maximum measurement allowed is 12.36" (313 mm). If the measurement is more than 12.36" (313 mm), the chain must be replaced. (Refer to Section 3.4.5, “Boom Extend and Retract Chains Removal and Replacement.”) 13. Lubricate the chain, while it is exposed, if it does not need to be replaced. (Refer to Section 3.4.2, “Chain Lubrication.”) 14.
Boom If no string or wire was installed to the end of the clevis: 12 18. From the rear of the boom, one person should push the threaded clevis end (6) of the retract chain (7) under the chain sheave and down between the intermediate boom and the outer boom. Keep the retract chain (7) to the right side of the boom, push the threaded clevis down to the tab (8) at the front underside of the outer boom. 19.
Boom 3.4.2 Chain Lubrication After inspection and before being returned to service, chains must be lubricated with a quality chain lubricant (“LUBRIPLATE” Chain & Cable Fluid, “LPS3” or equivalent). The lubricant must penetrate the chain joint to prevent wear. Applying lubricant to the external surfaces will prevent rust, but the chains should be articulated to make sure the lubricant penetrates to the working surfaces between the pins and links. 3.
Boom 3.4.4 Boom Chain Tension Adjustment Note: Always perform Section 3.4.3, “Boom Chain Tension Check” before adjusting the boom chain tension. 1. Remove the thumbscrew (4), lockwasher (5) and flat washer (6), holding the rear cover (7) to the rear of the outer boom (8). Lift the rear cover straight up until the capscrew in the top of the cover clears the retaining hole in the top of the outer boom. Remove the cover from the outer boom. 3.
Boom 5. Recheck chain tension. (Refer to Section 3.4.3, “Boom Chain Tension Check.”) 5 8 4 6. Further chain adjustment can be achieved by loosening all three chain locknuts (1 and 2) and moving the rear retract chain clevis (3) from the original mounting hole (4) in the anchor plate to the next hole (5). 7 3 1 6 MA9450 MH1751 9 2 OA0512 This is only acceptable when boom chain sag (9) cannot be acquired and the chain elongation measurement is still less than 12.36" (313 mm).
Boom 11 10 17 16 15 12 13 14 OH1090 MH0850 a. Component/Assembly Verification The inner (15) to intermediate (16) boom separation should be checked when assembling new boom sections or chains, or when the rear retract chain clevis has been moved forward on the anchor plate. If the distance is less than 8.5" (216 mm) or greater than 11" (279 mm): 1. Verify that the retract chain clevis (3) is not mounted in the last hole (7) in the anchor plate (8). 2.
Boom 3. To increase the separation distance: Loosen the retract chain locknut (1) on the bottom of the outer boom one or two turns and tighten the two extend chain locknuts (2) equally the same number of turns. A minimum of one full thread on the clevis must protrude beyond the elastic collar of the locknut. 4. To decrease the separation distance: Loosen the extend chain locknuts (2) at the rear of boom equally one or two turns and tighten the retract chain locknut (1) the same number of turns.
Boom 4. At the rear of the boom, locate the extend chain elastic locknuts (8). Record the amount of threads extending beyond both the elastic locknuts. These measurements will be the starting point for adjustment of the extend chains after installation. 5. Remove and replace the extend chains one at a time. Remove the right side elastic locknut (8) and flat washer (9), holding the right side extend chain clevis (10) to the anchor plate (11) on the inner boom (12).
Boom 11. Lay the new extend chain (1) on top of the outer boom (2) with the threaded clevis (3) toward the front of the boom. 16. Pull the anchor clevis (13) up around the double chain sheave and position the clevis between the yoke plates (14). 12. Attach the wire (4) to the threaded clevis (3) of the new extend chain. Loop the wire through the clevis and twist together to form a loop. 17. Coat the hex-socket head capscrew (15), saved, with anti-seize compound.
Boom 18 17 6. If the chain clevis has a threaded hole on the end (25), a string or wire can be attached to the retract chain clevis using a threaded eye (26) or a flat washer tack welded to a capscrew (27). The outside diameter of the eye or flat washer must be smaller than the diameter of the threads on the clevis. The string or wire will be used to pull the chain back through the boom during the reassembly.
Boom Note: Record the location of the shoulder bolt (1) to ensure correct installation. 9. At the rear of the boom, locate the two retract chain anchor plates (2) holding the retract chain to the inner boom just in front of the retract chain sheave (3). Remove the elastic locknut (4) and shoulder bolt (1) holding the retract chain clevis to the anchor plates. Discard the elastic locknut and save the shoulder bolt. The two anchor plates can remain in place on the inner boom. 13.
Boom 19. The person at the front of the boom should guide the threaded end of the clevis (10) through the hole in the tab (12) using a Phillips screwdriver (13). Insert the screwdriver through the hole in the tab and catch the countersunk hole in the end of the clevis. Guide the threaded clevis out as the person at the rear of the boom pushes the retract chain. 22. If re-installing a used chain insert the saved shoulder bolt (1), in the same position in the plates and clevis recorded during removal. 23.
Boom 3.5 3.5.1 BOOM SYSTEM - FOUR SECTION BOOM (10054) Boom System Description The boom operates via an interchange among the electrical, hydraulic and mechanical systems. Components involved include the joystick, Attachment Tilt cylinder, Extend/Retract cylinder, Lift/Lower cylinder, Slave cylinders, electronic sensors, extend and retract chains, various pivots, supporting hardware and other components. 3.5.
Boom 3.6.1 Inner Boom Removal 1. Remove any attachment from the quick attach assembly. (Refer to Section 3.10.1, “Disconnecting from an Attachment.”) Note: If you are replacing the inner boom with a new inner boom, remove the quick attach from the inner boom. (Refer to Section 3.10.3, “Quick Attach Removal.”) WARNING: Wear protective footwear with reinforced toe caps and slip-resistant soles. Failure to comply can result in foot or other bodily injury from crushing, slipping or falling.
Boom 9. Remove the thumbscrew (1), lockwasher (2) and flat washer (3) holding the rear cover (4) to the rear of the outer boom (5). Lift the rear cover straight up until the capscrew (6) in the top of the cover clears the retaining hole in the top of the outer boom. Remove the cover from the outer boom. 6 4 a. Remove the elastic locknut (14) and flat washer (15) from the lower retaining shoulder bolt (16).
Boom 22 20 21 18 14 15 17 19 16 13 MH1690 MH1780 13. At the rear of the boom, locate the inner boom extend chain locknut (21). Measure the amount of threads protruding beyond the elastic locknut and record that measurement for reassembly. 14. Using a 1-7/16" socket and a 12" extension, loosen the elastic locknut (21) until the nut is held on by a couple of threads. DO NOT remove the elastic locknut at this time. 15.
Boom 19. Remove the elastic locknut (1) and capscrew (2) holding the inner boom extend chain sheave (3) to the front of the secondary intermediate boom (4). Use a brass punch and a rawhide hammer to remove the sheave pin (5). 7 8 8 6 20. Inspect the sheave pin (5) for corrosion or damage. If the pin is damaged, it should be replaced. Minor corrosion can be repaired with fine emery cloth. Save the chain sheave, pin and capscrew. Discard the elastic locknut. 2 10 4 3 9 11 5 1 MH1800 21.
Boom 25. Remove the hose reel (33) as an assembly, from the rear of the boom. 30 31 12 28 32 29 27 26 16 18 25 13 17 15 14 MH1820 33 23. At the rear of the boom, remove the capscrews (19), lockwashers (20) and flat washers (21) holding the hose reel assembly (22), lower wear pad (23) and spacer (24) to the lower plate on the primary intermediate boom. Reassemble the capscrews, lockwashers and flat washers to hold the lower wear pad in place for primary intermediate boom removal.
Boom 28. Return to the operator’s cab, start the engine and fully retract the boom slowly. Shut the engine OFF, and exit the cab using the hand holds. 30. Remove the two capscrews (6) and lockwashers (7) holding the hose carrier support (8) and the lower wear pad to the secondary intermediate boom. Note: Record the location of the shoulder bolt (1) to ensure correct installation. 31. Pull the hose carrier support with hose carrier attached toward the rear of the boom.
Boom Note: If replacing the inner boom assembly with a new inner boom, the quick attach assembly and the Attachment Tilt cylinder should be removed at this time. If the inner boom is not to be replaced, the quick attach assembly and Attachment Tilt cylinder can remain in place. Proceed to Step 42. 33. Remove the elastic locknut (13) and capscrew (14) holding the Attachment Tilt cylinder rod end pin (15) to the quick attach assembly (16). Save the capscrew and discard the elastic locknut. 34.
Boom Note: The Attachment Tilt cylinder is heavy. Use a hoist and sling to support the Attachment Tilt cylinder when the base end pin is removed. 39. Remove the retaining ring (1) from one side of the base end pivot pin (2). Save the retaining ring. Use a brass punch and rawhide hammer to remove the base end pivot pin from the inner boom gooseneck (3). 40. Inspect the pivot pin (2) for nicks or surface corrosion. Use fine emery cloth to repair minor nicks or corrosion.
Boom 45. At the rear of the inner boom (15), remove the capscrews (16), lockwashers (17) and flat washers (18) holding the lower wear pad (19) to the bottom of the inner boom. Label the wear pad as “Inner Boom Bottom.” Save the capscrews, lockwashers, flat washers and wear pad inserts (20). 16 17 47. On each side of the inner boom, remove the rear elastic locknuts (25), capscrews (26) and flat washers (27) holding the rear of the hose carrier guide (28) in place. Save the capscrews and flat washers.
Boom 49. Tilt the back of the hose carrier guide (1) up. Use a light and look inside the inner boom and note which hoses go into which channels on either side of the boom. Label the right side outer hose (2) as “Auxiliary Female Coupler” and the right side inner hose (3) as “Attachment Tilt Extend.” Label the left side outer hose (4) as “Auxiliary Male Nipple” and the left side inner hose (5) as “Attachment Tilt Retract.
Boom 53. Remove the capscrews (15) and lockwashers (16) holding the lower side wear pads (17) and shims (18) to the side of the inner boom. The front capscrews will also hold the mounting clips (19) for the hose channel assembly to the side of the inner boom. Label the wear pads and shims as “Inner Boom Lower Side.” Save the shims, capscrews, lockwashers and wear pad inserts (20). 21 22 24 23 25 24 15 16 26 19 27 28 MH1960 17 56.
Boom 3.6.2 Secondary Intermediate Boom Removal WARNING: NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist. Failure to comply can result in death or serious personal injury. 1. Remove the inner boom as described in Section 3.3.1, “Inner Boom Removal.” 3.
Boom 5. Remove the socket head capscrews (17) and elastic locknuts (18) holding the extend chain clevis’ (19) to the yoke plates (20). 24 6. Inspect the yoke plates (20) for wear or distortion. If any wear or distortion is detected, both plates must be replaced. If no wear or distortion is detected, save the plates. Save the socket head capscrews and discard the elastic locknuts. 17 19 21 20 19 23 20 18 MH2330 7.
Boom 9. From the front of the boom, pull both extend chains out from between the secondary intermediate boom and the primary intermediate boom. 6 9 10. At the rear of the secondary intermediate boom (1), remove the capscrew (2) and lockwasher (3) holding the retract chain sheave pin (4) to the mounting plate on the left side of the secondary intermediate boom. 7 11. Remove the retract chain sheave pin (4) from the mount and the retract chain sheave (5).
Boom 19. If you are replacing the secondary intermediate boom with a new boom section, the following items need to be removed from the secondary intermediate boom: a. Remove the capscrews (11) and lockwashers (12) holding the bottom wear pad (13) and spacer (14) to the secondary intermediate boom. Label the wear pad and spacer as Secondary Intermediate Boom Bottom.” Save the capscrews, lockwashers, spacer and wear pad inserts (15). 22 19 21 20 18 16 18 17 11 12 MH2050 14 13 15 MH2040 b.
Boom d. Remove the capscrews (1), flat washers (2) and lockwashers (3) holding the lower wear pads (4) to the inside of the secondary intermediate boom. Label the wear pads as “Secondary Intermediate Boom Left” or “Secondary Intermediate Boom Right” sides. Save the capscrews, flat washers, lockwashers and wear pad inserts (5). 3.6.3 Primary Intermediate Boom Removal WARNING: Wear protective footwear with reinforced toe caps and slip-resistant soles.
Boom 2. At the front of the outer boom (12), remove the capscrews (13), lockwashers (14) and flat washers (15) holding the side wear pads (16) and shims (17) to the inside of the outer boom. Label the wear pads as “Primary Intermediate Boom Left Side Upper/ Lower” and “Primary Intermediate Boom Right Side Upper/Lower.” Save the capscrews, lockwashers, flat washers, shims and wear pad inserts (18). 4.
Boom b. At the rear of the boom, remove the capscrew (1) and lockwasher (2) holding the retract chain sheave pin (3) to the mounting plate inside the intermediate boom. c. Remove the retract chain sheave pin (3) from the mount and the retract chain sheave (4). Remove the retract chain sheave from the intermediate boom. d. Inspect the bushings inside the sheave (4). Replace the bushings if there are any signs of wear. 6 e. Inspect the sheave pin (3) for wear or damage.
Boom 11. While pulling the primary intermediate boom out of the outer boom, guide the retract chain into the rear of the boom. 12. Carefully lower the primary intermediate boom onto suitable supports or to the ground. 14 15 WARNING: NEVER weld or drill the boom. The structural integrity of the boom will be impaired if subjected to any repair involving welding or drilling. Failure to comply can result in death or serious personal injury. 16 18 13. Inspect the boom and welds.
Boom 17. Remove the capscrews (1), lockwashers (2) and flat washers (3) holding the side wear pads (4) and shims (5) to the primary intermediate boom. Label the wear pads and shims as “Primary Intermediate Boom Left Side Upper” and “Primary Intermediate Boom Right Side Upper/Lower.” Save the capscrews, lockwashers, flat washers, shims and wear pad inserts (6). 3.6.4 Outer Boom Removal WARNING: Wear protective footwear with reinforced toe caps and slip-resistant soles.
Boom 5. At the underside of the outer boom, locate the retract chain locknut (14). Measure the amount of threads protruding beyond the elastic locknut, and record that measurement for reassembly of the chain. Remove the elastic locknut and the flat washer (15). Save the flat washer and discard the locknut. 22 18 19 20 21 18 16 17 MH1130 15 14 MH1110 6. Remove the retract chain by pulling it out the rear of the outer boom. Place the retract chain on a clean surface. 10.
Boom 11. Remove the capscrew (1) and elastic locknut (2) holding the tube clamp (3) and clamp covers (4) to the extend (5) and retract (6) tubes under the boom. Discard the elastic locknut and retain the capscrew, covers and clamps. 6 14. Label the auxiliary tube assemblies (12) located under the Attachment Tilt tubes (13). Remove the capscrews (14) holding the tube clamps (15) and clamp covers (16) to the Attachment Tilt tube clamp stacking bolt (17) under the outer boom.
Boom 17. Label and remove the retract hoses (20) from the straight connectors on both Slave cylinders (21). Label and remove the extend hoses (22) from the straight connectors on both Slave cylinders (21). Plug the hose ends and cap the straight connectors on the Slave cylinders. 24 25 26 20 23 21 28 21 27 22 20 22 MH1200 18. Remove the capscrew (23) and elastic locknut (24) holding the upper Slave cylinder pivot pin (25) to the outer boom.
Boom 25. Remove the capscrew (1) and elastic locknut (2) holding the upper Lift/Lower cylinder pivot pin (3) to the outer boom. Securely block the Lift/Lower cylinder in position. Remove the pivot pin from the pin mount by pulling the pin out. It may be necessary to use an appropriate puller threaded into the pivot pin to remove the pin. Discard the elastic locknut and retain the capscrew. Repeat for the other Lift/Lower cylinder. 26. Inspect the pivot pins (3) for nicks or damage.
Boom 33. Use a hoist and slings to support the Extend/Retract cylinder. At the base end of the Extend/Retract cylinder, remove a retaining ring (8) from one side of the Extend/Retract cylinder base end pin (9). Use a brass punch and a rawhide hammer to remove the base end pin from the mounting ears (10) on the outer boom. 34. Lower the base end (11) of the Extend/Retract cylinder and remove the rod end of the cylinder from the retainer at the front of the boom.
Boom 41. On the left side of the outer boom, remove the locknut (1), angle indicator (2) and flat washers (3) from the weld stud. Save the angle indicator and all the hardware for reassembly. 3.6.5 Outer Boom Installation WARNING: Wear protective footwear with reinforced toe caps and slip-resistant soles. Failure to comply can result in foot or other bodily injury from crushing, slipping or falling.
Boom Note: If you are assembling a new outer boom assembly, continue with Step 4. If reassembling the existing boom assembly proceed to Step 5. 4. Assemble a new angle indicator decal (13) to the left side of the boom assembly. Place the hole in the decal around the weld stud (14) and align the upper edge of the decal parallel with the top edge of the boom assembly. 6. Assemble new or saved Lift/Lower cylinder bearings (18) into the Lift/Lower cylinder mounts (19) on each side of the boom assembly.
Boom 9. Slings and a hoist are required for this step. Position the Extend/Retract cylinder (1) with the extend and retract port elbows facing down. Place the rod end of the Extend/Retract cylinder (2) through the Extend/ Retract cylinder retainer at the front of the outer boom. 10. At the rear of the Extend/Retract cylinder, align the hole in the base end of the cylinder with the holes in the mounting ears (3) under the outer boom. 11. Coat the base end cylinder pin with anti-seize compound.
Boom 15. On the end of the boom pivot pin (10) closest to the capscrew hole, mark the capscrew mounting hole location. Coat the entire pin with anti-seize compound. 16. Insert the pin (10) from the outside of the boom assembly, making sure the marks (11) for the capscrew mounting hole stay in line with the capscrew mounting holes in the boom mounting hub. If necessary, use a rawhide hammer to install the pivot pin. 17. Shim the boom as required using the shims (12), saved, to maintain a .
Boom 23. Use a hoist and sling to position the Slave cylinder (1) onto the lower cylinder mount (2) located on the frame. The cylinder should be positioned with the extend and retract port fittings (3) to the outside. 29. Reassemble the boom proximity sensor (10) to the right side mounting plate. With the boom properly shimmed, position the boom assembly all the way to the right side. Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening. 30.
Boom 18 14 20 18 17 36. Assemble the boom retract hose (28) to the outside bulkhead fitting (retract tube) on the right side of the boom. Remove all twists from the boom retract hose, and tighten the hose end securely to the bulkhead fitting. 14 28 16 27 19 15 MH1160 MH1140 Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening. IMPORTANT: DO NOT fully tighten the tube connections, until all tubes are assembled at both ends. 34.
Boom 41. Assemble the tube clamp halves, saved, to the underside of the outer boom. Place an upper clamp half (1) on each side of the Attachment Tilt (upper) tubes (2). Secure each set of clamp halves to the boom with a locking plate (3), saved, and a stacking bolt (4), saved. Tighten the stacking bolt securely to hold the upper tubes in place. 12 11 10 9 42. Place a lower clamp half (5) on each side of the auxiliary hydraulic (lower) tubes (6).
Boom 50. At the front of the outer boom, reassemble the lower outside wear pads (21) and wear pad spacers (22): a. Place the wear pad inserts (23) into the cavities in the wear pad. Be sure the inserts are seated completely in the cavities. Fill each cavity with a good grade of lithium-based EP grease. b. Place a wear pad (21) and a spacer (22) into the outer boom with the hole offset of the wear pad toward the middle of the boom.
Boom a. Apply Loctite® 242 threadlocker to the threads of the two capscrews (6), saved. Insert a capscrew with a lockwasher (7), saved, and a flat washer (8), saved, through each of the mounting holes in the left side mounting plate (9). Place three flat washers (8), saved, onto each of the capscrews and insert the capscrews through the mounting holes in the left side of the boom. 4. Remove the left side mounting plate from the hose reel assembly.
Boom 8. Assemble the lower wear pad (13), saved, and wear pad spacer (14), saved, to the bottom of the primary intermediate boom: a. Place the wear pad inserts (15), saved, into the cavities in the wear pad. Be sure the inserts are seated completely into the cavities. Note: DO NOT apply Loctite to the capscrews (16), saved. The capscrews will be removed later to finish assembling the hose reel assembly. b.
Boom Note: Shim ALL upper rear wear pads as needed to maintain a total maximum gap of .06" (1,5 mm) at the rear of the pads and maintain a total minimum gap of .07 to .13" (1,8 to 3,3 mm) in the vertical direction. 10. Assemble the top wear pads to the top of the intermediate boom. Position the wear pads so the outside pads are offset to the outside and the center pad is offset to the right as seen in the following illustration. a. Apply Loctite® 242 threadlocker to the threads of the capscrews (1), saved.
Boom lockwashers (19), saved, and flat washers (20), saved. Be careful not to push the wear pad inserts out of the wear pads. 16. Assemble the side wear pads to the outer boom: a. Slide the primary intermediate boom over to one side as far as it will go, to allow wear pad installation. b. Place the wear pad inserts (10), saved, into the cavities of the side wear pads (11), saved. Fill the cavities of the wear pad with a good grade of lithium-based EP grease.
Boom 20. Install the primary intermediate boom front lower wear pads: 7 a. Place the wear pad inserts (1), saved, into the cavities of the front bottom wear pads (2), saved. 8 b. Place the wear pads and spacers (3), saved, into the primary intermediate boom with the offset of the wear pads toward the outside. 10 c. Apply Loctite® 242 threadlocker to the threads of the capscrews (4), saved. Line up the holes and secure in place with the capscrews (4) and lockwashers (5), saved.
Boom 1. Install the secondary intermediate boom lower wear pad: Note: DO NOT apply threadlocker to the threads of the two wear pad capscrews (11). The capscrews will be removed to assemble the hose carrier support in place after the inner boom has been installed. a. Insert a capscrew with a lockwasher (12), saved, through each of the mounting holes in the bottom of the secondary intermediate boom. b. Place the wear pad inserts (13), saved, into the cavities in the wear pad (14), saved.
Boom Note: Shim ALL upper rear wear pads as needed to maintain a total maximum gap of .06" (1,5 mm) at the rear of the pads and maintain a total minimum gap of .07 to .13" (1,8 to 3,3 mm) in the vertical direction. 3. Install the secondary intermediate boom upper rear wear pads: a. Apply Loctite® 242 threadlocker to the threads of the capscrews (1), saved, for the right side wear pad (2). b.
Boom 5. At the rear of the secondary intermediate boom, assemble the retract chain sheave (13) to the mounting ears on the left side of the boom. Place the sheave between the ears and insert the sheave pin (14) from the right side. Line up the hole in the pin retainer plate with the threaded hole in the right ear. Secure the pin in place with the capscrew (15), saved, and the lockwasher (16), saved. Tighten the capscrew securely. 6. Grease the sheave using the grease fitting in the pin.
Boom Note: Shim ALL side wear pads as needed to maintain a total minimum gap of .07 to .13" (1,8 to 3,3 mm) in the horizontal direction. 13. Assemble the side wear pads to the primary intermediate boom: a. Slide the secondary intermediate boom over to one side as far as it will go, to allow wear pad installation. b. Place the wear pad inserts (1), saved, into the cavities of the side wear pads (2), saved. Fill the cavities of the wear pad with a good grade of lithium-based EP grease. c.
Boom 15 12 14 12 13 14 Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening. 20. Align the holes in the yoke plates (22) with the hole in the mount on the outer boom. Coat the new shoulder bolt (23), with anti-seize compound, and insert the shoulder bolt through the yoke plates and the mount on the boom. Secure in place with a new elastic locknut (24). Tighten the locknut securely, but the yoke plates must pivot freely. 23 16 22 MH2350 18.
Boom 3.6.8 Inner Boom Installation WARNING: Wear protective footwear with reinforced toe caps and slip-resistant soles. Failure to comply can result in foot or other bodily injury from crushing, slipping or falling. WARNING: NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist. Failure to comply can result in death or serious personal injury.
Boom 5. Install the inner boom lower wear pad: 4. Assemble the upper side wear pads and hose channel assembly to the inner boom: ® a. Apply Loctite 242 threadlocker to the threads of the capscrews (12), saved. Insert a capscrew with a lockwasher (13), saved, through the upper hole in the mounting clip (14) and the front mounting hole of the upper wear pad (15) in the side plates of the inner boom. b.
Boom Note: Shim ALL upper rear wear pads as needed to maintain a total maximum gap of .06" (1,5 mm) at the rear of the pads and maintain a total minimum gap of .07 to.13" (1,8 to 3,3 mm) in the vertical direction. 6. Install the inner boom upper wear pads: a. Apply Loctite® 242 threadlocker to the threads of the capscrews (1), saved, for the upper wear pads (2). b. Place the wear pad shims (3), saved, and wear pad spacer (4) onto the top of the boom with the offset toward the outside of the boom.
Boom Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening. 12. Line up the lower mounting holes in the hose carrier assembly (14) with the holes in the bottom of the inner boom. Insert the four capscrews (15), saved, through the bottom boom plate and up through the hose carrier mounts. Secure the capscrews in place with new elastic locknuts (16). Tighten all four locknuts securely. 15.
Boom 16. Loosen the wear pad mounting bolts (1) holding the hose guide (2) and wear pads (3) to the side of the inner boom. Remove the wear pad mounting bolts (one at a time) with washers. 17. Apply Loctite® 242 threadlocker to the threads of the hose guide and wear pad mounting bolt (1). Reinsert the bolts with washers, but DO NOT fully tighten. Swing the back of the hose guide down to line up the rear notches with the holes in each side of the inner boom.
Boom 23. Spray the wear pad pathways on the underside of the inner boom with LPS3 or equivalent. 15 24. Lift the inner boom. While guiding the hoses into the secondary intermediate boom, carefully slide the inner boom into the front of the secondary intermediate boom. 16 25. Have a second person guide the “male” ends of the four hoses from the hose carrier into the secondary intermediate boom. Have the second person pull the hoses out the rear of the boom as the inner boom is being inserted. 26.
Boom holes and secure in place with the capscrews (9) and lockwashers (11), saved. Be careful not to push the wear pad inserts out of the wear pads. Note: Shim ALL side wear pads as needed to maintain a total minimum gap of .07 to .13" (1,8 to 3,3 mm) in the horizontal direction. d. Torque all wear pad mounting capscrews to 31 ±3 lb-ft (42 ±4 Nm). 34. Assemble the side wear pads to the secondary intermediate boom: a.
Boom 38. Place the inner boom extend chain (17) up and around the sheave (18) at the front of the secondary intermediate boom. Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening. 39. Place the extend chain clevis (19) between the mounting plates at the front of the secondary intermediate boom. Coat the shoulder bolt (20), saved, with anti-seize compound and insert through the plates and clevis. Secure the shoulder bolt in place with a new elastic locknut (21).
Boom Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening. 49. Assemble the hose reel assembly to the left side mounting plate inside the primary intermediate boom: a. Remove the elastic locknut (1) from the upper retaining capscrew (2). Discard the locknut. 9 6 7 8 b. Remove the elastic locknut (3) from the center shoulder bolt (4). Discard the locknut. c. Insert the center shoulder bolt through the lower hole in the left side mounting plate (5).
Boom j. Insert the shoulder bolt (19) back through the plates of the hose reel, inserting the spacers (20) back in position between the plates as the shoulder bolt is inserted. Place the flat washer (18) onto the shoulder bolt and secure in place with a new elastic locknut (17). Tighten securely. 50. Tie the strings (positioned inside the outer boom during the outer boom installation) to the male end of each of the Attachment Tilt and auxiliary hydraulic hoses coming off the bottom hose reel assembly. c.
Boom 52. Remove the strings from the hoses. 7 53. At the front of the outer boom, assemble the hose assemblies and tube assemblies to the mounting plate: 1 4 10 Note: Lubricate the radius at the opening in the bottom of the outer boom with soap and water, to allow the hoses to slide easily when tensioning the hoses. a. Assemble the right side Attachment Tilt hose (1) to the upper right side hole (2) on the mounting plate. Insert the male end of the right side hose through the upper right side hole.
Boom Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening. 56. Insert the capscrew (17), saved, through the quick attach and pin. Secure the capscrew in place with a new elastic locknut (18). Tighten securely. 19 20 21 22 20 13 21 23 14 18 ~ 15 17 MH1720 14 MH1730 58. Assemble the left auxiliary hydraulic hose (26) labeled “Female Coupler” from inside the gooseneck to the female coupler (27) bulkhead fitting. Tighten securely. 16 15 25 24 59.
Boom 60. Use a hoist and slings to position the Attachment Tilt cylinder (1) inside the gooseneck (2). Be sure the Attachment Tilt cylinder is positioned with the tube for the rod end positioned inside the gooseneck. 61. Coat the base end pivot pin (3), saved, with antiseize compound. Line up the hole in the cylinder base end with the mounting holes in the gooseneck, and insert the pivot pin through the gooseneck. Secure the pivot pin to the gooseneck with the two retaining rings (4), saved.
Boom 65. Clean up all debris, hydraulic fluid, etc., in, on, near and around the vehicle. WARNING: Avoid prolonged engine operation in closed areas without adequate ventilation. Failure to properly ventilate exhaust fumes can result in death or serious personal injury. WARNING: Hydraulic oil leaking under pressure can penetrate the skin and cause severe personal injury. DO NOT use your hand or any part of your body to check for hydraulic leaks.
Boom Environments in which material handling vehicles operate can vary widely, from outdoor moisture to mildly corrosive or highly corrosive industrial atmospheres, in addition to abrasive exposures such as sand and grit. Some effects can be as follows: • Moisture - Corrosive rusting reduces chain strength by pitting and cracking. • Temperature - Low temperature reduces chain strength by embrittlement. Going in and out of cold storage results in moisture from condensation.
Boom Edge Wear Turning or Protruding Pins Check the chain for wear on the link plate edges caused by running back and forth over the sheave. The maximum reduction of material must not exceed 5%. This can be compared to a normal link plate height by measuring a portion of chain that does not run over the sheave. Highly loaded chain, operating with inadequate lubrication, can generate abnormal frictional forces between pin and link plates.
Boom • Fatigue Cracking - Fatigue cracks (1) are a result of repeated cyclic loading beyond the chain’s endurance limit. The size of the load and the frequency of its occurrence are factors which determine when fatigue failure will occur. The loading can be continuous or intermittent (impulse load). • Stress Corrosion Cracking - The outside link plates are particularly susceptible to stress corrosion cracking (2).
Boom b. Expose Extend Chains for Inspection 1. Park the vehicle on level ground. Place the travel select lever in (N) NEUTRAL, place the neutral lock lever in the (N) NEUTRAL LOCK position, engage the parking brake switch and raise the boom to a horizontal (level) position. 2. Lower both outriggers completely 3. Fully extend the boom until both extend chains are taut. Shut the engine OFF. The extend chains will be visible for inspection with the vehicle in this state.
Boom 4. At the front underside of the boom, record the amount of threads extending beyond the elastic locknut (1). This measurement will be the starting point for adjustment of the boom retract chain. 5 5. Loosen the elastic locknut (1) far enough so that it can be removed by hand. 4 6 3 1 2 MA9430 MH1110 6. If the chain clevis has a threaded hole on the end (4), a string or wire can be attached to the retract chain clevis using a threaded eye (5) or a flat washer tack welded to a capscrew (6).
Boom 11. Measure the chain elongation. Measure across 17 pins (7), somewhere between the chain sheave and where the chain is laying in the pan or on the tarp. The maximum measurement allowed is 12.36" (313 mm). If the measurement is more than 12.36" (313 mm), the chain must be replaced. (Refer to Section 3.7.6, “Boom Extend and Retract Chains Removal and Replacement.”) 13. Lubricate the chain, while it is exposed, if it does not need to be replaced. (Refer to Section 3.7.2, “Chain Lubrication.”) 14.
Boom If no string or wire was installed to the end of the clevis: 7 18. From the rear of the boom, one person should push the threaded clevis end (1) of the retract chain (2) under the chain sheave and down between the intermediate boom and the outer boom. Keep the retract chain (2) to the right side of the boom, push the threaded clevis down to the tab (3) at the front underside of the outer boom. 19.
Boom d. Expose Inner Boom Retract Chain for Inspection The retract chain must be removed from the boom in order to be visually inspected. This must be done every 1000 hours or whenever the retract chain is removed from the boom. (If removal of the chain is required refer to Section 3.7.6, “Boom Extend and Retract Chains Removal and Replacement.”) 13 While doing the chain inspection, check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain.
Boom 8. Remove the elastic locknut (1) and flat washer (2) holding the retract chain threaded clevis (3) to the mounting tab on the primary intermediate boom (4). Save the flat washer and discard the elastic locknut. 7 5 ~ 8 1 3 ~ 6 2 MH5960 4 Wrap 24 gauge steel wire (5) tightly into the grooves of the threads of the clevis (6). Start the coils as close to the tab as possible. Make sure the end (7) has enough of a tail to wrap into a knot at the top of the clevis.
Boom 10. Place a pan or tarp, free of dirt, at the rear of the vehicle, for the chain to rest on as it is being removed from the boom. From the rear of the boom, pull the retract chain out the rear of the boom. Pull the chain through the middle of the two center hoses on the chain reel and over the top of the chain reel. 11. The part of the chain that is still inside the boom must be exposed for inspection. Have another person assist with this step. 12.
Boom 18. Lubricate the chain, while it is exposed, if it does not need to be replaced. (Refer to Section 3.7.2, “Chain Lubrication.”) 19. Pull the inner boom extend chain (1) up and around the sheave (2) at the front of the secondary intermediate boom. Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening. 20. Place the extend chain clevis (3) between the mounting plates at the front of the secondary intermediate boom.
Boom Front of Boom 15 22 14 19 13 12 20 MH6010 21 28. Coat the threads of the threaded clevis (14) with multi-purpose grease. MH6000 29. Have a second person assist with the next steps.
Boom 3.7.2 Chain Lubrication After inspection and before being returned to service, chains must be lubricated with a quality chain lubricant (“LUBRIPLATE” Chain & Cable Fluid, “LPS3” or equivalent). The lubricant must penetrate the chain joint to prevent wear. Applying lubricant to the external surfaces will prevent rust, but the chains should be articulated to make sure the lubricant penetrates to the working surfaces between the pins and links.
Boom 7 4 5 OA0512 OH0551 2. Tighten or loosen the two extend chain adjustment locknuts (6) located at the rear of the boom. Be sure each of the locknuts are adjusted equally so that each extend chain maintains the same tension. Equal chain tension can be checked by the position of the yoke (5) on the outer boom. The front of the yoke should be parallel with the front edge of the outer boom. 6 Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening. 5.
Boom a. Component/Assembly Verification The secondary intermediate (1) to primary intermediate (2) boom separation should be checked when assembling new boom sections or chains, or when the rear retract chain clevis has been moved forward on the anchor plate. 7 Measure the separation between the secondary intermediate and primary intermediate boom top plates. The distance (3) should be at least 8.5" (216 mm) and not greater than 11" (279 mm) with the boom fully retracted and the chains properly tensioned.
Boom 3.7.5 Inner Boom Chain Tension Adjustment 11 Note: Always perform the Section 3.7.3, “Boom Chain Tension Check,” before adjusting the inner boom extend chain tension. 9 MH1780 2. If there is no adjustment left on the extend chains, tighten the retract chain locknut (12) on the bottom of the primary intermediate boom several turns. 12 OH0551 1. Adjust the inner boom extend chain (9): If the chain sag measurement (10) is less than 1.5" (38 mm), tighten the extend chain adjustment locknut (11).
Boom 9 5 3 6 2 1 4 7 8 OH2870 If the distance is less than 13.75" (349 mm) or greater than 14.25" (362 mm): MH4070 5. Recheck chain tension. (Refer to Section 3.7.3, “Boom Chain Tension Check.”) a. Component/Assembly Verification The inner (7) to secondary intermediate (8) boom separation should be checked when assembling new boom sections or chains, or when the rear retract chain clevis has been moved forward on the anchor plate.
Boom 3.7.6 Boom Extend and Retract Chains Removal and Replacement a. Intermediate Boom Extend Chains Removal and Replacement 1. Park the vehicle on a hard, level surface. 2. Fully retract the boom and raise the boom to a horizontal position. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to (N) NEUTRAL LOCK position, engage the parking brake switch and shut the engine OFF. 3.
Boom 9. At the rear of the boom, attach one end of a wire (1) to the threaded clevis (2) on the right side intermediate boom extend chain. Loop the wire around and twist together to form a loop. Route the wire around the right side of the clevis anchor plate (3). 4 6 8 2 3 1 ~ 7 9 1 MH2590 10. Have a second person assist with the removal of the intermediate boom extend chain.
Boom Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening. 16. Place the flat washer (14), saved, onto the threaded end of the threaded clevis (15) and assemble a new elastic locknut (16). Thread elastic locknut onto the threaded clevis until the threads are flush with the top of the nut. 17 19 17. Cut the loop in the wire and remove the wire from the clevis. 18 16 20 14 15 MH2580 21.
Boom b. Inner Boom Extend Chains Removal and Replacement 1. Park the vehicle on a hard, level surface. 2. Fully retract the boom and raise the boom to a horizontal position. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to (N) NEUTRAL LOCK position, engage the parking brake switch and shut the engine OFF. 6. At the front of the boom, disconnect the inner boom extend chain clevis (11) from the anchor plates on the primary intermediate boom.
Boom 9. At the rear of the boom, attach one end of a wire (20) to the threaded clevis (21) on the inner boom extend chain. Loop the wire around and twist together to form a loop. Route the wire around the right side of the clevis anchor plate (22). 23 24 21 22 26 27 20 25 28 29 20 MH5720 10. Have a second person assist with the removal of the inner boom extend chain. One person should pull the chain from the front of the boom while the second person guides the wire into the boom from the rear.
Boom 18. After the chain is replaced inside the boom, assemble the sheave to the mount at the front of the secondary intermediate boom. 9 Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening. 19. Place the saved inner boom extend chain sheave (1) between the mounts at the front of the secondary intermediate boom. Insert the sheave pin (2), saved, through the mounts and the sheave.
Boom c. Secondary Intermediate Boom Retract Chain Removal and Replacement 1. Park the vehicle on a hard, level surface. 2. Fully retract the boom and raise the boom to a horizontal position. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to (N) NEUTRAL LOCK position, engage the parking brake switch and shut the engine OFF. 3. Remove the thumbscrew (15), lockwasher (16) and flat washer (17) holding the rear cover (18) to the rear of the outer boom (19).
Boom Note: Record the location of the shoulder bolt to ensure correct installation. 8. At the rear of the boom, locate the two retract chain anchor plates (1) holding the secondary intermediate boom retract chain to the secondary intermediate boom, just in front of the retract chain sheave (2). Remove the elastic locknut (3) and shoulder bolt (4) holding the secondary intermediate boom retract chain clevis to the anchor plates. Discard the elastic locknut and save the shoulder bolt.
Boom 17. Check and adjust the secondary intermediate boom retract chain tension. (Refer to Section 3.7.3, “Boom Chain Tension Check.”) d. Inner Boom Retract Chain Removal and Replacement 17 1. Park the vehicle on a hard, level surface. 2. Fully retract the boom and raise the boom to a horizontal position. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to the (N) NEUTRAL LOCK position, engage the parking brake switch and shut the engine OFF. 3.
Boom 9. Pull the inner boom retract chain clevis toward the rear of the boom, through the middle of the two center hoses on the chain reel and over the top of the chain reel. Let the clevis end of the retract chain hang out the rear of the boom. Use a piece of 17 gauge wire that is approximately 6 feet long and tie it to the clevis end of the inner boom retract chain. This wire will be used to guide the chain back into the boom when the boom is extended to expose the other end for removal.
Boom Wrap 24 gauge steel wire (8) tightly into the threads of the clevis (9). Start the coils as close to the tab as possible. Make sure the end (10) has enough of a tail to wrap into a knot at the top of the clevis. Push the clevis (9) and guide wire (8) into the primary intermediate boom (11), so that only the guide wire is hanging out of the tab. 20. Remove the 6 foot piece of wire attached to the rear anchor clevis of the old chain and attach it to the rear anchor clevis of the new chain. 21.
Boom 25. Remove the wire, and the threaded eye or capscrew with flat washer, from the end of the clevis. 6 Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening. 4 26. Place the flat washer (1), saved, onto the threaded clevis (2). Assemble a new elastic locknut (3) onto the threaded clevis. Turn the elastic locknut only 2 or 3 turns onto the clevis to allow assembly of the other end of the retract chain. 5 3 7 2 MH1790 30.
Boom 32. Pull the inner boom extend chain (1) up and around the sheave (2) at the front of the secondary intermediate boom. 3.8 Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening. 3.8.1 33. Place the extend chain clevis (3) between the mounting plates at the front of the secondary intermediate boom. Coat the saved shoulder bolt (4) with anti-seize compound and insert through the plates and clevis.
Boom 5. Locate the two hoses (1) attached to the base of the Attachment Tilt cylinder (2) inside the gooseneck (3). 6. Label and remove the hoses (1) from the elbow fittings (4) on the Attachment Tilt cylinder. Plug the hose ends and cap the elbow fittings on the Attachment Tilt cylinder to prevent dirt and debris from entering the hydraulic system and/or cylinder. 8. Remove the thumbscrew (8), lockwasher (9) and flat washer (10) holding the rear cover to the rear of the outer boom (12).
Boom 10. Label and remove the auxiliary hoses (16 and 17) from the tube assemblies (15) at the mounting plate. Cap the hose ends. Tie a string to each of the hoses to aid in the installation of the new hoses. 11. Label and remove the four hoses from the hose reel. The center bolt (18) can remain in place to hold the hose reel and side plates together. 12. Remove the elastic locknut (19) and flat washer (20) from the lower retaining shoulder bolt (21).
Boom 18. At the front of the boom, disconnect the inner boom extend chain clevis (1) from the anchor plates on the primary intermediate boom. Remove the elastic locknut (2) holding the shoulder bolt (3) to the anchor plates. Pull the extend chain clevis from between the plates and lay over the front of the inner boom (4). Save the shoulder bolt and discard the elastic locknut. 20.
Boom 24. Start the engine and extend the boom until the inner boom retract chain adjustment nut (23) on the bottom of the primary intermediate boom is visible. Shut the engine OFF. 25. Loosen the elastic locknut (23) on the inner boom retract chain clevis. DO NOT remove the elastic locknut at this time, but loosen the nut as far as possible to gain as much slack as possible in the retract chain. 28 24 25 26 27 23 MH2670 28.
Boom 30. Remove the four capscrews (1) and locknuts (2) holding the hose carrier support (3) to the hose carrier (4). To access the capscrews, it will be necessary to move the hoses to the side. Save the capscrews and hose carrier support. Discard the locknuts. 9 12 11 13 10 1 14 4 Note: Record the hose locations before removing them from the hose carrier assembly, to ensure correct installation. 3 2 MH1910 MH1860 31. Pull the inner boom straight out of the secondary intermediate boom.
Boom 38. Remove the hose carrier assembly (20) from the inner boom by carefully pulling the hose carrier straight out the rear of the inner boom (21). Pull both the upper and lower portion of the hose carrier assembly out at the same time. 20 42. Disassemble the hose channel assembly to replace any parts that are bent, twisted or damaged. Remove the capscrews (27) and lockwashers (28) holding the mounting clips (29) to the channels (30). Remove the retainer nuts (31) from the mounting clips. 43.
Boom 3.8.2 Hose Carrier Assembly Replacement 1. Carefully lay the new hose carrier assembly out flat on a hard surface. 2. Stretch the “male” ends (1) of the hoses out straight from the end of the hose carrier assembly (2). Measure back from the end of the “male” end of each hose to the center of the pivot point (3) of the hose carrier mount (4). This measurement should be 201" (510,5 cm). All four hoses MUST be equal in length from the hose carrier. 3.
Boom Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening. 10. Label each end of the hoses of the new hose carrier assembly for proper identification during reassembly: 7. Line up the lower mounting holes in the hose carrier assembly (12) with the holes in the bottom of the inner boom. Insert the four capscrews (13), saved, through the bottom boom plate and up through the hose carrier mounts. Secure the capscrews in place with new elastic locknuts (14).
Boom Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening. 5 2 14. Insert a capscrew (9), saved, through the hole in the inner boom. Secure the hose guide in place with a flat washer (10), saved, and a new elastic locknut (11). Tighten securely. 3 1 15. Tighten the wear pad and hose guide capscrews. Torque all wear pad mounting capscrews to 31 ±3 lb-ft (42 ±4 Nm). 2 11 10 6 4 9 7 MH2470 12.
Boom IMPORTANT: DO NOT allow the hoses to cross inside the inner boom. 17. At the front of the inner boom, pull the two hoses that were labeled “Attachment Tilt - Retract” (12) left side and “Attachment Tilt - Extend” (13) right side out of the opening in the back of the gooseneck. Let the hoses hang out of the back of the gooseneck. 18.
Boom 7. Remove the capscrews (1) and lockwashers (2) holding the lower wear pad to the bottom of the secondary intermediate boom. 7 6 8. Apply Loctite® 242 threadlocker to the threads of the capscrews. Line up the holes in the lower mounting plate on the hose carrier support (3) and reinsert the capscrews and lockwashers. Be careful not to push the inserts out of the wear pads. 9. Torque all wear pad mounting capscrews to 31 ±3 lb ft (42 ±4 Nm).
Boom 14. Place the inner boom extend chain (20) up and around the sheave (21) at the front of the secondary intermediate boom. Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening. 15. Place the extend chain clevis (22) between the mounting plates at the front of the secondary intermediate boom. Coat the shoulder bolt (23), saved, with anti-seize compound and insert through the plates and clevis. Secure the shoulder bolt in place with a new elastic locknut (24).
Boom IMPORTANT: Keep the four hoses in line (left to right) as they come out of the hose carrier assembly at the rear of the secondary intermediate boom. 16. Place a lockwasher (1), saved, onto each capscrew (2), saved. Insert the capscrews through the hose clamp support bracket (3), saved. Insert the capscrews from the side as shown. 4 4 4 8 1 6 4 10 18. Place another hose clamp half (4), saved, the right Attachment Tilt hose (6) and another hose clamp half (4) onto the capscrews. 22.
Boom 27. Remove the elastic locknut (19) and flat washer (20) from the lower retaining shoulder bolt (21). While pulling the shoulder bolt out, catch the spacers (22) from between the plates as the shoulder bolt is removed. Place the Attachment Tilt hoses and the auxiliary hydraulic hoses around the hose reel. Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening. 28.
Boom 32. At the front of the outer boom, assemble the hose assemblies and tube assemblies to the mounting plate: 7 1 4 Note: Where the hose assemblies come out of the outer boom, lubricate the radius in the outer boom with soap and water to allow proper tensioning of hoses. 10 a. Assemble the right side Attachment Tilt hose (1) as it comes down the outer boom to the upper right side hole (2) on the mounting plate. Insert the male end of the right side hose through the upper right side hole.
Boom 36. Adjust the inner boom extend and retract chains. (Refer to the Section 3.7.5, “Inner Boom Chain Tension Adjustment.”) 37. After adjustment is complete, assemble the rear cover to the rear of the outer boom. On the rear of the outer boom (21), position the rear cover (22) in place. Secure the cover with the flat washer (23), saved, internal-tooth lockwasher (24), saved, and thumbscrew (25), saved. Insert the thumbscrew through the bottom of the outer boom and into the rear cover.
Boom 3.9 BOOM WEAR PADS 3.9.1 The wear pads (1) on this vehicle are flat rectangular wear pads with metal inserts (2). Wear Pad Inspection Inspect all wear pads (3) for wear. If the angle indicators (4) on the ends of the wear pads are visible, the wear pads can be reused. If the pads show uneven wear (front to back), they should be replaced. Replace pads as a set if worn or damaged. 1 4 4 3 3.9.
Boom a. Inner Boom b. 8042/10042 Intermediate Boom All inner boom wear pads (5) are mounted on the rear outside of the inner boom. Coat all wear pad capscrews with Loctite 242® (blue) before installation. The wear pads (8) on the front of the intermediate boom can be replaced by removing the fasteners securing them to the top, sides and bottom of the boom. When removing pads, move the boom sections as needed to gain access for removal and installation of wear pads.
Boom d. 10054 Primary Intermediate Boom c. 10054 Secondary Intermediate Boom Coat all wear pad capscrews with Loctite before installation. 242® (blue) Coat all wear pad capscrews with Loctite 242® (blue) before installation. The wear pads (1) on the front of the intermediate boom can be replaced by removing the fasteners securing them to the top, sides and bottom of the boom.
Boom 3.10 e. Outer Boom All outer boom pads (7) are mounted on the front of the outer boom. Remove the top wear pads before removing the bottom wear pads. Lower the gooseneck to the ground until the intermediate boom raises up, providing clearance for removing the bottom pads. Fill the grease pockets (8) of the top rear boom wear pads with multipurpose grease. Use Loctite® 242 (blue) on all wear pad capscrews. Use shims as required to maintain a maximum gap of 0.
Boom 3.10.2 Connecting to an Attachment 1. Perform this procedure on a hard, level surface only. Position the vehicle directly behind the attachment to be mounted. 2. Tilt the quick attach backward. 3. Extend the boom approximately 10 ft (3,05 m) and drive the vehicle forward until the attachment pivot pins are below and between the two hooks on the attachment. 4. Raise the boom until the attachment pivot pins have seated fully in the hooks on the attachment. 3 5. Tilt the attachment up slightly.
Boom 3.10.4 Quick Attach Installation 1. Assemble the quick attach to the gooseneck. Line up the quick attach (11) between the mounts on the gooseneck. Assemble a washer (12), saved, on each side of the quick attach. Reassemble the shims (13), saved, between the quick attach and the gooseneck. DO NOT put all the shims on one side. The quick attach should be centered in the gooseneck. Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening. 5.
Boom 3.11 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that occur during operation of the boom. Boom Troubleshooting Problem Cause Remedy 1. Broken hydraulic hose(s) or tube(s) and/or connections leaking. 1. Locate break, replace hose(s) or tube(s), tighten connections. 2. Extend/Retract hydraulic system not operating properly. 2. Refer to Section 8, “Hydraulic System.” 3. Faulty Extend/Retract cylinder. 3. Repair cylinder (Refer to Section 8.
Boom Boom Troubleshooting (Continued) Problem Cause 5. Excessive Slave cylinder pivot pin noise and/or wear. 6. Dropping chain, or jerky boom extend or retract functions. Model 8042, 10042, 10054 Legacy Rev. 03/04 Remedy 1. Insufficient lubrication. 1. Lubricate at regular intervals. (Refer to appropriate owners manual for lubrication points.) Replace worn pins as needed. Refer to Section 3.3.4, “Outer Boom Installation.” 2. Worn bearing(s). 2.
Boom Boom Troubleshooting (Continued) Problem 7. Boom will not raise or lower. 8. Excessive Lift/Lower cylinder pivot pin noise and/or wear. 9. Rapid boom pad wear. 10. Auxiliary hydraulics will not operate. 3.176 Cause Remedy 1. Broken hydraulic hoses or tubes and/or connection leaks. 1. Locate break, replace hose(s) or tube(s), tighten connections. 2. Lift/Lower hydraulic system not operating properly. 2. Refer to Section 8, “Hydraulic System.” 3. Faulty Lift/Lower cylinders. 3.
Boom Boom Troubleshooting (Continued) Problem Cause 11. Excessive chain wear. Model 8042, 10042, 10054 Legacy Rev. 03/04 Remedy 1. Improper chain adjustment. 1. Adjust to correct tension. (Refer to Section 3.4.3, “Boom Chain Tension Check,” - 8042 and 10042 or Section 3.7.3, “Boom Chain Tension Check,” - 10054.) Replace chains as needed. (Refer to Section 3.4.5, “Boom Extend and Retract Chains Removal and Replacement,” 8042 and 10042 or Section 3.7.
Boom This Page Intentionally Left Blank 3.178 Model 8042, 10042, 10054 Legacy Rev.
Section 4 Cab and Covers Contents PARAGRAPH 4.1 4.2 4.3 4.4 4.5 4.6 4.7 TITLE Operator’s Cab and Covers Component Terminology. . . . . . . . . . . . . . . . . . . . . Operator’s Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 Operator’s Cab Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab and Covers 4.1 OPERATOR’S CAB AND COVERS COMPONENT TERMINOLOGY To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the vehicle cab and covers. The following illustration identifies the components that are referred to throughout this section.
Cab and Covers WARNING: DO NOT service the vehicle without following all safety precautions as outlined in the “Safety Practices” section of this manual. Failure to follow the safety practices may result in death or serious injury. 4.2 4.2.1 OPERATOR’S CAB Operator’s Cab Description The welded metal cab features a modular design, allowing for a relatively quick, simple exchange of the entire cab and/or component parts. The cab is bolted directly to the frame.
Cab and Covers 4.3 OPEN CAB COMPONENTS 4.3.1 7. If the seat is to be replaced: Remove the two capscrews (12 and 13), two washers (14), seat belt assembly (15), two spacers (16) and two flanged hex nuts (17). Transfer these parts and two tethers (6right and 7-left) to the replacement seat with the seat out of the cab. Seat/Seat Belt a. Seat Removal 1. Park the vehicle on a firm, level surface.
Cab and Covers 4.3.2 Steering Wheel, Column and Shifter b. Steering Wheel Installation The steering wheel and transmission travel and gear select lever are mounted on the steering column. 1. Install the steering wheel (21) onto the splined steering column shaft. a. Steering Wheel Removal 2. Secure the steering wheel with a M18-1,5 thin nut (20). Torque the nut to 50 lb-in (68 Nm). 1. Park the vehicle on a firm, level surface.
Cab and Covers 6. Working through the right dash panel opening, disconnect the transmission travel and gear select lever wiring connector (1). 1 d. Transmission Travel and Gear Select Lever Installation 1. Position the transmission travel and gear select lever (3) onto the steering column, aligning the pin (5) with the hole (6) in the steering column. 2. Attach the transmission travel and gear select lever with the collar (4) and two hex socket-head screws (2).
Cab and Covers 3. Unlock and open the rear door. Allow the engine and hydraulic fluid to cool. 10 4. Disconnect the battery negative (-) cable or cables at the battery negative (-) terminal. 5. Remove the four button-head screws securing the lower dash panel (9) to the cab. Remove the lower dash panel (9). 6. Remove the steering wheel. (Refer to Section 4.3.2, a. “Steering Wheel Removal.”) 7. Remove the transmission travel and gear selector lever. (Refer to Section 4.3.2, c.
Cab and Covers 9. Working through the right dash panel opening, label, disconnect and plug the load sense hose (1) at the top of the steering valve. Cap the fitting on the steering valve. 5 4 10. Disconnect the horn button wire (2) from the cab wiring harness. 1 7 6 3 2 MA8860 b. Steering Column and Valve Installation MA8680 11. Support the bottom of the steering valve (3), and remove the four hex-flange capscrews (4) and four lockwashers (5).
Cab and Covers Note: ALWAYS use new o-rings when servicing the vehicle. 5. Install new o-rings into the fittings. Lubricate the o-rings with clean hydraulic oil. 6. Working through the right dash panel opening, connect the four hoses (8 thru 11) to the appropriate ports, as noted in Step 8 of the removal procedure. 11. Start the engine and check the operation of steering system. Check for hydraulic fluid leaks. Check the hydraulic fluid level in the tank and add fluid as required. 12.
Cab and Covers 4.3.4 7. Remove the service brake pedal (6) from the cab. Brake Pedal and Valve a. Brake Valve Removal Refer to Section 8.12.3, a. “Service Brake Valve Removal,” for removal information. b. Brake Valve Installation Refer to Section 8.12.3, b. “Service Brake Valve Installation,” for installation information. c. Service Brake Pedal Removal 5 1. Park the vehicle on a firm, level surface.
Cab and Covers 4.3.5 b. Throttle Pedal Installation Throttle Pedal Replacement 1. Install the hex jam nut (13) and flat washer (14) onto the end of the throttle cable (15). Secure the cable to the throttle pedal (10). Secure the cable to the throttle pedal (10), with the cable clamp (17) and two locknuts (16). 8042 S/N 13198 thru 18990 10042 S/N 13198 thru 19030 10054 S/N 13198 thru 19079 a. Throttle Pedal Removal 1. Park the vehicle on a firm, level surface.
Cab and Covers b. Throttle Pedal Installation 8042 S/N 18991 and After 10042 S/N 19031 and After 10054 S/N 19080 and After 1. Position the throttle pedal in the cab. Line up the mounting holes in the throttle pedal with the mounting holes in the cab floor. a. Throttle Pedal Removal 1. Park the vehicle on a firm, level surface.
Cab and Covers This Page Intentionally Left Blank Model 8042, 10042, 10054 Legacy Rev. 10/03 4.
Cab and Covers 4.3.6 6. Repeat Step 5 to remove the boom extend/retract control cable (8). Joystick Assembly Replacement Joystick Assembly Removal 1. Park the vehicle on a firm, level surface. Set the park brake, ground the carriage, place the travel select lever in the (N) NEUTRAL position, place the neutral lock lever in the (N) NEUTRAL LOCK position, engage the parking brake and turn the ignition OFF. 7 6 2.
Cab and Covers 16 17 16 11 ~ 12 MA8630 13 Joystick Assembly Installation 9 10 MA8490 9. Remove four button-head capscrews (14) and remove the console panel (15). 1. Route the control cables through the opening, the console, and through the opening at the bottom of the cab. Secure the joystick panel assembly (17) with four button-head capscrews (16). 2. Route the control cables through the opening at the bottom of the frame. 3.
Cab and Covers 5. Connect the boom lift/lower control cable to the main control valve assembly: 9. Test the boom extend/retract and boom lift/lower joystick (6) function: a. Install the cable in the bracket, and slide the jam nut (1) over the end of the boom lift/lower control cable (2). DO NOT tighten the jam nuts at this time. a. Move the joystick handle rearward, activating the boom lift function. The boom should RISE. b. Connect the end of the cable to the shaft from the control valve.
Cab and Covers 12. Install the upper (11) and lower (10) transmission covers; secure using six hex nuts, six lockwashers and six flat washers (12). 11 6. Disconnect the boom auxiliary hydraulic control cable: 12 a. Remove the spring pin (14) and anchor pin. Save the spring pin and anchor pin for installation. ~ b. Loosen and remove the inner jam nut (15), and remove the auxiliary hydraulic control cable (16) from the bracket. Save the jam nut for installation.
Cab and Covers c. Adjust the jam nuts until the distance (6) from the outer jam nut to the end of the ferrule is the same as recorded during removal. Tighten the jam nuts. 8. Remove three capscrews (1), three lockwashers and three flat washers. 9. Remove the auxiliary hydraulic joystick assembly (2) from the vehicle. 2 ~ 5 3 4 1 6 MA8490 MA8530 b. Auxiliary Hydraulic Joystick Installation 4. Install the console panel (7) and secure using four button-head capscrews (8). 1.
Cab and Covers 5. Install the lower (9) and upper (10) transmission covers; secure using six hex nuts, six lockwashers and six flat washers (11). 10 11 ~ ~ 11 9 MA8620 4.3.8 Electrical Components a. Fuse Panel/Cab Harness Refer to Section 9.1.1, “General Overview (Cab Harness).” Model 8042, 10042, 10054 Legacy Rev. 10/03 4.
Cab and Covers 4.3.9 Miscellaneous Cab Components 4 3 2 1 16 15 14 13 12 13 8 7 6 5 10 9 11 1. Mirror Assembly 2. Lockwasher (2) 3. Hex Hd. Capscrew (2) 4. Tilt Angle Gauge 4.20 5. 6. 7. 8. 9. Lock Nut (4) Lock Nut (3) Flat Washer (3) Document Holder Step 10 MA8810 10. Flat Washer (4) 11. Hex Hd. Capscrew (4) 12. Lock Nut (2) 13. Flat Washer (2) 14. Arm Rest 15. Self-Tapping Screw (6) 16. Brush Strip Assembly (2) Model 8042, 10042, 10054 Legacy Rev.
Cab and Covers 4.4 4.4.1 ENCLOSED CAB (OPTIONAL) COMPONENTS Windshield Wiper Assembly Refer to Section 9.12.2, “Windshield Wiper Motor,” for removal and installation information. 4.4.2 6. Place a funnel at the base of the radiator to channel the drained coolant into the container. Open the radiator drain plug or petcock (17) located on the right side or the right side bottom of the radiator and allow the coolant to drain. Replace the drain plug, or close the petcock.
Cab and Covers Note: The button-head capscrew (1) at the lower rear position on each side of the heater will be secured with an insert nut (2). 10 ~ 11. Remove eight button-head capscrews (1 and 3), six nuts (4) and six lockwashers (5). 12. Carefully pull the heater assembly (6) forward. Label and disconnect the wiring harness connections (7) at the blower. 13. Remove the heater assembly (6). 9 7 11 6 ~ 4 8 5 2 ~ 4 MA8710 5 3 1 MA8730 14.
Cab and Covers 3. Pull the hoses (12 and 13) through the grommets, and connect to the heater. Secure with two hose clamps. 4. Install the heater access panel (14) and secure with four button-head capscrews (15) and four acorn nuts (16). 15 6. Connect the battery negative (-) cable or cables to the battery negative (-) terminal. IMPORTANT: When the engine is initially started, run it briefly at low idle and check the vehicle for any visual sign of fluid leakage.
Cab and Covers 4.4.5 Heater/Defroster System Components 7 6 1 2 5 3 4 8 12 9 11 10 11 13 19 27 14 28 2 2 15 21 20 2 22 23 2 22 23 2 26 2 2 24 16 18 17 16 17 1 25 1. Heater Hose (return to engine) 2. Hose Clamp (10) 3. Reducer 4. Wiring Harness 5. Hose Clamp 6. Defroster Duct 7. Heater/Fan Control 8. Defroster Hose 4.24 9. 10. 11. 12. 13. 14. 15. 16. 17.
Cab and Covers 4.4.6 Door and Latches 41 40 36 37 31 39 34 38 42 32 33 31 32 30 45 33 29 31 32 44 43 33 31 35 29. 30. 31. 32. 33. Door Assembly Strap Cap (6) Hex Head Capscrew (3) Hex Nut (3) Model 8042, 10042, 10054 Legacy 34. 35. 36. 37. 38. Upper Door Section Lower Door section Acorn Nut (2) Lockwasher (2) Screw (2) Rev. 10/03 39. 40. 41. 42. 43. Female Door Retainer Acorn Nut Lockwasher Door Bumper Lockscrew (2) MA8760 44. Striker Assembly 45. Nut Plate 4.
Cab and Covers 4.4.7 Windows Note: The slider window assembly (1), skylight glass (2) and left side rear glass (12) are bonded to the cab with adhesive. 2 4 8 1 3 4 5 6 7 9 4 5 10 9 8 18 5 3 11 7 4 23 5 6 18 12 17 19 14 18 11 22 20 13 21 16 1. Slider Window Assembly 2. Skylight Glass 3. Rear Window Hinge Block (2) 4. Torx Screw (6) 5. Flat Washer (4) 4.26 6. 7. 8. 9. 10. 11.
Cab and Covers 4.5 CAB REMOVAL WARNING: Risk of death or serious personal injury. NEVER modify, weld or drill the cab. WARNING: The protection offered by this ROPS/FOPS will be impaired if subjected to any modification or structural damage, at which time replacement is necessary. ROPS/ FOPS must be properly installed using fasteners of correct size and grade, and torqued to their specified value. IMPORTANT: To help ensure safety and optimum performance, replace the cab if it is damaged.
Cab and Covers 7. Working under the cab, loosen the clamp screw (1) and disconnect the heater control cable (2) from the heater control valve (3). Note: Label all hoses to ensure correct installation. 8. Loosen the hose clamps (4 and 5), and disconnect the heater hoses (6 and 7). 10. Disconnect the two cab-to-wiring harness connectors (10 and 11). Push the harness connectors through the opening (12) at the bottom of the cab. 10 11 2 1 3 6 4 12 5 7 MA8780 9.
Cab and Covers 13. Working under the cab, label and disconnect the hydraulic hoses (20 thru 27) at the cab fittings. Plug the hoses and cap the fittings. 13 22 21 20 23 24 14 15 27 16 26 25 MA8500 17 14. Remove six hex nuts, six lockwashers and six flat washers (28) securing the upper (29) and lower (30) transmission covers to the frame. Remove the covers. 18 19 MA8520 29 12. Vehicles equipped with auxiliary hydraulic only: Remove the auxiliary hydraulic joystick assembly. (Refer to Section 4.
Cab and Covers Follow steps 16 thru 18 for: 8042 S/N 13198 thru 18990, 10042 S/N 13198 thru 19030 or 10054 S/N 13198 thru 19079. 16. Remove one elastic locknut (1). Disconnect the throttle cable rod end (2) at the throttle lever extension bracket (3). 12 10 11 9 14 13 11 8 12 17. Remove two slotted pan-head screws (4) two lockwashers, two hex nuts and clamp (5) from the throttle cable bracket (6). 14 13 18.
Cab and Covers 4.6 CAB INSTALLATION WARNING: Wear protective footwear with reinforced toe caps and slip-resistant soles. Failure to comply can result in foot injury from falling objects or other bodily injury from slipping or falling. WARNING: NEVER lift a heavy object without the help of at least one assistant or a suitable sling or hoist. Failure to comply can result in death or serious personal injury. 1. Block all four wheels to help prevent the vehicle from moving.
Cab and Covers 13. Route the control cables through the opening at the bottom of the cab. 14. Connect control cables at the joystick: a. Install the end of the boom extend/retract cable (1) into the slider head (4) as recorded during removal. Tighten the upper jam nut (2). 15. Route the wiring harness connectors through the opening (9) at the bottom of the cab and up into the side console. 16. Connect the two cab-to-wiring harness connectors (10 and 11). 10 b.
Cab and Covers 18. Install the lower (14) and upper (15) transmission covers; secure using six hex nuts, six lockwashers and six flat washers (16). 16 15 21. Fill the cooling system completely with a 50/50 mixture of ethylene glycol and water, allowing time for the coolant to fill the engine block. The cooling system capacity is listed in Section 2.5.8, “Fluid and Lubricant Capacities.” 22. Connect the battery negative (-) cable or cables to the battery negative (-) terminal. ~ 23.
Cab and Covers 4.7 4.7.1 ACCESS PANELS AND COVERS Access Panel and Cover Replacement Note: Refer to appropriate parts manual for mounting hardware. The vehicle is equipped with various access panels and covers. Removal and installation are easily accomplished by observing the mounting configurations as shown. 6 5 1 7 4 3 2 8 MH3340 1. Hydraulic Oil Reservoir/ Fuel Tank Cover 2. Counterweight Cover 3. Transmission Cover, Lower (Model 8042, 10042, 10054, S/N 14053 & After) 4.34 4.
Section 5 Axles, Drive Shafts, Wheels and Tires Contents PARAGRAPH 5.1 5.2 5.3 5.4 5.5 5.6 TITLE Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1 Axle Assembly Description . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axles, Drive Shafts, Wheels and Tires 5.1 AXLE, DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGY To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the axles, drive shafts, wheels and tires. The following illustration identifies the components that are referred to throughout this section.
Axles, Drive Shafts, Wheels and Tires 5.3.2 WARNING: DO NOT service the vehicle without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. Failure to follow the safety practices may result in death or serious injury. 5.2 GENERAL INFORMATION IMPORTANT: To help ensure optimum performance, the drive shaft assemblies are specially balanced as a unit at the factory.
Axles, Drive Shafts, Wheels and Tires All wheels are a one-piece design with, ten, one-inch diameter holes equally spaced on a 13.18" diameter bolt circle. A 12-ply (or better) directional-tread tire, 13.00-24 or optional 15.5 x 25 Radial tire can be used on the 8042, and a 17.5 x 25 Radial, 12-ply (or better) directional-tread tire can be used on the 10042/10054. Tires are filled only with air when the vehicle is shipped from the factory. 5.3.
Axles, Drive Shafts, Wheels and Tires • Before disassembling any parts inside the carrier, remove the entire axle assembly from the vehicle and securely support it with the pinion facing up in an appropriate stand or rack. • DO NOT reuse oil or grease seals. CLEANING: Clean parts with machined or ground surfaces (such as gears, bearings and shafts) with emulsion cleaners or petroleum-based cleaners. DO NOT steam clean internal components and the interior of the planetary hub and axle housing.
Axles, Drive Shafts, Wheels and Tires 7. Label, disconnect and plug the left (3) and right (4) outrigger cylinder hydraulic hoses. Cap all fittings. 8. Support the outrigger assembly (5) using a suitable jack, hoist or overhead crane. 8. Connect the wiring connectors to the outrigger cylinder pressure switches (1 and 2). Secure the harnesses to the cylinders with wire ties. 9. Remove the eight capscrews (6), eight hex nuts (7), eight flat washers (8) and two mount plates (9).
Axles, Drive Shafts, Wheels and Tires 6 9 11 4 3 10 12 5 8 7 MH3270 Model 8042, 10042, 10054 Legacy Rev. 10/03 5.
Axles, Drive Shafts, Wheels and Tires c. Axle Removal WARNING: An improperly supported vehicle can fall, causing death or severe personal injury. Safely raise and adequately support the vehicle so that it will remain stable and in place before attempting to remove an axle. WARNING: Hot hydraulic fluid can cause severe burns. Wait for the hydraulic fluid to cool before servicing any hydraulic component. 5. Models 10042 and 10054, Front Axle Only: Remove outrigger assembly. Refer to Section 5.3.6, a.
Axles, Drive Shafts, Wheels and Tires 13. Remove the capscrew (4) and locknut (5) securing the lower position cylinder-mount pin (6) to the cylinder (7-Front or 8-Rear). Tap the cylinder mount pin out, and move the cylinder to prevent it from interfering with axle removal. 14. Remove the capscrew (9) and locknut (10) securing the axle pivot pin (11) to the frame. Note: Record the number and location of shims (12) to ensure correct installation. 15. Remove the pivot pin (11) and shims (12). 16.
Axles, Drive Shafts, Wheels and Tires d. Axle Inspection, Internal Service and Repair Detailed axle service instructions (covering the axle, differential, brakes and wheel-end safety, repair, disassembly, reassembly, adjustment and troubleshooting information) are provided in the ZF Axle Repair Manuals. (Refer to Section 5.3.8, “ZF Axle Repair Manuals.
Axles, Drive Shafts, Wheels and Tires 8 10 4 6 5 9 8 7 14 12 15 13 4 12 11 14 11 6 15 5 13 7 3 5 17 5 2 16 Model 8042, 10042, 10054 Legacy Rev. 10/03 MH3250 5.
Axles, Drive Shafts, Wheels and Tires 10. If reinstalling an axle previously removed from the vehicle, position the driveshaft yoke on the axle according to the alignment marks made earlier. If installing a new axle, note the position of the driveshaft yoke at the transmission. Align the driveshaft yoke on the axle in the same plane as the yoke on the transmission. 11. Install the wheel and tire assemblies. (Refer to Section 5.5.4, “Installing Wheel and Tire Assembly onto Vehicle.”) 12.
Axles, Drive Shafts, Wheels and Tires 5.3.
Axles, Drive Shafts, Wheels and Tires 5.3.9 Axle Assembly and Drive Shaft Troubleshooting (Continued) Problem 3. Vibration or intermittent noise when traveling. 4. Oil leaking from axle (differential housing and/or axle housings). 5. Oil leaking from wheel end housing (planet carrier). 5.14 Cause Remedy 1. Drive shaft universal joint assembly(ies) incorrectly tightened. 1. Tighten capscrews to correct torque. 2. Drive shaft universal joint(s) worn or damaged. 2.
Axles, Drive Shafts, Wheels and Tires 5.3.9 Axle Assembly and Drive Shaft Troubleshooting (Continued) Problem Cause 6. Oil leaking from steering cylinder. 7. Axle overheating. 8. High steering effort required. 9. Slow steering response. 10. Excessive noise when brakes are engaged. 11. Brakes will not engage. 12. Brakes will not hold the vehicle or braking power reduced. Model 8042, 10042, 10054 Legacy Rev. 10/03 Remedy 1. Hose fittings loose. 1. Tighten fittings. 2.
Axles, Drive Shafts, Wheels and Tires 5.3.10 Axle Internal Component Troubleshooting Note: The following conditions may be noticed when inspecting parts during axle repair. Perform all remedies that apply to the conditions noticed. Problem Cause Remedy (See Note) 1. Differential ring gear teeth broken on the heel of the tooth. 1. Incorrect alignment of ring and pinion gears (excessive play). 2. Differential ring gear teeth broken on the toe of the tooth. 1.
Axles, Drive Shafts, Wheels and Tires 5.4 5.4.1 DRIVE SHAFTS Drive Shaft Inspection and Service 3. Cross assemblies should flex and be free from excessive binding. A slight amount of drag or resistance is desirable on a new cross and bearing assembly. Excessive looseness causes unbalance. Whenever servicing the vehicle, conduct a visual inspection of the drive shafts and cross and bearing assemblies (universal joints, or U-joints).
Axles, Drive Shafts, Wheels and Tires 5.4.2 Drive Shaft Maintenance Refer to the appropriate owners/operators manual for information regarding the lubrication of the grease fittings on the drive shafts. 5.4.3 5. (SN 18991 (8042), 19031 (10042), 19080 (10054) & After Only) Disconnect the battery negative (-) ground cables (2) at the battery negative (-) terminals to prevent the engine from starting accidentally.
Axles, Drive Shafts, Wheels and Tires b. Engine-to-Transmission Drive Shaft 5.4.4 1. Level the vehicle, ground the carriage, place the travel select lever in the (N) NEUTRAL position, place the neutral lock lever in the (N) NEUTRAL LOCK position, engage the parking brake switch and shut the engine OFF. 2. Place an Accident Prevention Tag on both the ignition key switch and steering wheel, stating that the vehicle should not be operated. (Refer to Section 1.5, “Accident Prevention Tags.”) 3.
Axles, Drive Shafts, Wheels and Tires 4. Use a soft, round drive pin with a flat face approximately 1/32" (0,8 mm) smaller than the hole diameter in the yoke to drive on one end of the cross and bearing assembly until the opposite bearing assembly comes out of the yoke. 6 2 4 5. Turn the yoke over and tap on the exposed end of the cross until the opposite bearing assembly comes out of the yoke. 3 1 6. Remove the cross (2) from the yoke (4 or 5). 7.
Axles, Drive Shafts, Wheels and Tires 5.4.6 Drive Shaft Assembly To Transmission 1. Install the dust cap (7), split retaining ring (8) and felt seal (9) onto the splines of the drive shaft tube assembly. IMPORTANT: Ensure that the reference marks made before removal on the drive shaft and slip yoke are aligned. The drive shaft and yokes must be in the same plane to help prevent excessive vibration. 13 2. Align the reference marks made previously on the drive shaft and slip yoke. 11 3.
Axles, Drive Shafts, Wheels and Tires b. Engine-to-Transmission Drive Shaft 6. The drive shaft assembly is a balanced assembly. Mark the yoke and axle, transmission and the shaft and slip yoke so that these components can be returned to their original positions when reinstalled. Yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration. 10.
Axles, Drive Shafts, Wheels and Tires 5.5 WHEELS AND TIRES 8 WARNING: Risk of death or serious personal injury. Mismatched tire sizes, ply ratings or mixing of tire types (radial tires with bias-ply tires) may compromise vehicle stability and may cause vehicle to tip over. 9 The Model 8042 uses a wheel type with nominal dimensions of 9" x 24". An optional wheel type with a nominal dimension of 13" x 25" is available. The Model 10042 and 10054 uses wheels with nominal dimensions of 13" x 25".
Axles, Drive Shafts, Wheels and Tires 5.5.1 Removing Wheel and Tire Assembly from Vehicle WARNING: Risk of death or serious personal injury, if proper safety procedures are not followed. When removing the wheel and tire assembly from the vehicle, follow the instructions in the “Wheel Removal Instruction” box that follows: 4. Loosen but DO NOT remove the lug nuts on the wheel and tire assembly to be removed. 5. Place a suitable jack under the axle pad closest to the wheel being removed.
Axles, Drive Shafts, Wheels and Tires 5.5.2 5.5.4 Wheel Cleaning WARNING: Dirt and rust prevent the tire from seating properly on the wheel, which could result in an explosive separation. Such explosions could result in death or severe personal injury to the tire installer and to those in the area. Installing Wheel and Tire Assembly onto Vehicle IMPORTANT: The wheel and tire assemblies must be installed with the directional tread pattern “arrows” facing in the direction of forward travel.
Axles, Drive Shafts, Wheels and Tires 1. Position wheel onto studs on wheel end of axle. Wheel Dismounting Instructions: 2. Install wheel lug washers. 3. Install lug nuts and tighten in an alternating pattern (A thru K). Torque to 430 to 470 lb-ft (583 to 637 Nm). A H E • Use safety chains, or place the wheel and tire assembly in a safety cage when deflating a tire or when inflating a newly mounted tire. • Deflate tire completely before servicing. NEVER attempt to unseat the beads of an inflated tire.
Axles, Drive Shafts, Wheels and Tires c. Tire and Wheel Lubrication WARNING: Risk of death or serious personal injury. Use an approved tire-mounting lubricant only. NEVER use anti-freeze, silicones or petroleum-based lubricants. Prior to mounting the tire on the rim, apply a suitable lubricant to the bead-seat area of the wheel rim and tire bead. Use a lubricant specified by the wheel and tire manufacturers. d. Mounting Tire onto Wheel WARNING: Risk of death or serious personal injury.
Axles, Drive Shafts, Wheels and Tires e. Tire Speed and Road Surface Limitations The tires on this vehicle are designed for low-speed operations not to exceed 25 mph (40 km/hr). If the vehicle is towed at high speeds, high temperatures may develop under the tread bars, causing a shifting of the tread bars and a weakening of the tire material and cord fabric. There may be no visible evidence of this type of damage, but later, a failure can occur.
Axles, Drive Shafts, Wheels and Tires 5.6 BRAKES 5.6.1 CAUTION: Brake Disk Inspection. 1000 Check the brake disks for wear every 1,000 hours of operation or yearly. If the brake disks require service due to wear, the axle should be checked, serviced and repaired only by experienced service technicians who are aware of all safety instructions and particular component features. OH2690 DO NOT exceed 650 psi (45 bar) when pressurizing the park brake.
Axles, Drive Shafts, Wheels and Tires Note: If the brake disks are worn beyond their tolerance, the brake disk must be replaced on both sides of the axle at the same time. 6. Repeat steps 4 and 5 for the other side of the axle. 8. Reassemble the level plugs using new o-rings. 9. Re-install the axle fill plug (1) into axle housing. 10. Remove the remote portable hydraulic pressurizing unit on from the port (3). 7.
Axles, Drive Shafts, Wheels and Tires Note: If the brake disks are worn beyond 0.167" (4,25 mm), the brake disk must be replaced on both sides of the axle at the same time. b. Rear Axle WARNING: BLOCK ALL FOUR WHEELS. Failure to do so could result in death or serious injury from vehicle roll-away 1. Block all four wheels to help prevent the vehicle from moving after the parking brake is disabled. 2. Working through the level plug hole (4), carefully use a screwdriver to spread the brake disks apart.
Axles, Drive Shafts, Wheels and Tires This Page Intentionally Left Blank 5.32 Model 8042, 10042, 10054 Legacy Rev.
Section 6 Transmission: ZF 4 WG-98 TC Contents PARAGRAPH 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 TITLE Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission: ZF 4 WG-98 TC 6.1 TRANSMISSION ASSEMBLY COMPONENT TERMINOLOGY To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the transmission. The following illustration identifies the components that are referred to throughout this section.
Transmission: ZF 4 WG-98 TC WARNING: DO NOT service the vehicle without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. Failure to follow the safety practices may result in death or serious injury. 6.2 TRANSMISSION DESCRIPTION Instructions in this section pertain mainly to general specifications, towing, maintenance information, and transmission removal and installation procedures.
Transmission: ZF 4 WG-98 TC 6.5 6.5.1 TRANSMISSION SPECIFICATIONS Transmission General Specifications General transmission specifications are found in Section 2, “General Information and Specifications.” Transmission fluid information is found in Section 2.6.3, “Transmission.” 6.5.2 Transmission Performance Specifications Performance criteria is based on full throttle engine speed unless otherwise specified or not applicable. Travel Speed (standard tires, no load) First gear ..........................
Transmission: ZF 4 WG-98 TC CAUTION: DO NOT exceed 165 psi (39.6 bar) when back flushing the oil cooler. Applying too much pressure may damage the oil cooler/radiator. Disconnect and back flush the oil cooler portion of the radiator or the oil cooler (located behind the radiator) with oil and compressed air until all foreign material is removed. If necessary, remove the radiator or oil cooler from the vehicle, and clean the oil cooler circuit using oil, compressed air and steam. ~~ 1 6.6.
Transmission: ZF 4 WG-98 TC 6.7 TRANSMISSION REPLACEMENT Note: Contact the JLG Service Department at 1-877-554-5438 or 1-717-485-6657, if internal transmission repair is required during the warranty period. 5. Drain the hydraulic oil reservoir. (Refer to the appropriate owners/operators manual for information concerning the hydraulic oil and filter change.) 6. Disconnect the battery negative (-) cable or cables (1) at the battery negative (-) terminal, to prevent the engine from starting accidentally.
Transmission: ZF 4 WG-98 TC 9. Place a suitable receptacle under the transmission drain plug (5). Remove the transmission drain plug, and allow the transmission oil to drain into the receptacle. 10. Transfer the used transmission oil into a suitable, covered container, and label the container as “Used Oil.” Dispose of used oil at an approved recycling facility. Clean and reinstall the transmission drain plug.
Transmission: ZF 4 WG-98 TC 19. Label, disconnect and cap the transmission oil cooler inlet (1) and outlet (2) hoses at the transmission. The transmission oil cooler outlet hose, routed to the lower radiator fitting, is located on the top of the transmission. The transmission oil cooler inlet hose, routed to the upper radiator fitting, is located on top of the transmission. 21. Connect a lifting strap or chain to the lifting eye (3) at the top of the transmission, and to a suitable hoist or overhead crane.
Transmission: ZF 4 WG-98 TC 3 13 13 11 10 12 11 16 7 6 5 4 7 16 5 4 5 15 9 8 14 MH3380 Model 8042, 10042, 10054 Legacy Rev. 10/03 6.
Transmission: ZF 4 WG-98 TC 30. Remove any external transmission components as required, including the transmission temperature switch (1), and inlet (2) and outlet (3) cooler hose fittings. Cover all transmission openings. 31. Remove the transmission oil filter (4) and dispose of properly. Clean the filter mounting surface. Cover or cap the oil filter mount. 6.7.3 Transmission Installation WARNING: Risk of severe personal injury.
Transmission: ZF 4 WG-98 TC 10 7 12 6 11 12 5 17 14 16 17 13 15 16 15 16 8 19 9 18 MH3380 Model 8042, 10042, 10054 Legacy Rev. 10/03 6.
Transmission: ZF 4 WG-98 TC Note: The lifting ring must be repositioned, to allow the covers to be installed. 10. Attach the black wire (8) to the transmission housing with a capscrew (9) removed in Step 7. 7. Remove the two capscrews (1) securing the lifting ring (2) to the transmission housing. Save the capscrews for later use. 11. Secure the wiring harness to the transmission housing using the clip (10) and capscrew (11) removed in Step 7. 8.
Transmission: ZF 4 WG-98 TC 13. Install the hydraulic pump. Refer to Section 8.11.2, h. “Pump Installation.” 6.7.4 14. Install the engine-to-transmission drive shaft. (Refer to Section 5.4.7, b. “Engine-to-Transmission Drive Shaft.” Refer to the ZF 4 WG-98 TC Transmission Repair Manual, P/N 8990455 (ZF P/N 5871 135 002) for information on servicing the transmission after overhaul or repair. In general: 15. Install the transmission-to-axle drive shafts. Refer to Section 5.4.7, a.
Transmission: ZF 4 WG-98 TC 9. Reassemble all components and fill the transmission with clean, fresh Universal Tractor Fluid through the dipstick tube opening (1). Remove the dipstick and fill with approximately 3 gallons (11,4 liters) of Universal Tractor Fluid. Check the level by taking intermittent dipstick readings as outlined in the appropriate owners/operators manual. DO NOT overfill. Reinstall the dipstick when finished. 1 6.
Transmission: ZF 4 WG-98 TC 6.9 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that may occur during operation of the transmission. Note: Contact the JLG Service Department at 1-877-554-5438 or 1-717-485-6657, if internal transmission repair is required during the warranty period. 6.9.
Transmission: ZF 4 WG-98 TC 6.9.1 Transmission Troubleshooting (Continued) Problem 3. Low clutch pressure. 4. Lack of power. 5. Transmission overheating (oil above 248° F [120° C]). 6.16 Cause Remedy 1. Incorrect oil level. 1. Fill transmission to correct level with Universal Tractor Fluid. Refer to the appropriate owners/ operators manual. 2. Main pressure valve stuck open. 2. Clean the valve spool and housing. 3. Broken or worn coupling shaft or piston o-rings. 3.
Transmission: ZF 4 WG-98 TC 6.9.1 Transmission Troubleshooting (Continued) Problem Cause 6. Grinding or “clunking” noise from transmission. 7. Oil leaking from transmission. Model 8042, 10042, 10054 Legacy Rev. 10/03 Remedy 1. Oil level too low. 1. Fill oil to correct level. Refer to appropriate owners/operators manual. 2. Transmission filled with incorrect oil. 2. Drain transmission and fill to correct level with Universal Tractor Fluid. Refer to the appropriate owners/operators manual. 3.
Transmission: ZF 4 WG-98 TC This Page Intentionally Left Blank 6.18 Model 8042, 10042, 10054 Legacy Rev.
Section 7A Engine: Cummins 4BT3.9 and 4BTA3.9 Contents PARAGRAPH TITLE 7A.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.1.2 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.2 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine: Cummins 4BT3.9 and 4BTA3.9 7A.12 Engine Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.12.1 Split Taper Bushing Coupler and Drive Shaft Removal. . . . . . . . . . . . . . . 7A.12.2 Coupler and Drive Shaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.12.3 Coupler and Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.13 Engine Storage . . . . . . . . . . . . . . . . . . .
Engine: Cummins 4BT3.9 and 4BTA3.9 This Page Intentionally Left Blank Model 8042, 10042, 10054 Legacy Rev. 10/03 7A.
Engine: Cummins 4BT3.9 and 4BTA3.9 7A.1 7A.1.1 INTRODUCTION Disclaimer and Scope These instructions are written for worldwide use. In territories where legal requirements govern engine smoke emission, noise, safety factors, etc., apply all instructions, data and dimensions provided herein in such a way that after maintenance, service and repair of the engine, engine operation does not violate local regulations.
Engine: Cummins 4BT3.9 and 4BTA3.
Engine: Cummins 4BT3.9 and 4BTA3.9 7A.2 SAFETY INFORMATION WARNING: General Vehicle Operation WARNING: Before attempting to start the engine and/or operate the vehicle, read the owners/operators manual. • Before operating the engine and/or the vehicle, install any engine guards that were removed, and clear all personnel from the immediate area. • Check that the brakes are fully functional. • DO NOT exceed the stability limits of the vehicle.
Engine: Cummins 4BT3.9 and 4BTA3.9 Engine Repair Rotating Parts and Fan Blades WARNING: WARNING: Keep away from parts which rotate; the fan blades can appear invisible when the fan is rotating. Before beginning any adjustments or repairs, place accident prevention tags in the operator’s compartment and on the controls, and disconnect the battery negative cable. DO NOT pull or pry on the fan blades. This practice will cause fan failure.
Engine: Cummins 4BT3.9 and 4BTA3.9 7A.3 ENGINE SERIAL NUMBER DO NOT steam clean the following parts: The Cummins 4BT3.9 or 4BTA3.9 serial number (1) Is stamped on the front of the engine block, near the fan pulley. Information contained in the serial number is required in correspondence with the engine manufacturer.
Engine: Cummins 4BT3.9 and 4BTA3.9 7A.6 ENGINE COOLING SYSTEM The engine cooling system is a closed, pressurized system that consists of coolant passages in the engine, plus the oil cooler, thermostat, water pump, coolant heater, hoses, radiator and radiator overflow bottle. The engine is cooled by the circulation of coolant through passages in the cylinder block, engine head and radiator.
Engine: Cummins 4BT3.9 and 4BTA3.9 Note: Drain approximately two quarts (2 liters) of coolant. 5. Slowly turn the radiator cap (1) to the first stop and allow any pressure to escape. Remove the radiator cap. Place a funnel at the base of the radiator to channel the drained coolant into a container. Open the radiator petcock (2), and allow the coolant to drain into the funnel. Transfer the coolant into a properly labeled container. Dispose of properly. Close the radiator petcock. 4 3 5 1 MT1840 8.
Engine: Cummins 4BT3.9 and 4BTA3.9 14 10 15 11 13 12 9 16 13 MH4010 MS1160 10. Remove the thermostat housing (10), old gasket (11), thermostat (12), thermostat seal (13) and engine lift bracket (14). Clean all gasket surfaces (15). DO NOT let any debris into the thermostat opening. IMPORTANT: ALWAYS use the correct thermostat and install a new gasket. NEVER operate the engine without a thermostat, or engine damage will result. 7A.6.
Engine: Cummins 4BT3.9 and 4BTA3.9 4. Disconnect the negative (-) battery cable (1) and positive (+) battery cable (2) from the battery (3). 5. Remove the battery hold-down nuts (4) threaded hold-down rods (5) and hold-down bracket (6). Remove battery from vehicle. Store battery in a cool, dry area. 7 10 9 8 5 4 1 6 3 2 MH4010 WARNING: Hot coolant can cause severe burns or eye injury. NEVER remove the radiator cap while the engine is hot. The cooling system is under pressure.
Engine: Cummins 4BT3.9 and 4BTA3.9 10. Loosen clamp (11) on the radiator return (lower) hose (12). Work the hose off the radiator. Position the hose out of the way to allow radiator removal, or remove the hose from the engine. Inspect the hose, and replace if necessary. 12. Disconnect and cap the inlet (15) and outlet (16) fittings from the oil cooler (17). 13 19 14 15 18 11 12 16 17 MH4030 13. At the rear of the oil cooler, remove the six capscrews (18 and 19), lockwashers and flat washers.
Engine: Cummins 4BT3.9 and 4BTA3.9 14. Working above the radiator (1), remove capscrews (2), plain washers (3) and lockwashers (4) securing the radiator at the upper mounting tabs to the radiator shroud (5). The radiator shroud contains weld nuts that retain the capscrews. 15. At the sides of the radiator, remove the capscrews (6), radiator mount bushings (7), flat washers (8 and 10), spacers (11) and elastic locknuts (12) securing the radiator side mounting tabs to the radiator mount weldments. 16.
Engine: Cummins 4BT3.9 and 4BTA3.9 5. Place the oil cooler (22) into the vehicle, and install the capscrews (23 and 24), lockwashers and flat washers. 9. At the upper radiator hose (31), and with the clamp (32) installed over the hose, work the hose onto the radiator, and tighten the clamp. 33 37 31 32 24 23 25 22 35 26 MH4030 6. Uncap and connect inlet (25) and outlet (26) fittings to the oil cooler (22). 7.
Engine: Cummins 4BT3.9 and 4BTA3.9 12. Install the battery (1), hold-down bracket (2), threaded hold-down rods (3) and hold-down nuts (4). 4. Disconnect the negative (-) battery cable (8) from the battery (1). WARNING: 13. Connect the positive (+) battery cable (5) and negative (-) battery cable (6) to the battery (1). Hot coolant can cause severe burns or eye injury. NEVER remove the radiator cap while the engine is hot. The cooling system is under pressure. Wear protective clothing and safety glasses.
Engine: Cummins 4BT3.9 and 4BTA3.9 7. Remove plastic retainer (10) from around coolant heater element (11) and 110 volt cord (12). Using a 29-mm socket, remove heating element from engine block. b. Engine Block Heater Installation 1. Apply Teflon tape to coolant heater element threads (11), and install element using a 29-mm socket. DO NOT overtighten. Plug-in the 110-volt cord (12) into heater element, and install plastic retainer (10) around coolant heater element and 110-volt cord (12). 2.
Engine: Cummins 4BT3.9 and 4BTA3.9 7A.8 FUEL SYSTEM The fuel system includes a fuel tank (1), fuel level sender with gasket (2), instrument cluster gauge (not shown), fuel strainer (3), fuel lift pump (4), fuel filter (5), fuel supply hose (6) and fuel return line (7). The threaded fuel filler (8) has a fuel cap (9) and permits entry of diesel fuel into the tank. The fuel level sender (2) and instrument cluster gauge are described in Section 9.14.15, “Fuel Level Indicator and Fuel Level Sender.
Engine: Cummins 4BT3.9 and 4BTA3.9 6 2 9 4 8 5 3 7 1 PH28502 Model 8042, 10042, 10054 Legacy Rev. 10/03 7A.
Engine: Cummins 4BT3.9 and 4BTA3.9 7A.8.2 Fuel/Hydraulic Oil Tank Note: The fuel/hydraulic oil tank is part of a one piece unit divided into a two compartment (tank) unit. It is located on the right side of the vehicle, across from the operator’s cab. If it is determined that either the fuel or hydraulic oil tank must be removed, both the fuel and hydraulic oil must be drained before tank removal. Always dispose of hydraulic oil or fuel properly. WARNING: Explosion and fire hazard.
Engine: Cummins 4BT3.9 and 4BTA3.9 20 22 19 23 21 28 29 27 15 24 30 25 26 5 31 17 18 16 32 3 13 33 14 9 4 34 6 7 11 12 10 2 Model 8042, 10042, 10054 Legacy Rev. 10/03 8 7A.
Engine: Cummins 4BT3.9 and 4BTA3.9 b. Disassembly DANGER: NEVER weld in, on, near or around the fuel/hydraulic oil reservoir. Fuel and hydraulic fluid and fumes can cause the reservoir to explode. This can result in death or serious personal injury. The fuel/hydraulic oil reservoir is a one-piece unit and cannot be disassembled. The fuel level indicator and hydraulic filters can be removed and reused on the new replacement reservoir.
Engine: Cummins 4BT3.9 and 4BTA3.9 25 23 29 27 24 26 31 30 33 32 28 6 19 1 22 2 20 21 5 18 7 14 4 17 10 3 9 13 11 15 16 8 12 MH4270 13. Connect upper hydraulic hoses (21 and 22) to the tee fitting. 14. Attach fuel level sender harness connectors (23) to the sending unit (24). 15. Install the fuel sender with new gasket (24) into the fuel tank and secure with screws (25). DO NOT overtighten. 19. Fill fuel tank and hydraulic tank according to specifications. Refer to Section 2.
Engine: Cummins 4BT3.9 and 4BTA3.9 7A.8.3 b. Cleaning and Drying Fuel Level Sender and Gauge The fuel level sender and gauge assembly is described in Section 7A.8.3, “Fuel Level Sender and Gauge.” Clean the exterior of the pump with mineral spirits, and blow dry with compressed air. 7A.8.4 Note: Parts replacement is not practical. The fuel lift pump is serviced as an entire assembly. Fuel Lift Pump Inspection and Testing 1. Inspect the camshaft lever and return spring for excessive wear. 2.
Engine: Cummins 4BT3.9 and 4BTA3.9 4. Operate the starter to turn the engine over until fuel sprays from the nozzle. Examine the shape of the spray. If the spray is unduly “wet” or “streaky”, or obviously sprays to one side, or if the nozzle “dribbles” fuel, it may only be necessary to probe the nozzle holes to remove blockage. a.
Engine: Cummins 4BT3.9 and 4BTA3.9 IMPORTANT: The injector must not rotate in the bore of the cylinder head, or damage to the cylinder head will occur. If rust has formed on the hold-down nut, soak the nut with rust-penetrating solvent for a minimum of three minutes. Then, tap the injector body with a drift pin to help loosen any rust. 6 7 4. Use a 16-mm wrench to prevent the injector body (1) from turning. Loosen the hold-down nut (2) with a 24-mm box wrench. 2 1 4 MT3160 5 15.
Engine: Cummins 4BT3.9 and 4BTA3.9 and vibration into the operator’s cab. The tail pipe directs exhaust fumes to the right side of the vehicle, away from the cab. 4. Disconnect the negative (-) battery cable (8). Annoying rattles and noise vibrations in the exhaust system are usually caused by misalignment of parts. When aligning the system, leave all capscrews and nuts slightly loose until all parts are properly aligned, then tighten all fasteners working from the front of the system to the rear.
Engine: Cummins 4BT3.9 and 4BTA3.9 7A.9.2 7A.10 Exhaust System Installation Note: Keep all clamps loosened until entire exhaust system is in place. 2 AIR CLEANER ASSEMBLY If a replacement engine is being installed into the vehicle, the air cleaner assembly must be transferred to the new engine. The air cleaner assembly should be transferred to the replacement engine after the used engine is removed from the vehicle.
Engine: Cummins 4BT3.9 and 4BTA3.9 2. Remove the engine harness clamp (20), and move harness away from air cleaner assembly (16). 3. Remove the two capscrews (17) and lockwashers (18) securing the air cleaner mounting bracket (19) to the engine. Remove the air cleaner assembly. 7A.10.2 Air Cleaner Assembly Installation Note: Apply Loctite® 242 threadlock to the capscrew threads before installation. 1.
Engine: Cummins 4BT3.9 and 4BTA3.9 6. Label and disconnect the alternator ground wire (1), D+ (2) and B+ (3) harness wire leads. 7 4 5 RE D 2W 1 5 3 BL K G 38 6 ORG D+ 6 B+ 8 YEL D- 2 9 MA8420 11. Label and disconnect the back-up alarm harness connector (10) from the back-up alarm (11). 10 MA8400 11 Note: Record how the starter wires are installed to ensure correct installation later. 7. At the starter, remove the two red wires (4) from the upper solenoid stud (5). 8.
Engine: Cummins 4BT3.9 and 4BTA3.9 Note: The engine harness is routed and attached to the engine using hold-down clamps and plastic wire ties at various places on the engine. Before removing engine, ensure that the harness has been completely separated (disconnected) from the engine. Move the harness clear of the engine, and with the help of an observer, ensure that engine clears the harness during removal. 16. Remove the drive shaft assembly (10) from engine. To Engine 12 11 13.
Engine: Cummins 4BT3.9 and 4BTA3.9 Note: Always discard used elastic locknuts and install new elastic locknuts. 21. At the front right engine mount (1) remove the elastic locknut (2), rebound washer (3), engine isolator (4) and capscrew (5). Repeat for the front left engine mount (6). 16 23. At the exhaust pipe bracket (12), remove the capscrews (13) and lockwashers (14). Remove exhaust pipe bracket. 24.
Engine: Cummins 4BT3.9 and 4BTA3.9 7A.11.3 Engine Installation Note: Always replace used elastic locknuts with new elastic locknuts. Note: Refer to Section 2.3, “Torques,” for specific fastener torque specifications. Note: Always replace used elastic locknuts with new elastic locknuts. 8. Install the radiator overflow tube (20), and overflow tank(21), hose support (22), flat washer (23) and new elastic locknuts (24). 1.
Engine: Cummins 4BT3.9 and 4BTA3.9 9. Secure the throttle cable clevis (1) to the engine throttle lever (2), located just above the starter. To Engine 11 10. Install the throttle cable mount clamp (3) over the throttle cable (4). 11. Connect the fuel inlet line (5) to the fuel lift pump (6). 10 12 9 8 7 To Transmission MA8900 IMPORTANT: Yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration.
Engine: Cummins 4BT3.9 and 4BTA3.9 5 16 RE 15 D 18 2W BL K G 38 ORG D+ 14 6 13 B+ YEL 17 D- MA8400 18. Position the starter (19) in its mounting opening on the flywheel housing. Position the ground cable (20) over the lower starter bolt. Secure the starter with 12-point fasteners (21). Torque fasteners to 32 lb-ft (43 Nm). 19. Install the red, positive (+) battery cable (22) and two red wires (23) to the upper solenoid stud (24). Install a lockwasher and nut on stud, and finger tighten.
Engine: Cummins 4BT3.9 and 4BTA3.9 22. Install the exhaust system to the engine. Refer to Section 7A.9.2, “Exhaust System Installation.” 23. Install the radiator and oil cooler. Refer to Section 7A.6.3, “Radiator/Oil Cooler and Coolant Heater Replacement.” 24. Install the back-up alarm (1) and fasteners onto frame studs. 25. Connect the back-up alarm harness connector (2) to the back-up alarm (1). 2 5 1 6 8 4 3 7 MH4010 30.
Engine: Cummins 4BT3.9 and 4BTA3.9 Note: Have an assistant stand by with a Class B fire extinguisher. Start and idle the engine. 32. Fill the overflow tank (12), 1/4 to 1/2 full with a 50/50 mixture of ethylene glycol and water. Replace and tighten overflow tank cap (13). 33. Run engine to normal operating temperature then shut off the engine. While the engine is cooling, check for leaks. 34. Allow the engine to cool.
Engine: Cummins 4BT3.9 and 4BTA3.9 7A.12 ENGINE COUPLER Note: Before beginning, verify your current coupler type. If you have a hexagonal access cover plate (2), use the “Split Taper Bushing instructions for removal. Installation instructions remain the same for all applications. 5. Remove the capscrews and lockwashers (7) holding the access cover plate (8) to the bell housing of engine. Discard the capscrews and lockwashers. Let the cover plate rest on the tube of the drive shaft (9). 7 7A.12.
Engine: Cummins 4BT3.9 and 4BTA3.9 Note: It may be necessary to loosen/remove the motor mounts (25) on either side of the engine to gain access to the bottom capscrews (23) on the outer half of the coupler (24). Place a jack under the bell housing (use a wood block to support engine) and carefully lift the engine until the bottom edge of the bell housing is at the top edge of the frame member that mounts the rear axle to the frame. Watch the fan-to-radiator clearance as you are lifting the engine.
Engine: Cummins 4BT3.9 and 4BTA3.9 4. Remove the capscrews (1) securing the small access cover (2). 1 5 2 3 4 SH3070 2. Place the new coupler (4) into the indentation of the flywheel and use new Grade 8 capscrews and locknuts (3) to secure the coupler to the flywheel. SH3060 5. Remove the capscrews and locknuts (3) securing the coupler (4) to the flywheel. Turn the engine by hand, using the fan belt, until the capscrews line up with the access hole (2). 6.
Engine: Cummins 4BT3.9 and 4BTA3.9 Note: Before assembling the drive shaft (7) to the coupling (8); be sure the access cover plate (9) is placed on the engine-side of the frame member that mounts the rear axle to the frame. Note: Apply Loctite® threadlock 242 (Red) compound to all of the capscrews used during assembly. 7.
Engine: Cummins 4BT3.9 and 4BTA3.9 7A.13 ENGINE STORAGE If the engine is properly protected and stored according to the following recommendations, no corrosion damage will normally occur. Cummins Engine Company, Inc. and JLG are not responsible for any damage that occurs in relation to a service storage period. Use the following procedures immediately upon removing engine from service if it is being stored for an extended period of time. 1. Clean the outside of the engine. 2.
Engine: Cummins 4BT3.9 and 4BTA3.9 7A.
Engine: Cummins 4BT3.9 and 4BTA3.9 This Page Intentionally Left Blank 7A.44 Model 8042, 10042, 10054 Legacy Rev.
Section 7B Engine: Cummins QSB4.5T Contents PARAGRAPH TITLE 7B.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.1.2 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.2 Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine: Cummins QSB4.5T 7B.11 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.11.1 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.11.2 Engine Disassembly, Inspection and Service . . . . . . . . . . . . . . . . . . . . . . 7B.11.3 Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.12 Engine Coupler . . . . . . . . . . . . . .
Engine: Cummins QSB4.5T This Page Intentionally Left Blank Model 8042, 10042, 10054 Legacy Rev. 10/03 7B.
Engine: Cummins QSB4.5T 7B.1 7B.1.1 INTRODUCTION Disclaimer and Scope These instructions are written for worldwide use. In territories where legal requirements govern engine smoke emission, noise, safety factors, etc., apply all instructions, data and dimensions provided herein in such a way that after maintenance, service and repair of the engine, engine operation does not violate local regulations.
Engine: Cummins QSB4.
Engine: Cummins QSB4.5T 7B.2 SAFETY INFORMATION Engine Operation WARNING: General Vehicle Operation WARNING: Before attempting to start the engine and/or operate the vehicle, read the Owners/Operators Manual. • Before operating the engine and/or the vehicle, install any engine guards that were removed and clear all personnel from the immediate area. Never use Ether on Engines equipped with Cold Start Grid Heaters. Use of starting fluid, which contains Ether, can cause an explosion.
Engine: Cummins QSB4.5T Engine Coolant (anti-freeze/anti-boil over) Engine Oil WARNING: WARNING: DO NOT remove the radiator cap while the engine and coolant are hot. Hot coolant under pressure is dangerous and can injure the eyes and cause severe burns. • Cooling system corrosion inhibitors contain alkali (chemicals that break down organic substances such as skin and eye tissue), DO NOT swallow. Avoid prolonged or repeated contact with corrosion inhibitors.
Engine: Cummins QSB4.5T 7B.3 ENGINE SERIAL NUMBER DO NOT steam clean the following parts: The serial number (1) Is stamped on the front of the engine block, near the fan pulley. Information contained in the serial number is required in correspondence with the engine manufacturer. • Electrical Components • Wiring • Injectors • Fuel Pump • Belts and Hoses • Bearings During reassembly and inspection, thoroughly clean all parts, and, where present, remove burrs and scales. Front of vehicle 7B.5.
Engine: Cummins QSB4.5T 7B.6 ENGINE COOLING SYSTEM The engine cooling system is a closed, pressurized system that consists of coolant passages in the engine, plus the oil cooler, thermostat, water pump, coolant heater, hoses, radiator and radiator overflow bottle. The engine is cooled by the circulation of coolant through passages in the cylinder block, engine head and radiator.
Engine: Cummins QSB4.5T Note: Drain approximately two quarts (2 liters) of coolant. 5. Slowly turn the radiator cap (1) to the first stop and allow any pressure to escape. Remove the radiator cap. Place a funnel at the base of the radiator to channel the drained coolant into a container. Open the radiator petcock (2), and allow the coolant to drain into the funnel. Transfer the coolant into a properly labeled container. Dispose of properly. Close the radiator petcock. 5 1 3 4 MH4560 8.
Engine: Cummins QSB4.5T 7B.6.3 14 10 15 1. Park the vehicle on a firm, level surface. Level the vehicle, ground the attachment, place the travel select lever in the (N) NEUTRAL position, place the neutral lock lever in the (N) NEUTRAL LOCK position, engage the parking brake switch and shut the engine OFF. 11 13 12 9 13 Drain and Flush Radiator MS1160 10. Remove the thermostat housing (10), old gasket (11), thermostat (12), thermostat seal (13) and engine lift bracket (14).
Engine: Cummins QSB4.5T WARNING: Never remove the radiator cap while the engine is hot. The cooling system is under pressure. Hot coolant can cause severe burns or eye injury. Wear protective clothing and safety glasses. 6 4. Unlock and open rear engine door. Slowly turn the radiator cap (1) to the first stop, and allow any pressure to escape. Remove the radiator cap. 5. Locate the drain tube (2) and petcock (3) on the right side of the radiator.
Engine: Cummins QSB4.5T 7B.6.4 Radiator/Hydraulic and Transmission Cooler Replacement Before considering radiator or oil cooler replacement for other than obvious damage, conduct a cooling system pressure test check the coolant specific gravity, coolant level, fan belt tension and dash panel temperature indicator. • If the engine runs hot, check the temperature of the upper radiator hose. • If the hose is not hot, the thermostat may be stuck in the closed position.
Engine: Cummins QSB4.5T 9. Loosen the radiator side clamp (1) on the radiator input (upper) hose (2). Work the hose off the radiator (3). Position the hose out of the way to allow radiator removal, or remove the hose from the engine. Inspect the hose, and replace if necessary. Loosen clamp (4) on the radiator return (lower) hose (5). Work the hose off the radiator. Position the hose out of the way to allow radiator removal, or remove the hose from the engine. Inspect the hose, and replace if necessary. 11.
Engine: Cummins QSB4.5T This Page Intentionally Left Blank Model 8042, 10042, 10054 Legacy Rev. 10/03 7B.
Engine: Cummins QSB4.5T 12. Working at the back of vehicle, remove the capscrews (1) and lockwashers (2) securing the transmission oil cooler (3) to the hinges (4), and the capscrews (5) and washers (6) securing the other side of the transmission oil cooler to the weldnuts on the frame assembly (7). 13.
Engine: Cummins QSB4.5T 28 30 27 8 9 29 10 24 23 20 18 7 4 21 19 22 11 13 16 25 26 3 1 17 15 14 12 2 14 16 32 17 31 6 5 33 34 MH5000 35 Model 8042, 10042, 10054 Legacy Rev. 10/03 7B.
Engine: Cummins QSB4.5T 8. At the back of the vehicle, connect the transmission cooler inlet (1) and outlet (2) hoses. 5 6 7 1 8 9 MH4770 MH4800 2 9. Connect the hydraulic oil cooler inlet (3) and outlet (4) hoses. 11. Install the batteries (10), hold-down bracket (11), threaded hold-down rods (12) and hold-down nuts (13). 12. Connect the positive (+) battery cables (14) and negative (-) battery cables (12) to the batteries (10). 3 4 13 12 12 14 11 10 12 14 7 MH4210 MH4790 10.
Engine: Cummins QSB4.5T 7B.6.5 Block Heater Replacement 15 a. Engine Block Heater Removal 1. Level the vehicle, ground the attachment, place the travel select lever in NEUTRAL (N) and engage the neutral lock lever; engage the parking brake switch and shut off the engine. 2. Remove the ignition key. Secure accident prevention tags to the steering wheel and ignition key switch. (Refer to Section 1.5, “Accident Prevention Tags.”) WARNING: DO NOT attempt this procedure when the engine is hot.
Engine: Cummins QSB4.5T b. Engine Block Heater Installation 1. Apply Teflon tape to coolant heater element threads (1), and install element using a 29-mm socket. DO NOT overtighten. Plug-in the 110-volt cord (2) into heater element, and install plastic retainer (3) around coolant heater element and 110-volt cord. 5 MH5190 7B.7 3 ENGINE ELECTRICAL SYSTEM The engine electrical system, including the starter, alternator and primary wiring, is described in Section 9, “Electrical System.” 1 2 MH4710 2.
Engine: Cummins QSB4.5T This Page Intentionally Left Blank Model 8042, 10042, 10054 Legacy Rev. 10/03 7B.
Engine: Cummins QSB4.5T 7B.8 FUEL SYSTEM The fuel system includes a fuel tank (1), fuel level sender with gasket (2), instrument cluster gauge (not shown), fuel strainer (3), fuel lift pump (4), fuel filter (5), fuel supply hose (6) and fuel return line (7). The threaded fuel filler (8) has a fuel cap (9) and permits entry of diesel fuel into the tank. The fuel level sender (2) and instrument cluster gauge are described in Section 9.14.15, “Fuel Level Indicator and Fuel Level Sender.
Engine: Cummins QSB4.5T 6 2 9 4 8 5 3 7 1 PH28502 Model 8042, 10042, 10054 Legacy Rev. 10/03 7B.
Engine: Cummins QSB4.5T 7B.8.2 Fuel/Hydraulic Oil Tank Note: The fuel/hydraulic oil tank is part of a one piece unit divided into a two compartment (tank) unit. It is located on the right side of the vehicle, across from the operator’s cab. If it is determined that either the fuel or hydraulic oil tank must be removed, both the fuel and hydraulic oil must be drained before tank removal. Always dispose of hydraulic oil or fuel properly. WARNING: Explosion and fire hazard.
Engine: Cummins QSB4.5T 20 22 19 21 27 28 26 15 23 29 24 25 5 30 17 18 16 31 3 13 32 14 9 4 33 6 7 11 12 10 2 8 MH4270 Model 8042, 10042, 10054 Legacy Rev. 10/03 7B.
Engine: Cummins QSB4.5T b. Disassembly DANGER: NEVER weld in, on, near or around the fuel/hydraulic oil reservoir. Fuel and hydraulic fluid and fumes can cause the reservoir to explode. This can result in death or serious personal injury. d.
Engine: Cummins QSB4.5T 25 23 28 24 29 32 26 30 31 27 19 6 1 22 2 20 21 5 18 7 14 4 17 10 3 9 13 11 15 16 8 12 MH4270 13. Connect upper hydraulic hoses (21 and 22) to the t-fitting. 19. Fill fuel tank with No. 2 D fuel. Fill the hydraulic tank with ISO-46 hydraulic oil. 14. Attach fuel level sender harness connectors (23) to the sending unit (24). 20. Check fuel and hydraulic oil tanks for leaks. 15.
Engine: Cummins QSB4.5T 7B.8.3 b. Cleaning and Drying Fuel Level Sender and Gauge The fuel level sender and gauge assembly is described in Section 9.14.15, “Fuel Level Indicator and Fuel Level Sender.” 7B.8.4 Fuel Lift Pump Inspection and Testing 1. To test the diaphragm, remove the fuel inlet line (1) from the fuel lift pump (2). Block the fuel inlet with a finger and operate the hand plunger (3).
Engine: Cummins QSB4.5T 5. Operate the starter to turn the engine over until fuel sprays from the nozzle. Examine the shape of the spray. If the spray is unduly “wet” or “streaky,” or obviously sprays to one side, or if the nozzle “dribbles” fuel, it may only be necessary to probe the nozzle holes to remove blockage. a.
Engine: Cummins QSB4.5T IMPORTANT: The injector must not rotate in the bore of the cylinder head, or damage to the cylinder head will occur. If rust has formed on the hold-down nut, soak the nut with rust-penetrating solvent for a minimum of three minutes. Then, tap the injector body with a drift pin to help loosen any rust. 6 7 4. Use a 16-mm wrench to prevent the injector body (1) from turning. Loosen the hold-down nut (2) with a 24-mm box wrench. 2 1 4 MT3160 5 15.
Engine: Cummins QSB4.5T 7B.9 ENGINE EXHAUST SYSTEM WARNING: Exhaust fumes contain carbon monoxide, a colorless, odorless gas which is fatal when inhaled in a confined area. Avoid breathing exhaust fumes, and prevent engine operation from becoming a cause of toxic emissions. Exhaust system components reach high temperatures and can cause severe burns. DO NOT come into contact with hot exhaust system components.
Engine: Cummins QSB4.5T 5. Disconnect and remove the clamp (1) supporting the tail pipe (2), from the tail pipe support bracket (3). 6. Disconnect and remove the clamp (4) attaching the muffler (5) to the muffler mounting bracket (6) and exhaust pipe (7), and remove the muffler from the muffler mounting bracket. 5. Tighten all clamps. 6. Connect the negative (-) battery cables (10) to the batteries. 8 Rear of vehicle 12 10 MH4440 7 7. Start engine and check for exhaust leaks at all exhaust connections.
Engine: Cummins QSB4.5T 7B.11 ENGINE REPLACEMENT 12 7B.11.1 11 WARNING: 14 13 To avoid severe burns, DO NOT attempt to remove the engine when the engine, cooling system and hydraulic system are hot. Wait until all parts and systems are cool before proceeding. 18 15 16 14 Note: The radiator and oil cooler must be removed from the vehicle before engine removal. Refer to Section 7B.6.4, a. “Oil Coolers and Radiator Removal.” Several additional components must be removed before engine removal.
Engine: Cummins QSB4.5T 6. Remove the radiator overflow tube (1), overflow tank (2), hose support (3), flat washer (4) and elastic locknuts (5). 9 13 11 15 12 2 1 16 3 4 10 5 14 MH4730 Note: Record how the alternator and starter wires are installed to ensure correct installation later. MH5660 9. At the negative starter stud (13), label and disconnect the negative (-) battery cable (14). 7.
Engine: Cummins QSB4.5T 12. Use a small, flat knife blade (19), inserted next to the cap (18), so that the cap pops out of the protective cover. 20 13. Label the blue wire (20) from the starter solenoid terminal. Use a small phillips screwdriver to loosen the screw far enough to allow the blue wire to be removed from the terminal. 14. Remove the locknuts and washers (16) securing the coldstart grid heater (17) to the frame studs and place it, out of the way, on the engine. 16 MH5220 17.
Engine: Cummins QSB4.5T 19. Disconnect the fuel shut-off solenoid harness connector (1). For more information, refer to Section 9.14.2, “Fuel Shut-off Solenoid (SN 8042, 13198 - 18990, 10042, 13198 - 19030, 10054, 13198 - 19079).” 8 7 1 5 6 MH4660 23. Disconnect the fuel return line (7) from the injector pump (8). Install a plug in the end of fuel inlet line and cap the fitting on the injector pump. MS16902 24. Remove the capscrews (10) and lockwashers (11) securing the flange yoke (12) to the engine.
Engine: Cummins QSB4.5T IMPORTANT: Before the engine can be removed from the vehicle, the air conditioning hoses (13 and 14) need to be removed from the air conditioning compressor (15). This procedure must be completed by an authorized air conditioning service technician. This service technician will also need to be available when the new engine is installed to re-install the air conditioning hoses (13 and 14) to the air conditioning compressor (15).
Engine: Cummins QSB4.5T 7B.11.3 Engine Installation Note: Always replace used elastic locknuts with new elastic locknuts. 2 Note: Refer to Section 2.3, “Torques,” for specific fastener torque specifications. Note: The engine harness is routed and attached at various places on the engine using hold-down clamps and plastic wire ties. Before installing engine and with the help of an observer, ensure that engine clears the harness during installation. 6 1 15 1.
Engine: Cummins QSB4.5T To Engine 26 25 32 27 24 To Transmission MA8900 9. Raise the drive shaft assembly (24) into position. The slip-yoke end of the drive shaft mounts toward the engine. If reinstalling a drive shaft previously removed, align the flange yokes according to the alignment marks made during removal. IMPORTANT: Yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration. MS16902 14.
Engine: Cummins QSB4.5T 15. Connect the engine coolant temperature switch lead (1). 5 1 6 MH5220 16. Connect the oil pressure switch lead (2). 17. Connect the diagnostic system ground wire (3) at the buss bar (4). MH49102 19. Connect the back-up alarm harness connector (7) from the back-up alarm (8). 3 8 4 7 2 MH5210 MH5250 18. Install the locknuts and washers (5) that secure the coldstart grid heater (6) to the frame studs. 7B.40 Model 8042, 10042, 10054 Legacy Rev.
Engine: Cummins QSB4.5T 20. Insert the fork terminal of the blue wire (8) into the protective cover (9) on the starter solenoid terminal. Use a small phillips screwdriver to tighten the screw (10) securely. 21. Snap the tethered cap back in place over the screw in the protective cover. 24. At the positive starter stud (9), connect the positive (+) battery cable (10) and starter positive buss bar (11) with the wires (12) still attached to the bar. 25.
Engine: Cummins QSB4.5T 30. Install the batteries (1), hold-down bracket (2), threaded hold-down rods (3) and hold-down nuts (4). 31. Connect the positive (+) battery cables (5) and negative (-) battery cables (6) to the batteries (1). 40. Check for proper operation of all components. 41. Turn the engine OFF. 7B.12 ENGINE COUPLER 7B.12.1 4 Coupler and Drive Shaft Removal 1.
Engine: Cummins QSB4.5T 4. Remove the capscrews (15) securing the small access cover (16). 7B.12.2 Coupler and Drive Shaft Installation 1. Use cleaner to clean the backside of the coupler, where it comes in contact with the flywheel. 15 16 22 21 SH3070 Note: The new coupler weighs approximately 56 lbs (25,4 kg) and requires two people, one on each side, to install. SH3060 5. Remove the capscrews and locknuts (17) securing the coupler (18) to the flywheel.
Engine: Cummins QSB4.5T 3. Insert one capscrew into the access hole (1) on the rear right side of the bell housing and through the flywheel and coupler. Assemble a new elastic locknut onto the capscrew. DO NOT fully tighten at this time. 6. Install the small access cover plate (1), to the right side of the engine and tighten the hardware securely.
Engine: Cummins QSB4.5T 7B.13 ENGINE STORAGE If the engine is properly protected and stored according to the following recommendations, no corrosion damage will normally occur. Cummins Engine Company, Inc. and JLG are not responsible for any damage that occurs in relation to a service storage period. Use the following procedures immediately upon removing engine from service if it is being stored for an extended period of time. 13 1. Clean the outside of the engine. 2.
Engine: Cummins QSB4.5T 7. Run the engine for a short period to distribute lubricating oil and coolant throughout the engine. 8. Clean out the engine breather pipe (where fitted) and seal the end of the pipe. 9. Remove the fuel injectors and spray clean engine lubricating oil into cylinder bores. Divide four ounces (118,3 ml) of lubricating oil evenly between the four cylinders. 10. Remove the air filter and any pipe installed between the air filter and the induction manifold.
Engine: Cummins QSB4.5T Key to Possible Causes 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Engine: Cummins QSB4.5T This Page Intentionally Left Blank 7B.48 Model 8042, 10042, 10054 Legacy Rev.
Section 8 Hydraulic System Contents PARAGRAPH TITLE 8.1 8.2 8.3 8.4 8.5 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System 8.9 8.10 8.11 8.12 8.13 8.2 8.8.25 Attachment Tilt and Slave Circuit Description . . . . . . . . . . . . . . . . . . . . . . 8.8.26 Pump and Cooling Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8.27 Auxiliary Hydraulics Circuit Description. . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8.28 Outrigger Circuit Description (10042/10054). . . . . . . . . . . . . . . . . . . . . . . 8.8.29 Steering Circuit Descriptions. . . . . . . . . . . . . . . . .
Hydraulic System 8.1 HYDRAULIC COMPONENT TERMINOLOGY To understand the safety, operation and service information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the hydraulic components of the vehicle. The following illustration identifies the components that are referred to throughout this section.
Hydraulic System 8.2 SAFETY INFORMATION WARNING: DO NOT service the vehicle without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. Failure to follow the safety practices may result in death or serious injury. WARNING: Wait for hydraulic fluid to cool before servicing any hydraulic component. Hot hydraulic fluid can cause severe burns. Petroleum-based hydraulic fluids are used in this vehicle.
Hydraulic System 8.3 SPECIFICATIONS Refer to Section 2.5, “Specifications,” for hydraulic system specifications. 8.4 HYDRAULIC FLUID General information and specifications pertaining to hydraulic fluid are found in Section 2.5.8, “Fluid and Lubricant Capacities.” Use only clean, filtered fluid in the hydraulic system. After servicing or replacing a hydraulic system component, cycle all vehicle functions several times to remove (purge or “bleed”) air from the hydraulic system.
Hydraulic System 8.5 HOSES, TUBE LINES, FITTINGS, ETC. There are numerous hydraulic hoses, tubes, fittings, etc. used on this vehicle. Periodically inspect all of these and carefully examine any signs of wear, abrasion and/or deterioration. Determine whether any further use of the component would constitute a hazard. If in doubt, replace the component. 8.5.1 Replacement Considerations Conditions including, but not limited to, the following are sufficient for considering component replacement: 1.
Hydraulic System 8.6 HYDRAULIC PRESSURE DIAGNOSIS JLG Parts Department has two kits available to use for hydraulic system maintenance and troubleshooting: the Sky Trak Pressure Test Kit and the Sky Trak Flowmeter Kit. The kits are contained in a durable polyethylene carrying case for demanding field service conditions. Pressure Test Kit The hydraulic pressure test kit (1) is used to pressure test the various hydraulic components in the hydraulic system.
Hydraulic System 8.6.1 Pressure Checks and Adjustments When diagnosing trouble in the hydraulic system, use the hydraulic testing information in Section 8.7, “Hydraulic System Testing.” In general, follow the steps below whenever conducting pressure checks and performing adjustments: 1. Park the vehicle on a firm, level surface. Engage the park brake, place the travel select lever in (N) NEUTRAL, place the neutral lock lever in the (N) NEUTRAL LOCK position, level the boom and turn the engine OFF. 2.
Hydraulic System This Page Intentionally Left Blank Model 8042, 10042, 10054 Legacy Rev. 10/03 8.
Hydraulic System 8.7 8.7.
Hydraulic System Engine Information Idle . . . . . . . . . . . . . . . . . . . . . 1,050 ±50 rpm Full Speed. . . . . . . . . . . . . . . 2,750 ±100 rpm Hydraulic Oil Information Oil Type - 10W, meet ISO Grade 46 Capacity - Reservoir . . . . . 32.2 gal. (127 liter) Capacity - System. . . . . . . 57.5 gal. (218 liter) Note: To adjust relief settings, pressure reducing settings or standby pressure, turn the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure.
Hydraulic System 8.7.
Hydraulic System Engine Information Idle . . . . . . . . . . . . . . . . . . . . . 1,050 ±50 rpm Full Speed. . . . . . . . . . . . . . . 2,750 ±100 rpm Hydraulic Oil Information Oil Type - 10W, meet ISO Grade 46 Capacity - Reservoir . . . . . 32.2 gal. (127 liter) Capacity - System. . . . . . . . 64 gal. (242 liter) Note: To adjust relief settings, pressure reducing settings or standby pressure, turn the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure.
Hydraulic System 8.7.
Hydraulic System Engine Information Idle . . . . . . . . . . . . . . . . . . . . . 1,050 ±50 rpm Full Speed. . . . . . . . . . . . . . . 2,750 ±100 rpm Hydraulic Oil Information Oil Type - 10W, meet ISO Grade 46 Capacity - Reservoir . . . . . 32.2 gal. (127 liter) Capacity - System. . . . . . . . 64 gal. (242 liter) Note: To adjust relief settings, pressure reducing settings or standby pressure, turn the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure.
Hydraulic System This Page Intentionally Left Blank 8.16 Model 8042, 10042, 10054 Legacy Rev.
Hydraulic System 8.8 HYDRAULIC CIRCUITS AND TROUBLESHOOTING This section covers the hydraulic circuits and includes a circuit drawing, troubleshooting chart, and description of the circuit for each function. Typically, the circuit drawings illustrate the flow of oil for the hydraulic function being shown. The troubleshooting charts cover some common problems that can occur during the operation of the hydraulic system. Electrical and hydraulic functions are often related.
Hydraulic System 8.8.1 Brake Circuit and Troubleshooting (Refer to Section 8.8.21, “Brake Circuit Description,” for a more detailed explanation of this circuit.) FRONT AXLE BRAKE VALVE T MAIN CONTROL VALVE P SHUTTLE VALVE SECONDARY FUNCTION MANIFOLD C PSG G PLT AUX FRAME SWAY ATTACH TILT P RETURN FILTER IN T TO POWER STEERING UNIT LFT/LWR T EXT/RET LS HYDRAULIC RESERVOIR PUMP PBG T P PS PB Pressure Return Suction Load Sense REAR AXLE HYDRAULIC OIL COOLER MH3450 8.
Hydraulic System Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the following: 1. Hydraulic oil level in the reservoir 2. All hoses, tubes, fittings for leaks, kinks, interference, etc. 3. Air in the lines If service brakes are not holding, check the pressure at the brake valve. Not OK Replace brake valve. Not OK Replace brake valve. Not OK Refer to the appropriate Legacy Owners/Operators Manual. Check the brakes for mechanical failure. Not OK Refer to Section 5.3.
Hydraulic System 8.8.2 Boom Extend Circuit and Troubleshooting (Refer to Section 8.8.22, “Boom Extend/Retract Circuit Description,” for a more detailed explanation of this circuit.) AUX FRAME SWAY ATTACH TILT P RETURN FILTER IN T EXT/RET T LFT/LWR MAIN CONTROL VALVE HYDRAULIC RESERVOIR 10054 ONLY EXTEND V LOCKOUT VALVE PUMP T C R E EXTEND/ RETRACT CYLINDER HYDRAULIC OIL COOLER Pressure Return Suction Load Sense MH3500 8.20 Model 8042, 10042, 10054 Legacy Rev.
Hydraulic System Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the following: 1. Hydraulic oil level in the reservoir 2. All hoses, tubes, fittings for leaks, kinks, interference, etc. 3. Air in the lines Not OK Repair/replace cable connections. Ensure extend/ retract section of main control valve is functioning. Not OK Replace solenoid valve. Not OK Replace the extend lockout valve. Not OK Adjust/repair/replace relief valve on main control valve.
Hydraulic System 8.8.3 Boom Retract Circuit and Troubleshooting (Refer to Section 8.8.22, “Boom Extend/Retract Circuit Description,” for a more detailed explanation of this circuit.) AUX FRAME SWAY ATTACH TILT P RETURN FILTER IN T EXT/RET T LFT/LWR MAIN CONTROL VALVE HYDRAULIC RESERVOIR 10054 ONLY EXTEND V LOCKOUT VALVE PUMP T C R E EXTEND/ RETRACT CYLINDER HYDRAULIC OIL COOLER Pressure Return Suction Load Sense MH3530 8.22 Model 8042, 10042, 10054 Legacy Rev.
Hydraulic System Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the following: 1. Hydraulic oil level in the reservoir 2. All hoses, tubes, fittings for leaks, kinks, interference, etc. 3. Air in the lines Not OK Repair/replace cable connections. Ensure extend/ retract section of main control valve is functioning. Not OK Replace solenoid valve. Not OK Replace the extend lockout valve. Not OK Adjust/repair/replace relief valve on main control valve.
Hydraulic System 8.8.4 Boom Lift Circuit and Troubleshooting (Refer to Section 8.8.23, “Boom Lift/Lower Circuit Description,” for a more detailed explanation of this circuit.) AUX RETURN FILTER IN T P FRAME SWAY ATTACH TILT LFT/LWR T EXT/RET MAIN CONTROL VALVE HYDRAULIC RESERVOIR LEFT LIFT/LOWER CYLINDER HYDRAULIC OIL COOLER R R E E RIGHT LIFT/LOWER CYLINDER PUMP Pressure Return Suction Load Sense MH3540 8.24 Model 8042, 10042, 10054 Legacy Rev.
Hydraulic System Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the following: If the lift/lower cylinders do not raise, check the cable connections at the main control valve. 1. Hydraulic oil level in the reservoir 2. All hoses, tubes, fittings for leaks, kinks, interference, etc. 3. Air in the lines If OK Check main relief pressure on main control valve. Repair/replace cable connections. Ensure lift/lower section of main control valve is functioning.
Hydraulic System 8.8.5 Boom Lower Circuit and Troubleshooting (Refer to Section 8.8.23, “Boom Lift/Lower Circuit Description,” for a more detailed explanation of this circuit.) AUX RETURN FILTER IN T P FRAME SWAY ATTACH TILT LFT/LWR T EXT/RET MAIN CONTROL VALVE HYDRAULIC RESERVOIR LEFT LIFT/LOWER CYLINDER HYDRAULIC OIL COOLER R R E E RIGHT LIFT/LOWER CYLINDER PUMP Pressure Return Suction Load Sense MH3550 8.26 Model 8042, 10042, 10054 Legacy Rev.
Hydraulic System Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the following: 1. Hydraulic oil level in the reservoir 2. All hoses, tubes, fittings for leaks, kinks, interference, etc. 3. Air in the lines If the lift/lower cylinders do not lower, check the cable connections at the main control valve. Not OK Repair/replace cable connections. Ensure lift/lower section of main control valve is functioning. Not OK Adjust/repair/replace relief valve on main control valve.
Hydraulic System 8.8.6 Frame Sway (Left) and Stabilizer Circuit and Troubleshooting (Refer to Section 8.8.24, “Frame Sway and Stabilizer Circuit Description,” for a more detailed explanation of this circuit.) FRAME SWAY CYLINDER FTR FTB Ø .041 Ø .
Hydraulic System Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the following: 1. Hydraulic oil level in the reservoir 2. All hoses, tubes, fittings for leaks, kinks, interference, etc. 3. Air in the lines NOTE: When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing,” for correct pressure readings. With the boom below 40°, if the frame sway cylinder will not sway left, drifts or reacts slowly, check cable connections at the main control valve.
Hydraulic System 8.8.7 Frame Sway (Right) and Stabilizer Circuit and Troubleshooting (Refer to Section 8.8.24, “Frame Sway and Stabilizer Circuit Description,” for a more detailed explanation of this circuit.) FRAME SWAY CYLINDER FTR FTB Ø .041 Ø .
Hydraulic System Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the following: 1. Hydraulic oil level in the reservoir 2. All hoses, tubes, fittings for leaks, kinks, interference, etc. 3. Air in the lines NOTE: When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing,” for correct pressure readings. With the boom below 40°, if the frame sway cylinder will not sway right, drifts or reacts slowly, check cable connections at the main control valve.
Hydraulic System 8.8.8 Attachment Tilt (Down) and Slave Cylinder Circuit and Troubleshooting (Refer to Section 8.8.25, “Attachment Tilt and Slave Circuit Description,” for a more detailed explanation of this circuit.) ATTACHMENT TILT CYLINDER AUX FRAME SWAY ATTACH TILT EXT/RET P R RETURN FILTER IN T T LFT/LWR E MAIN CONTROL VALVE LEFT SLAVE CYLINDER HYDRAULIC OIL COOLER R E R E HYDRAULIC RESERVOIR PUMP RIGHT SLAVE CYLINDER Pressure Return Suction Load Sense MH3610 8.
Hydraulic System Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the following: 1. Hydraulic oil level in the reservoir 2. All hoses, tubes, fittings for leaks, kinks, interference, etc. 3. Air in the lines If the attachment tilt cylinder retracts slowly, check cable connections at main control Not OK Repair/replace cable connections. Ensure attachment tilt section of main control valve is functioning. Not OK Replace counterbalance valve.
Hydraulic System 8.8.9 Attachment Tilt (Up) and Slave Cylinder Circuit and Troubleshooting (Refer to Section 8.8.25, “Attachment Tilt and Slave Circuit Description,” for a more detailed explanation of this circuit.) ATTACHMENT TILT CYLINDER AUX FRAME SWAY ATTACH TILT EXT/RET P R RETURN FILTER IN T T LFT/LWR E MAIN CONTROL VALVE LEFT SLAVE CYLINDER HYDRAULIC OIL COOLER R E R E HYDRAULIC RESERVOIR PUMP RIGHT SLAVE CYLINDER Pressure Return Suction Load Sense MH3620 8.
Hydraulic System Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the following: 1. Hydraulic oil level in the reservoir 2. All hoses, tubes, fittings for leaks, kinks, interference, etc. 3. Air in the lines If the attachment tilt cylinder extends slowly, check cable connections at main control Not OK Repair/replace cable connections. Ensure attachment tilt section of main control valve is functioning. Not OK Adjust/repair/replace relief valve on main control valve.
Hydraulic System 8.8.10 Pump and Cooling Circuit and Troubleshooting AUX FRAME SWAY ATTACH TILT P RETURN FILTER IN T LFT/LWR T EXT/RET (Refer to Section 8.8.26, “Pump and Cooling Circuit Description,” for a more detailed explanation of this circuit.) MAIN CONTROL VALVE C PSG G PLT P PS FROM STABILIZER CYLINDER PB HYDRAULIC RESERVOIR PUMP PBG T SECONDARY FUNCTION MANIFOLD TO STABILIZER CYLINDER HYDRAULIC OIL COOLER Pressure Return Suction Load Sense MH3630 8.
Hydraulic System Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the following: 1. Hydraulic oil level in the reservoir 2. All hoses, tubes, fittings for leaks, kinks, interference, etc. 3. Air in the lines NOTE: When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing,” for correct pressure readings. If the pump is noisy or if all hydraulic functions are slow, check the suction line from the reservoir. Not OK Repair/replace suction line.
Hydraulic System 8.8.11 Auxiliary Hydraulics Circuit and Troubleshooting (Male Coupler Pressurized) (Refer to Section 8.8.27, “Auxiliary Hydraulics Circuit Description,” for a more detailed explanation of this circuit.) AUX FRAME SWAY ATTACH TILT EXT/RET P RETURN FILTER IN T T LFT/LWR AUXILIARY COUPLERS MAIN CONTROL VALVE HYDRAULIC OIL COOLER HYDRAULIC RESERVOIR PUMP Pressure Return Suction Load Sense MH3640 8.38 Model 8042, 10042, 10054 Legacy Rev.
Hydraulic System Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the following: 1. Hydraulic oil level in the reservoir 2. All hoses, tubes, fittings for leaks, kinks, interference, etc. 3. Air in the lines NOTE: When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing,” for correct pressure readings. If there are no auxiliary hydraulics functions, check cable connections at main control valve. Not OK Repair/replace cable connections.
Hydraulic System 8.8.12 Auxiliary Hydraulics Circuit and Troubleshooting (Female Coupler Pressurized) (Refer to Section 8.8.27, “Auxiliary Hydraulics Circuit Description,” for a more detailed explanation of this circuit.) AUX FRAME SWAY ATTACH TILT P RETURN FILTER IN T LFT/LWR T EXT/RET AUXILIARY COUPLERS MAIN CONTROL VALVE HYDRAULIC OIL COOLER HYDRAULIC RESERVOIR PUMP Pressure Return Suction Load Sense MH3650 8.40 Model 8042, 10042, 10054 Legacy Rev.
Hydraulic System Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the following: 1. Hydraulic oil level in the reservoir 2. All hoses, tubes, fittings for leaks, kinks, interference, etc. 3. Air in the lines NOTE: When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing,” for correct pressure readings. If there are no auxiliary hydraulics functions, check cable connections at main control valve. Not OK Repair/replace cable connections.
Hydraulic System 8.8.13 Outrigger Circuit (Up) and Troubleshooting (10042/10054) (Refer to Section 8.8.28, “Outrigger Circuit Description (10042/10054),” for a more detailed explanation of this circuit.) LEFT OUTRIGGER CYLINDER RIGHT OUTRIGGER CYLINDER E R R E AUX FRAME SWAY ATTACH TILT P RETURN FILTER IN T LFT/LWR T EXT/RET MAIN CONTROL VALVE OUTRIGGER SHUTTLE VALVE PUMP HYDRAULIC RESERVOIR B1 A1 A2 B2 T LS P OUTRIGGER VALVE HYDRAULIC OIL COOLER 8.
Hydraulic System Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the following: If the outriggers do not go up, check the left and right outrigger switches. 1. Hydraulic oil level in the reservoir 2. All hoses, tubes, fittings for leaks, kinks, interference, etc. 3. Air in the lines If OK Check the solenoid valves on the outrigger valve. Not OK Refer to Section 9.14.5, “Outrigger Switches (10042/ 10054 Only).” Refer to Section 9.7.
Hydraulic System 8.8.14 Outrigger Circuit (Down) and Troubleshooting (10042/10054) (Refer to Section 8.8.28, “Outrigger Circuit Description (10042/10054),” for a more detailed explanation of this circuit.) LEFT OUTRIGGER CYLINDER RIGHT OUTRIGGER CYLINDER E R E R AUX FRAME SWAY ATTACH TILT P RETURN FILTER IN T LFT/LWR T EXT/RET MAIN CONTROL VALVE OUTRIGGER SHUTTLE VALVE PUMP HYDRAULIC RESERVOIR B1 A1 A2 B2 T LS P OUTRIGGER VALVE HYDRAULIC OIL COOLER 8.
Hydraulic System Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the following: If the outriggers do not go down, check the left and right outrigger switches. 1. Hydraulic oil level in the reservoir 2. All hoses, tubes, fittings for leaks, kinks, interference, etc. 3. Air in the lines If OK Check the solenoid valves on the outrigger valve. Not OK Refer to Section 9.14.5, “Outrigger Switches (10042/ 10054 Only).” Refer to Section 9.7.
Hydraulic System 8.8.15 Front-Wheel Steering Circuit (Left Turn) and Troubleshooting (Refer to Section 8.8.29, “Steering Circuit Descriptions,” for a more detailed explanation of this circuit.
Hydraulic System If there is no front wheel steering, check the pressure at the “PSG” port of the secondary function manifold. Not OK Adjust/repair/replace the pressure reducing valve on secondary function manifold. Not OK Adjust/repair/replace the pressure reducing valve on secondary function manifold. Not OK Replace shuttle valve. Not OK Adjust/replace the relief valve. Not OK Consult factory to adjust the compensator pressure at the pump. Not OK Replace check valve fitting.
Hydraulic System 8.8.16 Front-Wheel Steering Circuit (Right Turn) and Troubleshooting (Refer to Section 8.8.29, “Steering Circuit Descriptions,” for a more detailed explanation of this circuit.
Hydraulic System If there is no front-wheel steering, check the pressure at the “PSG” port of the secondary function manifold. Not OK Adjust/repair/replace the pressure reducing valve on secondary function manifold. Not OK Adjust/repair/replace the pressure reducing valve on secondary function manifold. Not OK Replace shuttle valve. Not OK Adjust/replace the relief valve. Not OK Consult factory to adjust the compensator pressure at the pump. Not OK Replace check valve fitting.
Hydraulic System 8.8.17 Four-Wheel Steering Circuit (Left Turn) and Troubleshooting (Refer to Section 8.8.29, “Steering Circuit Descriptions,” for a more detailed explanation of this circuit.
Hydraulic System Not OK Refer to the steering circuits and components in Section 9.7, “Electrical System Troubleshooting,” and Section 9.14, “Switches and Solenoids.” Not OK Adjust/repair/replace the pressure reducing valve on secondary function manifold. Not OK Adjust/repair/replace the pressure reducing valve on secondary function manifold. Not OK Replace shuttle valve. Not OK Adjust/replace the relief valve. Not OK Consult factory to adjust the compensator pressure at the pump.
Hydraulic System 8.8.18 Four-Wheel Steering Circuit (Right Turn) and Troubleshooting (Refer to Section 8.8.29, “Steering Circuit Descriptions,” for a more detailed explanation of this circuit.
Hydraulic System Not OK Refer to the steering circuits and components in Section 9.7, “Electrical System Troubleshooting,” and Section 9.14, “Switches and Solenoids.” Not OK Adjust/repair/replace the pressure reducing valve on secondary function manifold. Not OK Adjust/repair/replace the pressure reducing valve on secondary function manifold. Not OK Replace shuttle valve. Not OK Adjust/replace the relief valve. Not OK Consult factory to adjust the compensator pressure at the pump.
Hydraulic System 8.8.19 Crab Steering Circuit (Left Turn) and Troubleshooting (Refer to Section 8.8.29, “Steering Circuit Descriptions,” for a more detailed explanation of this circuit.
Hydraulic System Not OK Refer to the steering circuits and components in Section 9.7, “Electrical System Troubleshooting,” and Section 9.14, “Switches and Solenoids.” Not OK Adjust/repair/replace the pressure reducing valve on secondary function manifold. Not OK Adjust/repair/replace the pressure reducing valve on secondary function manifold. Not OK Replace shuttle valve. Not OK Adjust/replace the relief valve. Not OK Consult factory to adjust the compensator pressure at the pump.
Hydraulic System 8.8.20 Crab Steering Circuit (Right Turn) and Troubleshooting (Refer to Section 8.8.29, “Steering Circuit Descriptions,” for a more detailed explanation of this circuit.
Hydraulic System Not OK Refer to the steering circuits and components in Section 9.7, “Electrical System Troubleshooting,” and Section 9.14, “Switches and Solenoids.” Not OK Adjust/repair/replace the pressure reducing valve on secondary function manifold. Not OK Adjust/repair/replace the pressure reducing valve on secondary function manifold. Not OK Replace shuttle valve. Not OK Adjust/replace the relief valve. Not OK Consult factory to adjust the compensator pressure at the pump.
Hydraulic System 8.8.21 Brake Circuit Description The brake system circuit, Section 8.8.1, “Brake Circuit and Troubleshooting,” includes the park brake and the service brake, along with the secondary function manifold, main control valve and various hoses, fittings and other components. When the engine is OFF and the ignition key switch is in the OFF position, the park brake is ON. The park brake is part of the front axle ONLY.
Hydraulic System 1 4 2 3 10 5 4. Pressure in both the front and rear axle brake lines is equal. A groove in each of the two spools opens to a cross-hole between the two spool bores, preventing uneven brake pressure. This feature is called the “equalizer” function. 5. Power-mode braking begins when the metering notches (6) in the spool (7) meter oil from the inlet port to the spool chamber. Fluid flows from the spool chamber, through the one-way orifice (8) and into the brake lines.
Hydraulic System 8. Controlling the force applied to the service brake pedal controls the amount of braking power. 9. If the first application of force applied to the service brake pedal was not enough to deliver the braking required, the one way orifices at the work ports help give the brake valve “pump up” ability. The one-way orifices allow unrestricted flow to the brake lines but also restrict the rate of decompression. 8.8.
Hydraulic System a. Boom Lift Circuit (refer to page 8.24) With the joystick in the boom lift position, pressure shifts the lift/lower spool valve in the main control valve to direct system pressure MA7200 through the counterbalance valve to the base end of both the left and right lift/lower cylinders. Return oil from the rod end of the cylinders flows through the pilot-operated check valve to the spool valve, to the oil cooler, to the return filter and then to the reservoir.
Hydraulic System 8.8.25 Attachment Tilt and Slave Circuit Description System pressure is applied in the attachment tilt and slave cylinder circuit from the attachment tilt section of the main control valve. Fluid flow is directed to either side of the attachment tilt and slave cylinder pistons by shifting of the spool valve in the attachment tilt section of the main control valve assembly. The spool valve is shifted by the operator joystick and its associated control cable.
Hydraulic System 8.8.28 Outrigger Circuit Description (10042/10054) System pressure is applied to the outrigger circuit through the main control valve to the outrigger valve. Fluid flow is directed to either side of the outrigger cylinders by the outrigger valve. The valve is controlled by the position of the left and right outrigger switches located on the side console. a. UP Position (refer to page 8.42) Pressing the top of the left and right outrigger switches will raise the outriggers.
Hydraulic System 1 3 1 2 4 8.8.29 Steering Circuit Descriptions Vehicle steering includes front-wheel steering, fourwheel steering and crab steering. a. Front-Wheel Steering MT3870 When the steer select switch (1) is in the frontwheel steer (center) position (2), the front wheels (3) will steer in the direction the steering wheel is turned and the rear wheels (4) will remain fixed. 1. Front-Wheel Steering Left Turn (refer to page 8.
Hydraulic System 5 7 5 6 8 MA7020 b. Four-Wheel Steering When the steer select switch (5) is in the fourwheel steer (rear) position (6), the front wheels (7) will steer in the direction the steering wheel is MT3880 turned and the rear wheels (8) will steer in the opposite direction. 1. Four-Wheel Steering Left Turn (refer to page 8.50) With the steer select switch (5) in the four-wheel steer (rear) position (6), one of the steer select valve solenoids is energized.
Hydraulic System 1 3 1 2 4 c. Crab Steering When the steer select switch (1) is in the crab steer (forward) position (2), the front wheels (3) will steer in the direction the steering wheel is MT3890 turned and the rear wheels (4) will steer in the same direction. 1. Crab Steering Left Turn (refer to page 8.54) With the steer select switch (1) in the crab steer (forward) position (2), one of the steer select valve solenoids is energized.
Hydraulic System 8.9 FOUR-WHEEL STEER INDEXING PROCEDURE If the vehicle does not drive “straight,” the steering could be out-of-phase. Perform the following indexing procedures to synchronize the front and rear steering. 1. With the steer select switch in the four-wheel steer position, turn the steering wheel full left. 2. While holding the steering wheel full left, toggle the steer select switch to the front-wheel steer position, and steer the front wheels back to center. 3.
Hydraulic System 8.10 HYDRAULIC RESERVOIR The hydraulic reservoir (1) and the fuel tank (2) are one unit. They are located on the right side of the vehicle under a cover (3). To remove the fuel tank/hydraulic reservoir cover, remove the capscrews (4), lockwashers (5) and flat washers (6) from the clips (7) on the cover. The fuel tank/ hydraulic reservoir is secured to the right side of the vehicle frame with four carriage bolts (8), lockwashers (9) and hex nuts (10).
Hydraulic System Occasionally, fluid may seep, leak or be more forcefully expelled from the filter head (11) when system pressure exceeds the rating of the filter head or breather. If the return filter becomes plugged, return hydraulic oil will bypass the filter when pressure reaches 25 psi (1,7 bar) and return to the reservoir unfiltered. Carefully examine fluid seepage or leaks from the hydraulic reservoir to determine the exact cause. Clean the reservoir and note where any seepage occurs.
Hydraulic System 8.11 HYDRAULIC SYSTEM PUMP 8.11.2 The piston pump (1) is attached to the transmission. The rotation of the pump shaft causes the cylinder block, shoe plate and pistons to rotate. The angle of the yoke face creates a reciprocating motion to each piston within the cylinder block. As the pistons move out of the cylinder block, a vacuum is created and fluid is forced into the void through a 2" inside diameter hose by atmospheric pressure.
Hydraulic System Note: On early production units, the check valve is a remote mounted inline type; installed between the pump and the main control valve. For these units, remove the outlet hose from the pump; the check valve can remain in place for pump removal. For these early production units, an update kit is available to update your unit to current production. Contact the JLG Parts Department at 717-485-6472 to order the kit. 8 13 11 14 9 13.
Hydraulic System 4 6 1 22 2 5 9 21 17 19 18 20 7 9 3 15 14 13 10 24 12 22 11 6 16 9 8 23 MH3420 d. Pump Disassembly 1. Remove the four screws (1) securing the pressure compensator subassembly (2) from the valve housing section (3) of the pump (4). Remove the three o-rings (5). 2. Secure the pump (4) with the pump shaft (6) pointing up in a suitable holding device or bench vise (if possible). 3.
Hydraulic System 6. Remove springs (13 and 14) and spring seat (15). 7. Lift the flange section (8) off the housing section (7). Remove the gasket (16) from between the two sections. Note: In most cases, the parts inside the cylinder block (17) will not require removal. CAUTION: 2. If installing, coat the outer edge of a new shaft seal (12) with a non-hardening sealant (Permatex® Aviation Form-A-Gasket No. 3 or equivalent). DO NOT damage the shaft seal.
Hydraulic System 7. Connect the load sense lines (17) to the Tee fitting (18). 3. Place the pump (4) and a new, oiled o-ring (22) into position on the transmission. Align the pump shaft with the internal transmission gear, so that the machined teeth mesh together. 8. Install the tank hose (14) onto the check valve manifold (11). 4. Align the bolt holes with the pump mount holes. Secure the pump to the transmission with four plain washers (21), four lockwashers (20) and four capscrews (19). 9.
Hydraulic System This Page Intentionally Left Blank Model 8042, 10042, 10054 Legacy Rev. 10/03 8.
Hydraulic System VALVES AND MANIFOLDS 10 Valves are devices that open or close passageways. Manifolds contain circuit passageways involved in the distribution of hydraulic fluid flowing under pressure. There are various valves and manifolds in use on this vehicle. As valves open and close, hydraulic fluid is directed to flow through various passageways to the prescribed circuit, causing vehicle functions to occur. 8.12.1 11 ~ 8.
Hydraulic System WARNING: 15 Escaping hydraulic fluid under pressure can penetrate the skin, causing death or serious injury. Relieve hydraulic pressure before servicing any hydraulic component. 12 12 5. With the engine OFF, operate all the hydraulic functions to relieve trapped pressure. 7. Place a suitable container to catch hydraulic fluid drainage beneath the frame. 14 13 16 ~ 6. Remove the transmission covers.
Hydraulic System 9 53 10 52 1 17 6 2 34 18 7 16 22 33 19 3 34 4 21 23 13 14 8 5 19 15 16 34 24 12 33 25 20 11 34 32 30 31 29 29 20 28 27 22 26 35 50 46 34 48 44 51 42 49 47 41 45 38 36 16 33 43 39 37 40 MH3480 8.78 Model 8042, 10042, 10054 Legacy Rev.
Hydraulic System Disassemble the Auxiliary Hydraulic Section b. Main Control Valve Disassembly This section covers disassembly of one half (54) of the main control valve, including the frame sway (55), attachment tilt (56), auxiliary hydraulics (57) and load sense outlet (58) sections of the main control valve. 1. Carefully separate the auxiliary hydraulic section (5) from the attachment tilt section (11).
Hydraulic System 8 24 5 7 9 3 4 10 2 24 11 22 1 6 18 16 15 17 23 20 19 15 14 12 5 21 13 8 6 26 25 MH3480 8.80 Model 8042, 10042, 10054 Legacy Rev.
Hydraulic System Disassemble the Attachment Tilt Section 1. Carefully separate the attachment tilt section (1) from the frame sway section (19). Avoid dislodging or losing the shuttle (20), spring (21) and poppet (22) in the frame sway section. 2. Remove the o-ring (23) from between the two sections. 3. Remove the shuttle (2), spring (3) and poppet (4) from the attachment tilt section (1). 4. Remove the two relief valves (24). Refer to “Disassemble the Relief Valves” on page 8.79. 5.
Hydraulic System 1 12 57 59 61 56 63 58 66 60 33 62 55 54 64 32 65 53 38 29 28 37 36 34 52 31 40 30 42 39 41 12 54 7 35 44 47 48 49 8 50 51 27 26 5 10 14 3 11 46 9 39 45 6 13 43 2 4 13 17 19 21 23 16 15 18 20 25 22 24 14 MH3470 8.82 Model 8042, 10042, 10054 Legacy Rev.
Hydraulic System 1. To disassemble the outlet, lift/lower, extend/retract and mid-inlet/outlet sections of the main control valve (1), remove the three nuts (2 and 3) from the end of the three tie rods (4 and 5). Pull the tie rods out through the section assemblies. 2. Disassemble each section as required. Some sections include a pre-adjusted relief valve that regulates pressure in a specific circuit.
Hydraulic System 26 27 3 28 23 4 3 4 22 25 24 4 3 2 1 9 7 11 3 13 15 17 10 19 8 6 12 21 4 14 18 16 20 5 MH3470 8.84 Model 8042, 10042, 10054 Legacy Rev.
Hydraulic System Disassemble the Relief Valve (Lift/Lower and Extend/ Retract Sections) The relief valves (3) on the lift/lower section (1) and the extend/retract section (2) are preset at 3250 ±50 psi (224 ±3,5 bar). 1. Remove the relief valve (3) from the appropriate section. Disassemble the Mid-Inlet/Outlet Section 1. Remove the shuttle (28) from the mid-inlet/outlet section (22). 2. Remove the shut-off plug (23). 3. Remove the remaining plugs (24 and 26) and o-rings (25 and 27). 2.
Hydraulic System 8 26 9 25 16 5 6 1 15 21 12 2 3 13 7 4 15 19 14 20 11 10 21 27 18 17 24 22 23 15 21 MH3480 8.86 Model 8042, 10042, 10054 Legacy Rev.
Hydraulic System f. Main Control Valve Assembly This section covers the assembly of the load sense outlet, auxiliary hydraulics, attachment tilt and frame sway sections of the main control valve (16). Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. Assemble the Load Sense Outlet Section 1. Install a new oiled o-ring (9) and the plug (8) into the load sense section (3). 2.
Hydraulic System 1 23 19 16 17 19 21 19 22 13 18 14 12 8 15 7 5 10 3 11 6 9 4 2 19 20 MH3470 8.88 Model 8042, 10042, 10054 Legacy Rev.
Hydraulic System g. Main Control Valve Assembly This section covers assembly of the outlet, lift/lower, extend/retract and mid-inlet/outlet sections of the main control valve (1). Note: ALWAYS replace o-rings with new o-rings lubricated with clean hydraulic oil to help ensure a leakproof seal and proper vehicle performance. For each relief valve (19): 1. Assemble the relief valve (19) in the reverse order of the disassembly procedure.
Hydraulic System h. Main Control Valve Installation WARNING: Avoid prolonged engine operation in closed areas with inadequate ventilation. Failure to properly ventilate exhaust fumes can result in death or serious injury. 1. Insert the carriage bolts (2 and 3) from the bottom into the main valve (4). 4 7. Start the engine and run at approximately one-third to one-half throttle for about one minute without moving the vehicle or operating any hydraulic functions.
Hydraulic System 2. Place an Accident Prevention Tag on both the ignition key switch and the steering wheel, stating that the vehicle should not be operated. Refer to Section 1.5, “Accident Prevention Tags.” WARNING: DO NOT get under a raised boom unless the boom is blocked up. Always block the boom before doing any servicing that requires the boom to be up. Unexpected lowering of the boom may cause death or serious injury. ~ 3. Temporarily block up or support the raised boom.
Hydraulic System 4. Remove the 650 psi (45 bar) pressure relief valve (4). b. Secondary Function Manifold Disassembly, Cleaning, Inspection and Assembly 5. Remove the solenoid nuts (5), coils (6) and cartridges (7). 1. Secure the secondary function manifold (1) in a suitable bench vise, if possible. 6. Remove the check valve (8). 7. Clean all components with a suitable cleaner before inspection. 8. Inspect the solenoid cartridges for proper operation.
Hydraulic System c. Secondary Function Manifold Installation 1. Align the secondary function manifold with its mounting holes on the frame. 2. Secure the secondary function manifold with two carriage bolts and hex flange nuts. Torque fasteners to specification. Refer to the fastener torque chart in Section 2.3, “Torques.” 8.12.3 Service Brake Valve The service brake valve (9) is secured with four capscrews and lockwashers at the base of the steering column support (10), concealed by the lower dash cover.
Hydraulic System WARNING: Hot hydraulic fluid can cause severe burns. Wait for hydraulic fluid to cool before servicing any hydraulic component. 3. Unlock and open the rear door. Allow the hydraulic fluid to cool. 6. Remove the four capscrews (8) and four lockwashers (9) mounting the service brake valve (10) to the steering column support. Note: DO NOT disassemble the service brake valve. The service brake valve is not serviceable and must be replaced in its entirety, if defective.
Hydraulic System b. Service Brake Valve Installation 1. Install the service brake valve (10) with the four lockwashers (9) and four capscrews (8) to mount the brake valve to the steering column support. Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. 2. Use new oiled o-rings as required. Reattach and secure all valves, hoses, clamps, etc. 3.
Hydraulic System 1 MH3680 c. Brake Test Carefully bleed the brake lines as soon as the brake valve is installed in the vehicle. Air in the system will not allow the brakes to apply properly. There are four brake bleeder locations (1) on the axles. Work with an assistant to perform this procedure. WARNING: Avoid prolonged engine operation in closed areas with inadequate ventilation. Failure to properly ventilate exhaust fumes can result in death or serious injury. 1.
Hydraulic System 8.12.4 Shuttle Valve The shuttle valve (2) is attached to the brake valve (3) with a tee fitting (4). The shuttle valve joins the brake valve load sense line (5), the shuttle IN line (6) from the main control valve and the steering valve shuttle IN line (7). The shuttle valve contains a pressure dependent, two-way check and is a non-serviceable item. It must be replaced in its entirety if defective. 4 5 ~ 3 ~ 6 2 7 MA7440 a. Shuttle Valve Removal 1.
Hydraulic System c. Shuttle Valve Installation Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. 1. Reattach and secure hoses, fittings, etc. Attach the shuttle IN steering valve line at port P1 (2) and the shuttle-in main control valve line at port P2 (3), and the load sense brake valve line at port P3 (4) of the shuttle valve (1). 1 3 P2 5.
Hydraulic System a. Power Steering Valve Removal 1. Park the vehicle on a firm, level surface, fully retract all hydraulic cylinders, ground the attachment (if any), place the travel select lever in (N) NEUTRAL, place the neutral lock lever in the (N) NEUTRAL LOCK position, engage the park brake switch and shut the engine OFF. 6 2. Place an Accident Prevention Tag on both the ignition key switch and the steering wheel, stating that the vehicle should not be operated. Refer to Section 1.
Hydraulic System 8.12.6 Steer Select Valve 2 The vehicle can be used in the front-wheel, four-wheel or crab steering mode. The steer select valve (1) controls the direction of hydraulic fluid flow to the steering cylinders mounted on each axle. The steer select valve (1) is attached to a manifold mounted on a mounting plate inside the frame near the fuel tank. 3 1 3 7 6 5 6 5 4 MA8370 Verify the correct operation of the steer select valve solenoids before considering replacement of the valve.
Hydraulic System WARNING: Hot hydraulic fluid can cause severe burns. Wait for hydraulic fluid to cool before servicing any hydraulic component. 4. Unlock and open the rear door. Allow the hydraulic fluid to cool. WARNING: Escaping hydraulic fluid under pressure can penetrate the skin, causing death or serious injury. Relieve hydraulic pressure before servicing any hydraulic component. 5. Label or otherwise mark the hydraulic hoses (8) in relation to the steer select manifold (9).
Hydraulic System c. Steer Select Manifold and Valve Installation 1. Attach the steer select manifold (2) and valve (4) to the mounting plate on the frame using the two socket head capscrews (3). 6. Wipe up any hydraulic fluid spillage in, on, near and around the vehicle, work area and tools. d. Steering Test Refer to Section 8.7, “Hydraulic System Testing.” 2 4 1 1. Conduct a pressure check of the steering hydraulic circuit at the secondary function manifold. 2.
Hydraulic System The outrigger valve (6) contains two solenoid valve assemblies (7) that direct the flow of hydraulic fluid according to position of the outrigger switches. WARNING: Hot hydraulic fluid can cause severe burns. Wait for hydraulic fluid to cool before servicing any hydraulic component. 4. Unlock and open the rear door. Allow the hydraulic fluid to cool. 7 ~ WARNING: ~ Escaping hydraulic fluid under pressure can penetrate the skin, causing death or serious injury.
Hydraulic System b. Outrigger Valve Disassembly, Cleaning, Inspection and Assembly 1. Place the outrigger valve assembly on a suitable work surface. 2. Remove the solenoid valve assemblies (1) from the outrigger valve (2) by removing the four socket head capscrews (3). Discard the four o-rings (4). 3 Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. 7.
Hydraulic System 8.12.8 WARNING: Avoid prolonged engine operation in closed areas with inadequate ventilation. Failure to properly ventilate exhaust fumes can result in death or serious injury. 5. Start the engine and run at approximately 1/3-1/2 throttle for about one minute, without moving the vehicle or operating any hydraulic functions. WARNING: Outrigger Shuttle Valve (10042/10054) The outrigger shuttle valve (10) is attached to the main control valve (11) with a straight fitting (12).
Hydraulic System c. Outrigger Shuttle Valve Installation WARNING: Hot hydraulic fluid can cause severe burns. Wait for hydraulic fluid to cool before servicing any hydraulic component. 4. Unlock and open the rear door. Allow the hydraulic fluid to cool. 5. Remove the transmission covers. WARNING: Escaping hydraulic fluid under pressure can penetrate the skin, causing death or serious injury. Relieve hydraulic pressure before servicing any hydraulic component. 6.
Hydraulic System a. Extend Lockout Valve Removal WARNING: Hydraulic oil leaking under pressure can penetrate the skin and cause severe personal injury. DO NOT use your hand or any part of your body to check for hydraulic leaks. When checking for hydraulic leaks, wear safety glasses and gloves to help provide protection from spraying hydraulic oil. Use a piece of cardboard or paper to search for leaks. 5. Inspect for leaks and check the level of the hydraulic fluid in the reservoir. Shut the engine OFF.
Hydraulic System 6. Disconnect the wiring connection to the solenoid valve on the extend lockout valve (1). 13 7. Disconnect, label and cap all hydraulic fittings and hoses during removal from the extend lockout valve (1). Disconnect the tank line (2). Disconnect the main control line (3) and the extend/retract cylinder line (4). Remove the fittings (5, 6, 7 and 8). C1 T 11 2 V1 12 5 8 4 MH3790 7 9 2. Clean all components with a suitable cleaner before inspection. 6 1 3.
Hydraulic System c. Extend Lockout Valve Installation 1. Place the extend lockout valve (14) into position on the mounting plate on the vehicle frame (15). WARNING: Avoid prolonged engine operation in closed areas with inadequate ventilation. Failure to properly ventilate exhaust fumes can result in death or serious injury. 5. Start the engine and run at approximately 1/3-1/2 throttle for about one minute, without moving the vehicle or operating any hydraulic functions.
Hydraulic System 8.13 HYDRAULIC CYLINDERS 8.13.1 This section covers servicing the attachment tilt (1), slave (2), extend/retract (3), lift/lower (4), frame sway (5), stabilizer (6), steering (7), outrigger (8) and optional (swing carriage and side tilt) hydraulic cylinders on the vehicle. 1 3 2 4 5 6 General Cylinder Disassembly Instructions WARNING: To help prevent severe burns, proceed with caution when applying heat to parts.
Hydraulic System 4. ALWAYS use new oiled o-rings, seals, gaskets, etc. DO NOT overstretch seals, wipers and o-rings. After installing such parts, verify that they are not twisted in their grooves. 5. To aid in installation, lubricate piston seals and the seal installation path with clean, filtered hydraulic oil. 6. Lubricate the outer surfaces of the seals and o-rings and the inside of the tube, piston and head gland with clean, filtered hydraulic oil.
Hydraulic System 18 1 19 8 3 17 2 20 20 9 5 13 4 6 21 12 16 15 14 11 7 10 22 23 For Early Production b. Attachment Tilt Cylinder Disassembly Note: An additional o-ring may be included at the base of the cylinder rod. This additional o-ring may be discarded, as it served only in a temporarily protective role. 1. Clean the attachment tilt cylinder (1) with a suitable cleaner before inspection. Remove all dirt, debris and grease from the cylinder.
Hydraulic System 7. Carefully pull the rod (4) along with the head gland (7) and all attachments straight out of the tube (2). 8. Fasten the rod end in a soft-jawed vise, and put a padded support below and near the threaded end of the rod to help prevent damage to the rod. 9. Remove the locknut (9) from the rod (4). The locknut is a deformed-thread type nut torqued at 1850-2000 lb-ft (2508-2712 Nm).
Hydraulic System 18 1 19 8 3 17 2 20 20 9 5 13 6 21 4 12 16 15 14 11 7 10 22 23 4. Install both precision wearbands (17) and the capped T-seal (18) onto the piston (8). Note: The T-seal actually consists of four components; a wide, flexible inner band, the flexible T-seal band itself, and two supportive split caps that mount on either side of the “T” itself. 5. Install the head gland (7) and piston (8) onto the rod (4). IMPORTANT: Protect the finish on the rod at all times.
Hydraulic System 24 32 26 27 30 25 31 28 29 MH4290 For Current Production b. Attachment Tilt Cylinder Disassembly Note: An additional o-ring may be included at the base of the cylinder rod. This additional o-ring may be discarded, as it served only in a temporarily protective role. 1. Clean the attachment tilt cylinder (24) with a suitable cleaner before inspection. Remove all dirt, debris and grease from the cylinder. IMPORTANT: Avoid using excess force when clamping the cylinder in a vise.
Hydraulic System 24 18 16 25 6 17 4 1 7 21 15 3 14 17 2 20 5 19 13 9 8 10 22 12 23 11 9. Carefully pull the rod (1) along with the head gland (2) and all attachments straight out of the tube (3). 10. Fasten the rod end in a soft-jawed vise, and put a padded support below and near the threaded end of the rod to help prevent damage to the rod. 11. Remove the two setscrews (4) from the locknut (5). Under each setscrew is a nylon ball (6). Be sure to remove the nylon balls from the locknut.
Hydraulic System c. Attachment Tilt Cylinder Cleaning 1. Thoroughly clean the inner surface of the attachment tilt cylinder with trichlorethylene or another approved cleaner. 2. Discard all seals, back-up rings and o-rings. Replace with new items from complete seal kits (18) to help ensure proper cylinder function. 3. Clean all metal parts with an approved cleaning solvent such as trichlorethylene. Carefully clean cavities, grooves, threads, etc.
Hydraulic System f. Attachment Tilt Cylinder Installation 1. Attach a suitable sling to an overhead crane or other suitable device and to the attachment tilt cylinder. Make sure the device used can actually support the cylinder. Place the attachment tilt cylinder in position within the gooseneck. Refer to Section 3, “Boom.” 2. Install the lower attachment tilt cylinder pin by tapping it through the bottom of the quick attach (if installed). Install the retaining bolt. 3.
Hydraulic System 8.13.5 a. Slave Cylinder Removal Slave Cylinders Each slave cylinder (1) is secured to the vehicle frame and outer boom with cylinder mount pins, capscrews and nuts. 1. Park the vehicle on a firm, level surface, fully retract all hydraulic cylinders, then raise the boom to approximately a 30-degree angle. Support the boom. Place the travel select lever in (N) NEUTRAL, place the neutral lock lever in the (N) NEUTRAL LOCK position, engage the park brake switch and shut the engine OFF. 2.
Hydraulic System 1 12 3 5 16 17 11 20 4 7 10 9 8 13 14 15 6 7 2 19 18 b. Slave Cylinder Disassembly Note: An additional o-ring may be included at the base of the cylinder rod. This additional o-ring may be discarded, as it served only in a temporarily protective role. 1. Clean the slave cylinder (1) with a suitable cleaner before inspection. Remove all dirt, debris and grease from the cylinder. IMPORTANT: Avoid using excess force when clamping the cylinder in a vise.
Hydraulic System 9. Remove the precision wearbands (10) and the capped T-seal (11) from the piston (5). Note: The T-seal actually consists of four components; a wide, flexible inner band, the flexible T-seal band itself, and two supportive split caps that mount on either side of the “T” itself. 10. Remove the locknut (12) from the rod (3). The deforming-thread type nut was coated with Loctite #271 (red) and torqued to 900-1050 lb-ft (1220-1424 Nm). Discard the nut.
Hydraulic System 1 12 3 5 16 17 11 20 4 7 10 9 8 13 14 15 6 7 2 19 18 4. Install the deep Z-seal with rod back-up (13) in the head gland (4) orienting the edge (19). 5. Carefully install the head gland (4) onto the rod (3). 6. Carefully install the piston (5) onto the rod (3). Note: If a white, powdery residue remains on the threads and parts, clean the residue away with a soft brass wire brush prior to reassembly, and wipe with Loctite “T” cleaner before proceeding. 7.
Hydraulic System 3. Use new oiled o-rings, and reattach and secure the hydraulic hoses to the slave cylinder fittings. WARNING: Avoid prolonged engine operation in closed areas with inadequate ventilation. Failure to properly ventilate exhaust fumes can result in death or serious injury. 8.13.6 Extend/Retract Cylinder The extend/retract cylinder (21) is located under the boom, attached to the rear of the outer boom and the front of the intermediate boom. 4.
Hydraulic System 1 2 4 12 17 13 19 3 24 22 18 5 23 7 14 16 20 15 25 6 9 26 8 11 21 20 10 MH2880 6. Attach a suitable sling to an overhead crane or other suitable device and to the extend/retract cylinder. Make sure the device used can actually support the cylinder. IMPORTANT: Avoid using excess force when clamping the cylinder in a vise. Apply only enough force to hold the cylinder securely. Excessive force can damage the cylinder tube (2). 7.
Hydraulic System 5. Using a pin spanner wrench, unscrew the head gland (6) from the tube (2). The head gland was originally torqued to 300-400 lb-ft (407-542 Nm), so a considerable amount of force is required. Carefully slide the head gland down along the rod toward the eyelet end, away from the cylinder tube (2). IMPORTANT: When sliding the rod and piston assembly out of the tube, prevent the threaded end of the tube from damaging the piston (7).
Hydraulic System 24 1 23 26 21 22 11 2 25 3 6 20 14 12 4 15 5 7 19 9 16 13 17 8 7 18 10 e. Extend/Retract Cylinder Assembly Note: Follow Section 8.13.3, “General Cylinder Assembly Instructions.” 1. Install a new small oiled o-ring (1) and new back-up ring (2) into the piston (3). 2. Install the square ring (4), the piston seal (5) and both precision wearbands (6) onto the piston (3). 3.
Hydraulic System IMPORTANT: When sliding the rod (20) and piston assembly into the tube, prevent the threaded end of the tube from damaging the piston (3). Keep the rod centered within the tube to help prevent binding. Protect the finish on the rod at all times. Damage to the surface of the rod can cause seal failure. 14. Carefully insert the rod (20) with all attachments straight into the tube (24). 15. Using a pin spanner wrench, thread the head gland (9) into the tube (24).
Hydraulic System 8.13.7 Lift/Lower Cylinder The lift/lower cylinders (1) are anchored to the underside of the outer boom and to the vehicle frame. 3. Unlock and open the rear door. Allow the hydraulic fluid to cool. WARNING: Escaping hydraulic fluid under pressure can penetrate the skin, causing death or serious injury. Relieve hydraulic pressure before servicing any hydraulic component. 4. Label or otherwise mark the lift/lower cylinder hydraulic hoses. Disconnect and cap all hoses and fittings. 5.
Hydraulic System 3 8 2 4 12 9 5 11 6 10 7 MH2890 5. Using a pin spanner wrench, unscrew the locking collar (7) from the tube (3). The locking collar was originally torqued to 300-400 lb-ft (407-542 Nm), so a considerable amount of force is required. 6. Carefully slide the locking collar (7) and the head gland (8) down along the rod toward the eyelet end, away from the cylinder tube (3).
Hydraulic System 1 6 2 13 12 14 10 11 16 7 3 9 18 4 8 5 15 17 19 20 12. Remove the small o-ring (11) from within the piston (7). 13. Remove the o-ring (12) and back-up ring (13) from the head gland (6). Slide the rings off the rod (4) to remove them from the rod. 14. Remove the precision wearbands (14) from within the head gland (6). Remove the sealed, outside diameter heavy-duty rod wiper (17) and the deep Zseal with back-up (15) from the other end of the head gland.
Hydraulic System 1. Install a new small oiled o-ring (11) into the piston (7). IMPORTANT: When sliding the rod (4) and piston assembly into the tube, prevent the threaded end of the tube from damaging the piston (7). Keep the rod centered within the tube to help prevent binding. Protect the finish on the rod at all times. Damage to the surface of the rod can cause seal failure. 2. Install the capped T-seal (10) and both precision wearbands (9) onto the piston (7). 12.
Hydraulic System 1 21 20 11 14 12 13 9 8 2 3 6 10 7 17 5 19 18 16 15 18 19 4 17 For S/N 19235 & After b. Lift/Lower Cylinder Disassembly Note: An additional o-ring may be included at the base of the cylinder rod. This additional o-ring may be discarded, as it served only in a temporarily protective role. 1. Clean the lift/lower cylinder (1) with a suitable cleaner. Remove all dirt, debris and grease from the cylinder. IMPORTANT: Avoid using excess force when clamping the cylinder in a vise.
Hydraulic System 9. Remove the two setscrews (9) from the locknut (10). Under each setscrew is a nylon ball (11). Be sure to remove the nylon balls from the locknut. Discard the nylon balls. 10. Remove the locknut (10) from the rod (5). The locknut is torqued at 1735-1885 lb-ft (2352-2556 Nm). Note: It may be necessary to apply heat to break the bond of the sealant between the locknut (10) and the rod (5) before the piston (8) can be removed.
Hydraulic System 1 16 4 3 14 17 2 5 20 18 19 15 7 6 9 8 11 12 13 10 21 10 8 6 12 13 e. Lift/Lower Cylinder Assembly Note: Follow Section 8.13.3, “General Cylinder Assembly Instructions.” 1. Install a new small oiled o-ring (1) into the groove in the end of the rod (2). 2. Install the capped T-seal (3) and the precision wearband (4) onto the piston (5).
Hydraulic System IMPORTANT: Avoid using excess force when clamping the cylinder in a vise. Apply only enough force to hold the cylinder securely. Excessive force can damage the cylinder tube (18). 10. Secure the lift/lower cylinder in a soft-jawed vise or other acceptable holding equipment if possible. 11. Lubricate the inside of the tube (18) and outside of the piston (5) and head gland (7) with clean, filtered hydraulic oil. 12.
Hydraulic System 8.13.8 a. Frame Sway Cylinder Removal Frame Sway Cylinder The frame sway cylinder (1) is attached to the right side of the frame at the front axle and to the cast loop on the axle. 1 1. Park the vehicle on a firm, level surface, fully retract all hydraulic cylinders, ground the attachment (if any), place the travel select lever in (N) NEUTRAL, place the neutral lock lever in the (N) NEUTRAL LOCK position, engage the park brake switch and shut the engine OFF. 2.
Hydraulic System 2 5 4 3 6 3 MT1900 b. Frame Sway Cylinder Disassembly Note: An additional o-ring may be included at the base of the cylinder rod. This additional o-ring may be discarded, as it served only in a temporarily protective role. 1. Clean the frame sway cylinder (2) with a suitable cleaner. Remove all dirt, debris and grease from the cylinder. IMPORTANT: Avoid using excess force when clamping the cylinder in a vise. Apply only enough force to hold the cylinder securely.
Hydraulic System 6 1 4 15 14 9 16 17 12 13 19 11 8 2 5 3 7 20 10 18 2 IMPORTANT: When sliding the rod and piston assembly out of the tube, DO NOT damage the piston by scraping it against the threads in the tube. Keep the rod in line with the tube to prevent binding. 6. Carefully withdraw the rod (6) straight out of the tube (5). Keep the rod straight during withdrawal to help avoid scratching, nicking or damaging the tube. 7.
Hydraulic System d. Frame Sway Cylinder Inspection and Repair 1. Inspect all parts for wear, damage, etc. If inner surfaces of the cylinder (1) do not display an ultrasmooth, polished finish, or are damaged in any way, replace the damaged part. Often, dirty hydraulic fluid causes failure of internal seals and damage to the polished surfaces within the component. 2. Inspect the inside of the tube (5) for scoring and other damage. If the tube is damaged, replace it with a new tube. 3.
Hydraulic System f. Frame Sway Cylinder Installation 1. Lubricate the cylinder pins with multi-purpose, lithium-based grease. 2. Use a sling and hoist or other suitable lifting device to help install the cylinder. Orient the cylinder with the cylinder eyelet on top and the rod eyelet on the bottom. 3. Install the upper cylinder pin. Drive the lubricated cylinder pin through the cylinder eyelet, frame mount and self-aligning bearing. Secure the pin with a capscrew and hex-locknut.
Hydraulic System 8.13.9 a. Stabilizer Cylinder Removal Stabil-TRAK Cylinder The stabilizer cylinder (1) is attached to the left side of the frame at the rear axle and to the cast loop on the axle. 1. Park the vehicle on a firm, level surface, fully retract all hydraulic cylinders, ground the attachment (if any), place the travel select lever in (N) NEUTRAL, place the neutral lock lever in the (N) NEUTRAL LOCK position, engage the park brake switch and shut the engine OFF. 2.
Hydraulic System 10 19 9 1 18 24 17 6 16 21 15 8 20 13 23 3 14 4 5 12 11 2 22 ~ 7 3 MH2900 For S/N 13198 thru 19356 b. Stabilizer Cylinder Disassembly Note: An additional o-ring may be included at the base of the cylinder rod. This additional o-ring may be discarded, as it served only in a temporarily protective role. 1. Clean the stabilizer cylinder (1) with a suitable cleaner. Remove all dirt, debris and grease from the cylinder.
Hydraulic System 5. Use a pin spanner wrench to unthread the head gland (9) from the tube (2). The head gland is installed at a torque of 300-400 lb-ft (407-542 Nm), so a considerable amount of force is required to remove it. Carefully slide the head gland down along the rod toward the eyelet end, away from the cylinder tube. IMPORTANT: Protect the finish on the rod at all times. Damage to the rod can cause premature seal failure. 6. Carefully withdraw the rod (10) straight out of the tube (2).
Hydraulic System 10 9 1 18 17 16 6 15 8 13 3 14 4 12 5 11 2 ~ 7 3 MH2900 4. Install new oiled o-ring (18), back-up ring (17) and oiled o-ring (16) onto the head gland (9). If the backup ring is not flat on both sides, the side with the arc must be toward the o-ring. 10. Secure the rod eyelet in a soft-jawed vise or other suitable holding device. Place a padded support below the threaded end of the rod to help prevent damaging the rod. 5. Install the head gland (9) onto the rod (10).
Hydraulic System IMPORTANT: Use a suitable installation tool or compression sleeve to help prevent twisting or damaging the seals and o-rings when installing the piston (12) and head gland (9) into the cylinder. When sliding the rod and piston assembly in the tube, DO NOT damage the piston by scraping it against the threads in the tube. Keep the rod in line with the tube to prevent binding. 14. Keep the rod (10) straight and carefully insert the rod into the tube (2).
Hydraulic System 3 5 5 4 6 21 20 19 22 2 16 17 17 18 10 16 8 19 7 9 3 18 1 13 20 21 15 14 15 14 12 11 For S/N 19357 & After b. Stabilizer Cylinder Disassembly Note: An additional o-ring may be included at the base of the cylinder rod. This additional o-ring may be discarded, as it served only in a temporarily protective role. 1. Clean the stabilizer cylinder (1) with a suitable cleaner. Remove all dirt, debris and grease from the cylinder.
Hydraulic System 5. Use a pin spanner wrench to unthread the head gland (9) from the tube (2). The head gland is installed at a torque of 300 ±50 lb-ft (407 ±68 Nm), so a considerable amount of force is required to remove it. Carefully slide the head gland down along the rod toward the eyelet end, away from the cylinder tube. IMPORTANT: Protect the finish on the rod at all times. Damage to the rod can cause premature seal failure. 6. Carefully withdraw the rod (10) straight out of the tube (2).
Hydraulic System 18 20 20 19 4 21 3 1 6 5 16 9 7 7 8 10 9 17 22 2 18 8 5 11 23 1 4 12 12 14 15 14 13 MH4310 e. Stabilizer Cylinder Assembly Note: Follow Section 8.13.3, “General Cylinder Assembly Instructions.” 1. Install the deep Z-seal with rod back-up (1) into the head gland (2), orienting the edge (3). 2. Install the precision wearbands (4) into the head gland (2). 3.
Hydraulic System 10. Secure the rod eyelet in a soft-jawed vise or other suitable holding device. Place a padded support below the threaded end of the rod to help prevent damaging the rod. 11. Apply Loctite Threadlocker #271 (red) to the locknut (15) in accordance with Loctite instructions. Install the nut onto the threaded end of the rod. Torque the nut to 1175-1400 lb-ft (1593-1898 Nm). IMPORTANT: Avoid using excess force when clamping the cylinder in a vise.
Hydraulic System 8.13.10 Outrigger Cylinders (10042/10054) Each outrigger cylinder (1) is secured to the outrigger frame (2) with a capscrew, elastic hex locknut and pivot pin at the top and at the bottom of the outrigger leg (3). a. Outrigger Cylinder Removal 1. Park the vehicle on a firm, level surface, fully retract all hydraulic cylinders except the outrigger cylinders. Lower the outriggers, but DO NOT allow the outriggers to touch the ground.
Hydraulic System 5 4 7 6 MH2911 2. Place the outrigger cylinder in a soft-jawed vise or other acceptable holding equipment if possible. For Early Production b. Outrigger Cylinder Disassembly Note: An additional o-ring may be included at the base of the cylinder rod. This additional o-ring may be discarded, as it served only in a temporarily protective role. 1. Clean the outrigger cylinder (4) with a suitable cleaner before inspection. Remove all dirt, debris and grease from the cylinder.
Hydraulic System 3 2 6 6 7 8 14 15 10 4 9 16 11 1 13 5 12 17 18 MH2911 4. Extend the rod (1) to allow access to the base of the cylinder. 6. Carefully pull the rod (1) with all attachments straight out of the tube (3). IMPORTANT: Protect the finish on the rod at all times. Damage to the surface of the rod can cause seal failure. 7. Fasten the rod end in a soft-jawed vise and put a padded support below and near the threaded end of the rod to help prevent damage to the rod. 5.
Hydraulic System 11. Remove the locknut (11) from the rod (1). The deforming-thread type nut was coated with Loctite #271 (red) and torqued to 1300-1500 lb-ft (17632034 Nm). Discard the nut. 2. Remove slight scratches on the piston, rod, or inner surface of the tube with very fine grit emery cloth. Use the emery cloth in a rotary motion to polish out and blend the scratch(es) into the surrounding surface.
Hydraulic System 10 8 6 6 12 11 5 4 1 3 2 9 7 MH2911 8. Install the capped T-seal (1) and precision wearbands (2) onto the piston (3). Note: The T-seal actually consists of four components: a wide, flexible inner band, the flexible T-seal band itself, and two supportive split caps that mount on either side of the “T” itself. 9. Install new oiled o-ring (4), back-up ring (5) and oiled o-ring (7) onto the head gland (8). 10.
Hydraulic System 13 14 16 15 MH4320 2. Place the outrigger cylinder in a soft-jawed vise or other acceptable holding equipment if possible. For Current Production b. Outrigger Cylinder Disassembly Note: An additional o-ring may be included at the base of the cylinder rod. This additional o-ring may be discarded, as it served only in a temporarily protective role. 1. Clean the outrigger cylinder (13) with a suitable cleaner before inspection. Remove all dirt, debris and grease from the cylinder.
Hydraulic System 15 9 10 5 4 9 11 2 1 14 12 14 16 7 6 13 8 18 17 3 6 7 8 MH4320 4. Extend the rod (1) to allow access to the base of the cylinder. 7. Carefully pull the rod (1) with all attachments straight out of the tube (4). IMPORTANT: Protect the finish on the rod at all times. Damage to the surface of the rod can cause seal failure. 8. Fasten the rod end in a soft-jawed vise and put a padded support below and near the threaded end of the rod to help prevent damage to the rod. 5.
Hydraulic System Note: It may be necessary to apply heat to break the bond of the sealant between the locknut (11) and the rod (1) before the piston (5) can be removed. Some parts of cylinders are sealed with a special organic sealant and locking compound. 2. Remove slight scratches on the piston, rod, or inner surface of the tube with very fine grit emery cloth. Use the emery cloth in a rotary motion to polish out and blend the scratch(es) into the surrounding surface.
Hydraulic System 2 1 3 9 2 12 10 8 11 7 4 6 5 6 5 4 MH4320 8. Install the capped T-seal (1) and precision wearbands (2) onto the piston (3). 10. Carefully insert the rod (8) with all attachments straight into the tube (9). Note: The T-seal actually consists of four components: a wide, flexible inner band, the flexible T-seal band itself, and two supportive split caps that mount on either side of the “T” itself. 11. Apply Loctite #242 (blue) to the threads of the head gland (7).
Hydraulic System f. Outrigger Cylinder Installation 1. Lubricate the outrigger cylinder pins with multipurpose lithium-based grease. 2. Use a sling and hoist or other suitable lifting device to help install the cylinder. Orient the cylinder with the cylinder eyelet on top and the rod eyelet on the bottom. 3. Install the upper cylinder pin. Drive the lubricated cylinder pin through the outrigger frame mount and the cylinder eyelet, aligning the mount pin bolt holes with the outrigger cylinder mount holes.
Hydraulic System 8.13.11 Swing Carriage (Optional) 2 The optional swing carriage provides a way to swing the carriage attachment from side-to-side. The swing carriage includes two cylinders (1) that operate together to provide the side-to-side motion. 3 X 2 1 R 4 X MT2450 a. Swing Carriage Cylinder Removal E MT1960 2. Swing the carriage to the centered position. 10. Use a sling and hoist or other suitable lifting device to support the cylinders (5).
Hydraulic System 5 1 6 4 2 3 8 7 MT1911 For Early Production b. Swing Carriage Cylinder Disassembly Note: An additional o-ring may be included at the base of the cylinder rod. This additional o-ring may be discarded, as it served only in a temporarily protective role. 1. Clean the swing carriage cylinder (1) with a suitable cleaner to remove dirt, debris, grease, etc. IMPORTANT: Avoid using excess force when clamping the cylinder in a vise. Apply only enough force to hold the cylinder securely.
Hydraulic System 9. Remove the two setscrews (8), with locking inserts (9), from the piston (7). Pry or drill out the setscrews as required. DO NOT damage the piston threads. New setscrews with locking inserts will be required for reassembly. 10. Remove the piston (7) from the rod (4). Note: Loctite Threadlocker #271 (red) and 440-500 lb-ft (597-678 Nm) were applied to the piston (7) when it was installed.
Hydraulic System 4 1 14 19 18 16 10 8 9 3 2 12 5 22 17 15 20 11 13 14 24 23 21 7 9 8 6 MT1911 7. Install a new piston square seal (10), square ring (11) and precision wearband (12) onto the piston (7). 8. Apply Loctite Primer “T” and Threadlocker #271 (red) to the threads of the piston (7) in accordance with Loctite instructions. Thread the piston (7) onto the rod (4) and torque to 440-500 ft-lb (597-678 Nm). 9.
Hydraulic System 1 22 15 11 13 12 3 5 2 6 7 14 4 15 9 12 10 11 19 21 23 24 19 18 17 17 8 16 20 For Current Production b. Swing Carriage Cylinder Disassembly Note: An additional o-ring may be included at the base of the cylinder rod. This additional o-ring may be discarded, as it served only in a temporarily protective role. 1. Clean the swing carriage cylinder (1) with a suitable cleaner to remove dirt, debris, grease, etc.
Hydraulic System 9. Fasten the rod end in a soft-jawed vise, and put a padded support below and near the threaded end of the rod to help prevent damage to the rod. 10. Remove the precision wear band (10) from the piston (9). 11. Remove the two setscrews (11), and nylon balls (12), from the piston (9). Pry or drill out the nylon balls as required. DO NOT damage the piston threads. New nylon balls will be required for reassembly. 12. Remove the piston (9) from the rod (5).
Hydraulic System 2 1 5 6 13 14 15 7 12 9 3 4 6 5 10 8 11 MH4330 6. Install a new piston square seal (1), square ring (2). 7. Apply Loctite #242 (blue) to the threads of the piston (3). Thread the piston (3) onto the rod (4) and torque to 425-500 ft-lb (576-678 Nm). 8. Apply Loctite #242 (blue) to the threads of the two setscrews (5). Install two setscrews (5) with nylon balls (6) into their holes in the piston (3). Tighten until the nylon balls are deformed into the threads of the rod. 9.
Hydraulic System f. Swing Carriage Cylinder Installation 1. Install the swing carriage cylinder(s) (16) on the pivot mount (20). Secure the rod ends to the pivot mount using the shims (25) and bearings (26). Insert the pin (19) and secure with the bolt (17) and nut (18). 20 18 g. Swing Carriage Cylinder Pressure Checking and Circuit Bleeding 1. Attach a 4000 psi (276 bar) gauge to the test fitting on the main control valve to test the system pressure.
Hydraulic System 8.13.12 Side Tilt Carriage Cylinder (Optional) The optional side tilt carriage cylinder (1) provides a way to tilt the carriage attachment from side-to-side. The side tilt carriage includes a cylinder that operates to provide the side tilt motion. a. Side Tilt Carriage (Optional) Removal 1. Level the boom (place the boom in a horizontal position). 2. Tilt the carriage (2) to fully retract the side tilt carriage cylinder (3). 3.
Hydraulic System 4 2 5 7 3 5 5 6 8 MT1950 Model 8042, 10042, 10054 Legacy Rev. 10/03 8.
Hydraulic System 6 9 1 7 2 20 19 12 11 10 18 14 17 13 8 9 16 5 15 4 2 3 5 MT1921 b. Side Tilt Carriage Cylinder Disassembly Note: An additional o-ring may be included at the base of the cylinder rod. This additional o-ring may be discarded, as it served only in a temporarily protective role. 1. Clean the side tilt carriage cylinder (1) with a suitable cleaner to remove dirt, debris, grease, etc. 2. If necessary, remove both grease fittings (2) from the cylinder tube end and the rod end. 3.
Hydraulic System IMPORTANT: When sliding the rod and piston assembly into the tube, prevent the threaded end of the tube from damaging the piston (8). Keep the rod centered within the tube to help prevent binding. 9. Carefully pull the rod (6) with all attachments straight out of the tube (4). 10. Fasten the rod end in a soft-jawed vise, and put a padded support below and near the threaded end of the rod, to help prevent damage to the rod. 11.
Hydraulic System 18 20 5 4 3 11 8 7 10 14 9 19 16 2 6 18 12 20 13 1 15 17 19 MT1921 e. Side Tilt Carriage Cylinder Assembly 8. Carefully slide the piston (13) onto the rod (11). Note: Follow the general assembly instructions in Section 8.13.3, “General Cylinder Assembly Instructions.” 9. Apply Loctite Primer “T” and Threadlocker #271 (red) to the threads of the locknut (16) in accordance with Loctite instructions.
Hydraulic System IMPORTANT: When sliding the rod and piston assembly in the tube, prevent the threaded end of the tube from damaging the piston seal (14). Keep the rod centered within the tube to help prevent binding. 13. Carefully insert the rod (11) with all attachments straight into the tube (17). Using a pin spanner wrench, begin to thread the head gland into the tube. Install new locking inserts (18) into the head gland.
Hydraulic System 3 1 4 6 2 4 4 5 7 MT1950 f. Side Tilt Carriage Cylinder Installation 1. Install the side tilt carriage cylinder (2) onto the side tilt carriage (1). Secure the rod end to the side tilt carriage with the cylinder rod pin (6) and snap rings (4). Secure the tube end to the pivot base (7) with the cylinder base pin (5) and snap rings (4). 2. Lubricate the pivot pins (5 and 6) with multi-purpose grease.
Hydraulic System g. Side Tilt Carriage Cylinder Pressure Checking and Circuit Bleeding 1. Attach a 4000 psi (276 bar) gauge to the test fitting on the main control valve to test the system pressure. Pressure readings should be 3000 ±100 psi (207 ±7 bar). Refer to Section 8.7, “Hydraulic System Testing.” To check the cylinder pressure, consult the factory. 2. Start with the side tilt carriage cylinder balanced, that is, with the carriage level and centered, not tilted. 3. Tilt the carriage fully left.
Hydraulic System This Page Intentionally Left Blank 8.176 Model 8042, 10042, 10054 Legacy Rev.
Section 9 Electrical System Contents PARAGRAPH 9.1 9.2 9.3 9.4 9.5 9.6 9.7 TITLE PAGE Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7 9.1.1 General Overview (Cab Harness) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7 9.1.2 General Overview (Engine Harness) (SN 8042, 13198 - 18990, 10042 13198 - 19030, 10054, 13198 - 19079) . . . . . . 9.8 9.1.
Electrical System 9.7.13 9.7.14 9.7.15 9.7.16 9.7.17 9.7.18 9.7.19 9.7.20 9.7.21 9.7.22 9.7.23 9.7.24 9.7.25 9.7.26 9.7.27 9.7.28 9.7.29 9.7.30 9.7.31 9.7.32 9.7.33 9.7.34 9.7.35 9.7.36 9.7.37 9.7.38 9.7.39 9.7.40 9.7.41 9.7.42 9.7.43 9.7.44 9.7.45 9.7.46 9.2 10042 Electrical Schematic (SN 13198 Through 16782, Without Lighting Package) 9.62 10042 Electrical Schematic (SN 13198 Through 16782, With Lighting Package and SN 16783 Through 19030) 9.
Electrical System 9.8 9.7.47 Heater Circuit and Troubleshooting (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7.48 Roadlights Main Beam Circuit and Troubleshooting (Option) . . . . . . . . . . . . . . . . 9.7.49 Roadlights Hazard Lights Circuit and Troubleshooting (Option) . . . . . . . . . . . . . . 9.7.50 Roadlights Turn Signals Circuit and Troubleshooting (Option) . . . . . . . . . . . . . . . 9.7.51 Roadlights Side & Dipped Beam Lights Circuit and Troubleshooting (Option) . . .
Electrical System 9.8.26 9.8.27 9.9 9.10 9.11 9.12 9.13 9.14 9.4 Transmission, Reverse Third Gear Circuit, (SN 10054, 13198 - 19079) . . . . . . . . Transmission, Reverse Third Gear Circuit, (SN 8042, 18991 - 19987, 10042, 19031 - 19987 And 8042/10042, 0160002332 & After) . . . . . . . . . . . . . . . 9.8.28 Transmission, Reverse Third Gear Circuit, (SN 10054, 19080 - 19987 And 0160002332 & After). . . . . . . . . . . . . . . . . . . . . . 9.8.29 Dash Panel Warning Indicator Troubleshooting. . . . .
Electrical System 9.14.15 9.14.16 9.14.17 9.14.18 9.14.19 Fuel Level Indicator and Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Angle Sensor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . Boom Extend Interlock Sensor Removal/Replacement (10054 Only) . . . . . . . . . . Service Brake Switch. . . . . . . . . . . . . . . . . . .
Electrical System This Page Intentionally Left Blank 9.6 Model 8042, 10042, 10054 Legacy Rev.
Electrical System 9.1 ELECTRICAL COMPONENT TERMINOLOGY To understand the safety, operation, and service information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the electrical components of the vehicle. The following illustration identifies the components that are referred to throughout this section. 9.1.
Electrical System 9.1.2 General Overview (Engine Harness) (SN 8042, 13198 - 18990, 10042 13198 - 19030, 10054, 13198 - 19079) Tie Strap Back-up Alarm Fuel Shut-off Solenoid Connector Boom Angle Sensor Connector Engine Block Heater Hyd. Oil Tank Fuel Tank Engine Low Oil Pressure Sender Oil Pressure Switch Connector Trans. Temp. Switch Hyd. Temp. Conn. Fuel Sender Conn. Water Temperature Sensor Starter Conn. Upper Trans. Connector Lower Trans. Connector Diodes Boom Extend Sensor Conn.
Electrical System 9.1.3 General Overview (Engine Harness) (SN 8042, 18991 - 19987, 10042 19031 - 19987, 10054, 19080 - 19987 And 8042/10042/10054, 0160002332 & After) Back-up Alarm Boom Angle Sensor Connector Hyd. Oil Tank Fuel Tank Engine Low Oil Pressure Sender Water Temperature Sensor Connector Oil Pressure Switch Connector Engine Harness Continued. See Page 9.10 Trans. Temp. Switch Hyd. Temp. Conn. Engine Block Heater Upper Trans. Connector Fuel Sender Conn. Trans. Temp. Conn.
Electrical System 9.1.3 General Overview (Engine Harness) (SN 8042, 18991 - 19987, 10042 19031 - 19987, 10054, 19080 - 19987 And 8042/10042/10054, 0160002332 & After) (Continued) Batteries Frame Ground Stud To Engine Starter Engine Grid Heater Engine Starter Engine Alternator ECM Fuses Cold Start Grid Heater Fuses Grid Heater Relays Ground Buss Bar Diagnostic Connector Engine Harness Continued. See Page 9.9 Diode VesPaks Terminating Resistor MH5590 ECM Connectors Terminating Resistor 9.
Electrical System 9.1.4 General Overview (ECM Cab Harness) (SN 8042, 18991 - 19987, 10042 19031 - 19987, 10054, 19080 - 19987 And 8042/10042/10054, 0160002332 & After) A Engine Function Indicator Lights Throttle Sensor Connectors A Engine Function Indicator Lights Fuse Block Connectors Engine Air-Intake Heater Indicator Light MH5600 Model 8042, 10042, 10054 Legacy Rev. 10/03 9.
Electrical System 9.2 9.2.1 SERVICE WARNINGS CAUTION: DO NOT disconnect the battery while the engine is running. This will cause a voltage surge in the alternator charging system that will immediately ruin internal components. General CAUTION: DO NOT disconnect any wiring without first stopping the engine, turning all electrical switches to the OFF position an disconnecting the battery ground (-) cable from the battery.
Electrical System 9.4 EFFECTIVE GROUND CONNECTIONS 1. Effective ground connections are essential to the efficient operation of electrical components. If an inadequate ground is suspected or determined, establishing another ground may be desired. Also, in the event a factory-authorized accessory is being installed, it is necessary to follow the proper sequence for providing an electrical ground.
Electrical System 9.5.3 Cleaning and Drying Clean a wire harness with a natural bristle brush and the same detergent used to clean the vehicle. Allow the harness to air dry. DO NOT allow surface temperatures to exceed 300° F (149° C). 9.5.4 Inspection and Repair Replace a harness only if it is damaged or unusable. If a splice or repair must be made to a wire, always use rosin core solder to bond wires together. Use heat-shrink tubing or insulating electrical tape to cover all splices or bare wires. 9.
Electrical System 9.6 FUSES AND RELAYS 9.6.1 Fuses and relays help to protect the electrical system. In general, a blown fuse is a symptom of another electrical problem. Address the true problem, not just the symptom. Simply replacing the fuse often will not solve the problem. Blown fuses are usually due to simple causes, including loose or corroded connections, or a defective relay. Circuit Protection - Fuses The fuse is the most common method used for protecting wiring circuits.
Electrical System 9.6.2 Fuse and Relay Locations a. Fuse Block Fuse Locations SN 8042/10042, 13198 - 16782 Without Lighting Package SN 10054, 13198 - 16782 Without Lighting Package 10 10 11 7.5 7.5 20 10 11 9 10 20 10 10 7.5 40 MH4820 9 8 10 7 10 6 10 6 4 3 2 1 10 4 10 7.5 7.5 40 7.
Electrical System b. Engine Compartment Fuse Locations (SN 8042, 18991 - 19987, 10042 19031 - 19987, 10054, 19080 - 19987 And 8042/10042/10054, 0160002332 & After) Cold Start Grid Heater Fuses The two 125 amp fuses (15) that protect the cold start grid heater are located inside the engine compartment and are mounted on a bracket mounted on the left side of the frame rail.
Electrical System c. Fuse Block Relay Locations 8042/10042 10054 1 2 3 4 1 5 8 11 2 5 9 12 3 6 10 13 4 7 6 7 14 15 MH4840 9.18 MH4850 No.
Electrical System d. Engine Compartment Relay Locations (SN 8042, 18991 - 19987, 10042 19031 - 19987, 10054, 19080 - 19987 And 8042/10042/10054, 0160002332 & After) There are two relays located inside the engine compartment, mounted on a bracket mounted to the left frame rail. The relays (16) control the engine grid heater. There is an engine fuel relay (17), mounted on the right frame rail next to the engine.This relay is part of the Cummins engine harness and also part of the ECM Diagnostic System.
Electrical System 9.6.3 Fuse and Relay Replacement WARNING: DO NOT perform service or maintenance on the vehicle with the engine running, with the exception of the transmission level check. Contact with moving parts can cause death or serious personal injury. Shut off the engine and disconnect the negative (-) battery cable(s) at the negative (-) battery terminal(s) before checking the electrical system fuses or relays. b.
Electrical System ECM Fuses 1. Locate the three fuse holders. Remove the clear plastic protective cover (10) from the holder (11). 2. Remove the failed fuse from the holder and replace with a new fuse. 3. Reassemble the plastic cover onto the fuse holder and securely snap the cover in place. Replace any tie wraps that were removed, securing the fuse holders to the wire harness. c.
Electrical System 9.7 9.7.1 ELECTRICAL SYSTEM TROUBLESHOOTING Introduction The electrical system produces, stores and distributes electricity in the operation of the vehicle. An engine-driven, 12-volt, 65-amp alternator, equipped with an internal, solid-state voltage regulator, produces electricity. Current from the alternator charges the battery and powers electrical system components.
Electrical System b. Flash-Out of Fault Codes Offboard Diagnostics Fault flash-out mode can be entered through the use of a diagnostic switch or the accelerator pedal. To enter the fault flash-out mode, the key switch must be in the RUN position with the engine not running. INSITE™, is the Windows®-based PC service/ programming/diagnostic tool for 944E-42 engine. It is used to help troubleshoot and repair the engine with extended fault diagnostics and processing power.
Electrical System 9.7.4 Probing Electrical Connectors (POWER ON AT ALL TIMES) FUSE BLOCK 1 a. Front Probe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Note: DO NOT insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures.
Electrical System Testing a Fuse Powering Several Loads With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Review the system schematic and locate the fuse that is open. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Open the first connector or switch leading from the fuse to each load. 2. Disconnect the load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). 3.
Electrical System 3. If the vehicle has one battery, disconnect the negative (-) battery cable at the negative (-) battery terminal (1). 5. Remove the suspect relay (5) from the fuse block. If the vehicle has dual batteries, disconnect both negative battery cables from both negative (-) battery terminals (2). 5 MH4880 1 2 MH4890 4. The fuse block relays (5) are located in the fuse block and is mounted behind the right side console access panel (3).
Electrical System 7. When reassembling the right side console access panel (3), torque the screws (4) to 3 - 5 lb-ft (13 - 22 Nm). 8. If the vehicle has one battery, connect the negative (-) battery cable to the negative (-) battery terminal (1). 10 12 10 If the vehicle has dual batteries, connect both negative battery cables to both negative (-) battery terminals (2). Testing Relays located in the Engine Compartment 1.
Electrical System 7. To test the operation of the relays, connect a 12-volt DC positive lead to the positive terminal (1). Connect the negative lead to the mounting bracket or negative post (2), listening for a “click” sound as the contacts close. Replace the relay if the contacts do not close. 4 3 2 Testing Diodes To test diodes in the electrical system, set the DMM dial on R x1 setting and connect one lead to each side (9) of the diode. Note the reading on the DMM. Reverse the leads and note reading.
Electrical System 9.7.5 Electrical Symbols Directory The following directory shows the most common electrical symbols used in the electrical schematics and circuit diagrams in this section.
Electrical System 9.7.6 8042 Electrical Schematic Legend (SN 13198 Through 18990) Wire No. Page Gauge Color From Function To 9.38 or 1 12 WHT Ignition Switch 3-Way Connector (Pin B) to Park Brake Switch Connector (Pin 5) 9.40 9.39 or 2A 18 BLK Splice 20 (Ground) to Fuel Level Sender 9.41 9.38 or 2AA 18 BLK Splice 20 (Ground) to Boom Switch Relay (Pin 85) 9.40 9.39 or 2B 16 BLK Splice 20 (Ground) to Steer Select Valve Solenoid (4-Wheel) (–) 9.41 9.
Electrical System Wire No. 2T 2W 2X 3 3A 3B 3C 5 6 7 8 9 10 11 Page 9.39 or 9.41 9.39 or 9.41 9.39 or 9.41 9.38 9.38 9.40 9.40 9.40 9.39 or 9.41 9.38 or 9.40 9.39 or 9.41 9.38 or 9.40 9.38 or 9.40 9.39 or 9.41 9.38 or 9.40 9.39 or 9.41 9.38 or 9.40 9.39 or 9.
Electrical System Wire No. † § Page Gauge Color From Function To 9.38 or Instrument Panel Connector (Pin J12) 18 GRN 9.40 to Cab/Chassis Female Connector (Pin B1) (Cab Harness) 18 9.39 or 18 GRN Cab/Chassis Male Connector (Pin B1) to Transmission Temperature Switch (Engine Harness) 9.41 9.38 or 14 BLK Splice 20 (Ground) to Cab Ground Stud (Cab Harness) 9.40 9.38 or 20 12 BLK Cab Ground Stud to Cab/Chassis Male Connector (Pin A3) (Cab Harness) 9.40 9.
Electrical System Wire No. 31 32 34 35 38 39 40 40A 40B Page 9.38 or 9.40 9.39 or 9.41 9.38 or 9.40 9.38 or 9.40 9.39 or 9.41 9.38 or 9.40 9.39 or 9.41 9.38 or 9.40 9.39 or 9.41 9.38 or 9.40 9.38 or 9.40 9.39 or 9.41 9.38 or 9.40 9.38 or 9.
Electrical System Wire No. Page Gauge Color From Function To 9.39 or 47A 16 ORG/WHT Splice 47 to Stabil-TRAK™ Cylinder (SOL 4A) (+) 9.41 9.39 or 47B 16 ORG/WHT Splice 47 to Stabil-TRAK™ Cylinder (SOL 4B) (+) 9.41 9.38 or 48 16 PUR/BLK Stabilizer Lock Relay (Pin 30) to Boom Switch Relay (Pin 87A) 9.40 9.39 or 16 RED/BLU Not Used 49 9.41 9.38 or 16 WHT/YEL Option Fuse to Option Connector 50 9.40 9.38 or 16 WHT/RED Option Fuse to Option Connector 51 9.40 9.
Electrical System Wire No. Page 9.39 or 9.41 9.38 or 9.40 9.39 or 9.41 Gauge Color 18 GRN Splice 105 to Lower Transmission Connector (Pin 4, Solenoid Y4) 12 BLU/ORG Neutral Start Relay (Pin 87) to Cab/Chassis Male Connector (Pin B2) (Cab Harness) 12 BLU/ORG Cab/Chassis Female Connector (Pin B2) to Starter (Pin 50) (Engine Harness) 107 9.38 18 BLU † 107A 107B 9.40 9.40 9.38 or 9.40 9.38 or 9.40 9.38 or 9.40 9.38 or 9.40 9.38 or 9.40 9.38 or 9.40 9.38 or 9.40 9.38 or 9.40 9.38 or 9.40 9.
Electrical System Wire No. † § Page Gauge Color From Function To 9.38 or 155 16 GRN/RED Instrument Panel Connector (Pin J15) to Roadlights Connector (Option) (Turn Signals) 9.40 9.38 or Instrument Panel Connector (Pin J2) 156 16 RED/WHT 9.40 to Roadlights Connector (Option) (Instrument Panel Backlight) 9.38 or 157 16 BRN Jumper Wire (Wire 7 to Wire 35) 9.40 9.38 or 16 BLK Horn Button to Cab/Chassis Female Connector (Pin A5) (Cab Harness) 9.40 158 9.
Electrical System This Page Intentionally Left Blank Model 8042, 10042, 10054 Legacy Rev. 10/03 9.
Electrical System 23 12C J2 J10 22 21C ROAD/ WORKLIGHT OPTION 154 155 152 2GG 12B 30 86 85 87A HEADLIGHT SWITCH RELAY C D E A B C D E OPEN 10.0 OPTION 51 OPTION 85 19 30 87A LIGHT SWITCH RELAY A B 7 2JJ 11 11 58 O S P R 15 O S P R 50 O 30 27A 6 28 15 40B 2KK 12A 157 18 8 1 11 1 2 2DD 35 16 E 3 9 24A 158 HORN BUTTON 35 C 10 1 38 26 20 6 8 15.0 9 24 114B 52 10.0 52 HEATER INSTR.
Electrical System 8042 (13198 - 16782, w/oLighting Package) 47 BATTERY + 47B 47 47A 28 ENGINE HARNESS MALE CONNECTOR A3 B3 A1 28B 28 28A 2K 40 47 28 2P 28B 47B + - + - + - + - + - 3 40 12B - 18 + - + - + - + - 47A 27C 27 27 5 152 BLU A B A B 35 106 30 50 M BLK 12A BATTERY GRND 27D BRN 4B GND STARTER C C 2T 10 28A 2M C5 + STABIL-TRAK CYLINDER SOLENOIDS 4A B1 BOOM SENSOR 2N + - - 2L 16 34 RED C4 158 158 + + - A5 B4 24A + - B2 24A A B C
Electrical System 23 86 87A 10.0 OPTION 51 OPTION WIPER/ WASHER 32 OPTION WIPER/ WASHER C D E A B C D E 87A 6 28 15 STEER SELECT SWITCH 2GG 20 LIGHT SWITCH RELAY 11B 11A 11 58 O S P R 15 O S P R 50 O 30 A B 7 2JJ S P R 19 29 40B 2KK 12A 157 2DD 35 1 1 16 E 3 9 24A 158 HORN BUTTON 35 C 10 1 38 6 8 11A 10.0 15.0 9 24 HORN/HEATER 114B 52 10.0 52 HEATER 22 12 3C 85 29 40.0 LIGHTS 2 40.0 27 MAIN 26B 26 27B 26 48 30 86 42A INSTR.
Electrical System 8042 (13198 - 16782, w/Light Package & 16783 -18990) 47 BATTERY + 47B 47 47A 28 ENGINE HARNESS MALE CONNECTOR A3 B3 A1 B1 28B 28 28A 2K 40 2P 47B + - + - + - + - + - 3 12B 4B + 27C 27D 40 BRN STABIL-TRAK CYLINDER SOLENOIDS 18 4A 12A + - + - + - + - 47A 27 27 5 152 BLU B A B 35 106 30 50 M BLK A § BATTERY GRND - 28 GND STARTER C C 2T 10 28A 2M C5 BOOM SENSOR 2N 28B + - 47 - 2L 16 34 RED B4 C4 158 158 + + - A5 24A + - B2
Electrical System 9.7.9 Wire No. 1 2A 2AA 2B 2BB 2C 2CC 2D 8042 Cab Harness, Engine Harness & ECM Cab Harness Electrical Schematic Legend (SN 18991 - 19987 And 0160002332 & After) Page 9.50 9.51 9.50 9.51 9.50 9.51 9.50 9.51 9.50 9.51 Gauge 10 16 18 16 18 16 18 16 18 16 Color WHT BLK BLK BLK BLK BLK BLK BLK BLK BLK 2E 9.51 18 BLK 2EE 9.50 18 BLK 2F 9.51 18 BLK 2FF 2G 2GG 2H 2HH 2J 2JJ 2K 2KK 2L 2LL 2M 2MM 2N 2P 2R 2T 2X 3A 3B 3C 9.50 9.51 9.50 9.51 9.50 9.51 9.50 9.51 9.50 9.51 9.50 9.51 9.
Electrical System Wire No. 11A 11B 12 12A 12AA 12B 12C 15 16 17 18 20 20A 20B 20C 20D 20E 21C 22 23 24 24A 26 26A 26B 27 27A 27B 27C 27D 27F 28 28A 28B 29 Page 9.50 9.50 9.50 9.50 9.50 9.50 9.50 Gauge 16 16 18 12 12 12 16 Color LT GRN/BLU LT GRN/BLU DK BLU DK BLU DK BLU DK BLU DK BLU 9.50 18 LT BLU 9.51 16 LT BLU 9.50 18 BRN 9.51 16 BRN 9.50 18 GRY 9.51 16 GRY 9.50 18 GRN 9.51 9.50 9.51 9.50 9.51 9.51 9.51 9.51 9.51 9.50 9.
Electrical System Wire No. 31 32 Page Gauge Color 9.50 16 ORG/RED 9.51 9.50 16 14 ORG/RED GRY/WHT 9.50 16 RED/BLK 9.51 16 RED/BLK 34 34A 35 38 39 40 40A 40B 41 41A 41B 42A 42B 45 45A2 45B 46 47 47A 47B 48 49 50 51 52 101 101A 101B 102 102A 102B 9.51 & 9.52 9.50 9.51 16 RED/WHT 16 16 BRN/WHT BRN/WHT 9.
Electrical System Wire No. Page 9.50 9.51 9.51 9.51 9.50 9.51 9.51 9.51 9.50 9.51 9.51 9.51 9.50 9.51 & 9.52 9.50 9.50 9.50 9.50 9.50 9.50 9.50 9.50 9.50 9.50 9.50 9.50 9.51 9.51 9.
Electrical System Wire No. BNE BNF BNH BNP BNW Page 9.52 9.52 9.52 9.52 9.52 Gauge 16 16 16 14 14 Color BLK BLK BLK BLK BLK BP 9.52 16 RED/GRN BP1 9.52 16 RED/GRN BPB 9.52 16 RED/WHT BPB1 9.52 16 RED/WHT BPC 9.52 16 RED/WHT BPC1 9.52 16 RED/WHT BPD 9.52 16 RED/WHT BPD1 9.52 16 RED/WHT BPM 9.52 14 RED/GRN BPM1 9.52 14 RED/GRN BPS 9.52 14 RED/GRN BPS1 9.52 14 RED/GRN C 9.
Electrical System Wire No. Page Gauge Color F 9.52 6 RED From - Function - To Grid Heater Relay 2 (Pin 1) to Engine Grid Heater (Pin 2) G 9.52 1/0 RED Battery 1, Positive (+) Terminal to Starter 12V Buss Bar GH1 GH1A GH1B GH2 GH2A GH2B GH3 GH4 GHG GHG1 GHG2 GHG3 9.52 9.52 9.52 9.52 9.52 9.52 9.52 9.52 9.52 9.52 9.52 9.
Electrical System Wire No. Page Gauge Color THS 9.52 18 WHT THS1 9.52 18 WHT WL 9.52 18 BLK WL1 9.52 18 BRN WSL 9.
Electrical System This Page Intentionally Left Blank Model 8042, 10042, 10054 Legacy Rev. 10/03 9.
Electrical System 30 85 87A OPTION 86 51 OPTION 85 12A WIPER/ WASHER 32 87A D E A B C D E LIGHT SWITCH RELAY 157 ENGINE OIL WATER TEMP. FUEL GAUGE STABIL-TRAK ALTERNAT0R HYD. OIL TEMP. C 2GG 20A 40B 16 18 CAB HARNESS FEMALE CONNECTOR 47 17 6 28 15 40 B 2KK 2DD 11A E 3 16 9 24A CAB GROUND STUD HORN BUTTON 158 158 35 C 10 2MM 20A 1 20 18 8 D 2 20A 20A 20A 38 26 35 6 8 39 STABILIZER 41A 11A 10.0 24 10.0 42A 85 52 INSTR. PANEL 7.
Electrical System 8042 (18991 & After) 47 47B 47 47A 28 ENGINE HARNESS MALE CONNECTOR A3 B3 A1 STARTER 12V BUSS BAR 28B 28 28B 28A 2K 40 47 C5 B2 A5 B4 C4 A4 B5 C1 C2 A2 C3 2P BOOM SENSOR 2N A B A B A B AB AB AB 3 12B 4B + - 27D 27C AB1 BRN STABIL-TRAK CYLINDER SOLENOIDS 40 4A AB AB A B A B D+ B+ AG1 GND (-) 2L 28A 6 BLK 12A A B A B 35 2M STARTER See Page 9.
Electrical System 9.7.11 8042 ECM Cab Harness & Engine Harness (SN 18991 - 19987 And 0160002332 & After) STARTER 12V BUSS BAR + 106 See Page 9.51 BPB1 GND (-) 38 BATTERY 1 6 7.5 OPEN 50 CNS4 DLP 51 CNS4 ENGINE BLOCK 10.0 OPTION WIPER/ WASHER CNS5 3 J87L J87H CNS2 CNL2 CNH2 BP BN G CNS1 F CNS E D C 10.0 A STABILIZER B C 10.0 B CNL4 CNH CNL CNS CNL A 2 P7 DIAGNOSTIC PLUG CNL1 CNH P3 FEMALE CONNECTOR STEER SELECT SWITCH 1 CNH4 15.0 A 10.0 B INSTR. PANEL C 7.
Electrical System 9.7.12 10042 Electrical Schematic Legend (SN 13198 Through 19030) Wire No. Page Gauge Color From Function To 9.62 or 1 12 WHT Ignition Switch 3-Way Connector (Pin B) to Park Brake Switch Connector (Pin 5) 9.64 9.63 or 18 BLK Splice 20 (Ground) to Fuel Level Sender (Engine Harness) 9.65 2A 9.62 or 16 BLK Splice 2 to Left Outrigger Switch Connector (Pin 7) (Outrigger Harness) 9.64 9.62 or 18 BLK Splice 20 (Ground) to Boom Switch Relay (Pin 85) 2AA 9.64 9.
Electrical System Wire No. 2HH 2J 2JJ 2K 2KK 2L 2M 2N 2P 2R 2S 2T 2W 2X 3 3A 3B 3C 5 6 7 8 9 10 11 † § Page 9.62 or 9.64 9.63 or 9.65 9.62 or 9.64 9.63 or 9.65 9.62 or 9.64 9.63 or 9.65 9.63 or 9.65 9.63 or 9.65 9.63 or 9.65 9.63 or 9.65 9.63 or 9.65 9.63 or 9.65 9.63 or 9.65 9.63 or 9.65 9.62 9.62 9.64 9.64 9.64 9.63 or 9.65 9.62 or 9.64 9.63 or 9.65 9.62 or 9.64 9.62 or 9.64 9.63 or 9.65 9.62 or 9.64 9.63 or 9.65 9.62 or 9.64 9.63 or 9.
Electrical System Wire No. 11B Page Gauge Color From Function To 9.64 16 LT GRN/BLU § Steer Select Switch Connector Jumper (Pin 2) to (Pin 8) 9.62 or 12 18 DK BLU Light Switch Relay Fuse to Light Switch Relay (Pin 86) 9.64 9.62 † Light Switch Relay (Pin 87) to Splice 12A to Road/Worklights Connector (Option) 12A 12 DK BLU 9.64 § Light Switch Relay (Pin 87) to Splice 12A 12AA 9.64 12 DK BLU § Splice 12A to Road/Worklights Connector (Option) 9.
Electrical System Wire No. † § Page Gauge Color From Function To 9.62 or 10 RED Main Fuse to Splice 100 (Cab Harness) 9.64 27 9.63 or 10 RED Splice 27 to Starter (Pin 30) (Engine Harness) 9.65 9.62 † Optional Lights Fuse to Splice 27 to Light Switch Relay (Pin 30) 27A 12 RED 9.64 § Optional Lights Fuse (Lights 1) to Splice 27 to Headlight Switch Relay (Pin 30) 9.62 † Optional Lights Fuse to Main Fuse 27B 12 RED 9.64 § Optional Lights Fuse (Lights 1) to Splice 100 9.
Electrical System Wire No. Page Gauge 9.62 41 DK BLU/WHT † 16 41C 9.63 or 9.65 9.64 9.63 or 9.65 9.64 9.63 or 9.65 9.64 16 42 9.
Electrical System Wire No. Page Gauge Color From Function To 9.62, 9.63, 62 16 PUR/WHT Right Outrigger Switch Connector (Pin 3) to Outrigger Valve Solenoid (Right Down) (Pin 1) 9.64 or 9.65 9.62, 9.63, 63 16 BRN/YEL Left Outrigger Switch Connector (Pin 1) to Outrigger Valve Solenoid (Left Up) (Pin 1) 9.64 or 9.65 9.62, 9.63, 64 16 GRY/PUR Left Outrigger Switch Connector (Pin 3) to Outrigger Valve Solenoid (Left Down) (Pin 1) 9.64 or 9.65 9.
Electrical System Wire No. Page 9.62 or 9.64 9.63 or 9.65 Gauge Color 12 BLU/ORG Neutral Start Relay (Pin 87) to Cab/Chassis Male Connector (Pin B2) (Cab Harness) 12 BLU/ORG Cab/Chassis Female Connector (Pin B2) to Starter (Pin 50) (Engine Harness) 107 9.62 18 BLU † 107A 107B 9.64 9.64 9.62 or 9.64 9.62 or 9.64 9.62 or 9.64 9.62 or 9.64 9.62 or 9.64 9.62 or 9.64 9.62 or 9.64 9.62 or 9.64 9.62 or 9.64 9.62 or 9.64 9.63 or 9.65 9.63 or 9.65 9.63 or 9.65 9.62 or 9.64 9.63 or 9.
Electrical System Wire No. † § Page Gauge Color From Function To 9.62 or 155 16 GRN/RED Instrument Panel Connector (Pin J15) to Roadlights Connector (Option) (Turn Signals) 9.64 Instrument Panel Connector (Pin J2) 9.62 or 16 RED/WHT 156 to Roadlights Connector (Option) (Instrument Panel Backlight) 9.64 9.62 or 16 BRN Jumper Wire (Wire 7 to Wire 35) 157 9.64 9.62 or 16 BLK Horn Button to Cab/Chassis Female Connector (Pin A5) (Cab Harness) 9.64 158 9.
Electrical System This Page Intentionally Left Blank Model 8042, 10042, 10054 Legacy Rev. 10/03 9.
Electrical System J2 J10 23 12C 21C For additional information on the 10042 Outrigger Circuit, refer to Section 9.7.42, “10042 Outrigger Circuit and Troubleshooting.” 22 ROAD/ WORKLIGHT OPTION 154 155 152 12B 30 86 85 87A HEADLIGHT SWITCH RELAY OUTRIGGERS 10.0 60E 51 OPTION B C D E A B C D E 87A A B 1 2KK 12A 157 2DD 35 2 11 16 10.
Electrical System 10042 (13198 - 16782, w/o Lighting Package) 47 28 ENGINE HARNESS MALE CONNECTOR A3 B3 A1 28 28B 28B 28A 2K 40 47 47B 2P + - + - + - + - + - 3 12B 4B + BATTERY GRND - 27C 27D 28 BRN STABIL-TRAK CYLINDER SOLENOIDS 40 4A + - + - + - 2L 28A 27 27 A B A B 35 2M 106 30 50 5 M 152 BLU BLK 12A + - - BOOM SENSOR 2N + - 47A B1 BATTERY + 47B 47 47A GND STARTER C C 2T 10 18 5 C5 16 34 38 C4 158 + + - A5 B4 + - B2 24A 8 - 2
Electrical System For additional information on the 10042 Outrigger Circuit, refer to Section 9.7.42, “10042 Outrigger Circuit and Troubleshooting.” 30 85 87A 60E 51 30 86 85 WIPER/ WASHER 32 87A 7 7 10.0 ENGINE OIL WATER TEMP. FUEL GAUGE ALTERNAT0R HYD. OIL TEMP.
Electrical System 10042 (13198 - 16782, w/Light Package & 16783 -19030) 47 28 ENGINE HARNESS MALE CONNECTOR A3 B3 A1 28 BATTERY + 47B 47 47A 28B 28B 28A 2K 40 47 2P + - + - + - + - + - 3 12B 4B + - BRN STABIL-TRAK CYLINDER SOLENOIDS 40 4A 27C + - + - + - + - 2L 28A 27 27 A B A B 35 2M 106 30 50 5 M 152 BLU BLK 12A § BATTERY GRND 27D 28 - BOOM SENSOR 2N + - 47A B1 47B GND STARTER C C 2T 10 18 5 C5 16 34 38 C4 158 + + - A5 B4 24A + - B
Electrical System 9.7.15 Wire No. 1 2A 2AA 2B 2BB 2C 2CC 2D 2DD 2E 2EE 2F 2FF 2G 2GG 2H 2HH 2J 2JJ 2K 2KK 2L 2LL 2M 2MM 2N 2P 2R 2T 2X 3A 3B 3C 6 7 10042 Cab Harness, Engine Harness & ECM Cab Harness Electrical Schematic Legend (SN 19031 - 19987 And 0160002332 & After) Page 9.74 9.75 9.74 9.74 9.75 9.74 9.74 9.75 9.74 9.75 9.74 & 9.75 9.74 9.
Electrical System Wire No. Page Gauge Color 9.74 16 GRN/WHT 9.75 16 LT GRN/WHT 9.74 16 GRN/BLK 9.75 16 LT GRN/BLK 9.74 16 TAN 9.75 9.74 9.74 9.74 9.74 9.74 9.74 9.74 16 16 16 18 12 12 12 16 TAN LT GRN/BLU LT GRN/BLU DK BLU DK BLU DK BLU DK BLU DK BLU 9.74 18 LT BLU 9.75 16 LT BLU 9.74 18 BRN 9.75 16 BRN 9.74 18 GRY 9.75 16 GRY 9.74 18 GRN 9.75 9.74 9.75 9.74 9.74 9.75 9.75 9.75 9.75 9.75 9.74 9.
Electrical System Wire No. 27C 27D 27F 28 28A 28B 29 31 32 Page 9.74 9.75 9.74 9.75 9.74 Gauge 12 12 12 12 12 Color RED RED RED RED RED 9.74 16 PUR/WHT 9.75 9.75 9.75 9.74 16 18 18 12 PUR/WHT PUR/WHT PUR/WHT RED 9.74 16 ORG/RED 9.75 9.74 16 14 ORG/RED GRY/WHT 9.74 16 RED/BLK 9.75 16 RED/BLK 34 34A 35 38 39 40 40A 40B 41 41A 41B 42A 42B 45 45A2 45B 46 47 47A 47B 48 49 50 51 52 60A 9.75 & 9.76 9.74 9.75 16 RED/WHT 16 16 BRN/WHT BRN/WHT 9.
Electrical System Wire No. 60B 60C 60D 60E 61 62 63 64 101 101A 101B 102 102A 102B 103 103A 103B 104 104A 104B 105 105A 105B 106 107A 107B 111 111A 112 112A 113 113A 113B 114A 114B 150 150A 150B Page 9.74 9.74 9.74 9.74 9.74 & 9.75 9.74 & 9.75 9.74 & 9.75 9.74 & 9.75 9.74 9.75 9.75 9.75 9.74 9.75 9.74 9.75 9.74 9.75 9.74 9.75 9.75 9.75 9.74 9.75 9.75 9.75 9.74 9.75 9.75 9.75 9.74 9.75 & 9.76 9.74 9.74 9.74 9.74 9.74 9.74 9.74 9.74 9.74 9.74 9.74 9.74 9.75 9.75 9.
Electrical System Wire No. Page Gauge Color 9.74 16 YEL/GRN 152A1 152A2 152A3 152B 153 153A 154 155 9.75 9.74 9.74 9.74 9.74 9.74 9.74 9.74 9.74 16 16 16 16 16 16 16 16 16 YEL/GRN BLK/WHT BLK/WHT BLK/WHT BLK/WHT GRY/WHT GRY/WHT BLU/WHT GRN/RED 156 9.74 16 RED/WHT 157 9.74 9.74 9.
Electrical System Wire No. CNL1 CNL2 CNL3 CNL4 CNS CNS1 CNS2 CNS3 CNS4 CNS5 Page 9.76 9.76 9.76 9.76 9.76 9.76 9.76 9.76 9.76 9.76 Gauge 18 18 18 18 18 18 18 18 18 18 Color GRN GRN GRN GRN DRAIN DRAIN DRAIN DRAIN DRAIN BLK D 9.
Electrical System Wire No. Page Gauge Color 9.76 18 BLK 9.76 18 VIO PH1 9.76 18 BLU PH1A 9.76 16 PNK/BLU RTS 9.76 18 BLK SL 9.76 18 BLK SL1 9.76 18 GRN 9.76 18 BLK 9.76 18 YEL THG 9.76 18 BLK THG1 9.76 18 BLK THP 9.76 18 RED THP1 9.76 18 RED THS 9.76 18 WHT THS1 9.76 18 WHT WL 9.76 18 BLK WL1 9.76 18 BRN WSL 9.
Electrical System This Page Intentionally Left Blank Model 8042, 10042, 10054 Legacy Rev. 10/03 9.
Electrical System 30 85 87A 60E 51 12A WIPER/ WASHER 32 87A D E A B C D E LIGHT SWITCH RELAY 157 2GG 20A 11A B 2KK ENGINE OIL WATER TEMP. FUEL GAUGE STABIL-TRAK CAB GROUND STUD 158 HORN BUTTON 158 35 C 10 2MM 20A 20A 20A 26 35 16 9 24A 1 20 18 E 3 58 O S P R 15 O S P R 50 O LEFT OUTRIGGER SWITCH 7 38 RIGHT OUTRIGGER 60B SWITCH 60D 8 1 UP 1 2 60C 20A 60 60E 2A 7 2B 63 2 60A DOWN 3 1 64 6 8 8 41A UP 1 61 DOWN 3 9 7.
Electrical System 10042 (19031 & After) 47 47 47B 47A 28 ENGINE HARNESS MALE CONNECTOR A3 B3 A1 STARTER 12V BUSS BAR 28B 28 28B 28A 2K 40 47 C5 B2 A5 B4 C4 A4 B5 C1 C2 A2 C3 2P BOOM SENSOR 2N A B A B A B AB AB AB 3 12B 4B + - 27D 27C 4A BRN AB A B A B 2L 28A 6 D+ B+ AG1 GND (-) A B A B 35 2M See Page 9.
Electrical System 9.7.17 10042 ECM Cab Harness & Engine Harness (SN 19031 - 19987 And 0160002332 & After) STARTER 12V BUSS BAR + 106 See Page 9.75 BPB1 GND (-) 38 BATTERY 1 6 7.5 OPEN 50 CNS4 DLP 51 CNS4 ENGINE BLOCK 10.0 OPTION WIPER/ WASHER CNS5 3 J87L J87H CNS2 CNL2 CNH2 BP BN G CNS1 F CNS E D C 10.0 A STABILIZER B C 10.0 B CNL4 CNH CNL CNS CNL A 2 P7 DIAGNOSTIC PLUG CNL1 CNH P3 FEMALE CONNECTOR STEER SELECT SWITCH 1 CNH4 15.0 A 10.0 B INSTR. PANEL C 7.
Electrical System 9.7.18 10054 Cab Harness & Engine Harness Electrical Schematic Legend (SN 13198 Through 19079) Wire No. Page Gauge Color From Function To 9.84 or 1 12 WHT Ignition Switch 3-Way Connector (Pin B) to Park Brake Switch Connector (Pin 5) 9.86 9.85 or 2A 18 BLK Splice 20 (Ground) to Fuel Level Sender 9.87 9.84 or 2AA 18 BLK Splice 20 (Ground) to Boom Switch Relay (Pin 85) 9.86 9.85 or 16 BLK Splice 20 (Ground) to Steer Select Valve Solenoid (4-Wheel) (–) 2B 9.87 9.
Electrical System Wire No. 2S 2T 2W 2X 3 3A 3B 3C 5 6 7 8 9 10 11 11A 11B Page 9.85 or 9.87 9.85 or 9.87 9.85 or 9.87 9.85 or 9.87 9.84 9.84 9.86 9.86 9.86 9.85 or 9.87 9.84 or 9.86 9.85 or 9.87 9.84 or 9.86 9.84 or 9.86 9.85 or 9.87 9.84 or 9.86 9.85 or 9.87 9.84 or 9.86 9.85 or 9.
Electrical System Wire No. 17 18 20 † § Page 9.84 or 9.86 9.85 or 9.87 9.84 or 9.86 9.85 or 9.
Electrical System Wire No. 29 31 32 34 35 38 39 40 40A 40B Page 9.86 9.84 or 9.86 9.85 or 9.87 9.84 or 9.86 9.84 or 9.86 9.85 or 9.87 9.84 or 9.86 9.85 or 9.87 9.84 or 9.86 9.85 or 9.87 9.84 or 9.86 9.84 or 9.86 9.85 or 9.87 9.84 or 9.86 9.84 or 9.
Electrical System Wire No. Page Gauge Color From Function To 9.84 or Stabilizer Lock Relay (Pin 87A) 16 ORG/WHT 9.86 to Cab/Chassis Female Connector (Pin A3) (Cab Harness) 47 9.85 or 16 ORG/WHT Cab/Chassis Male Connector (Pin A3) to Splice 47 (Engine Harness) 9.87 9.85 or 16 ORG/WHT Splice 47 to Stabil-TRAK™ Cylinder (SOL 4A) (+) 47A 9.87 9.85 or 47B 16 ORG/WHT Splice 47 to Stabil-TRAK™ Cylinder (SOL 4B) (+) 9.87 9.84 or 48 16 PUR/BLK Stabilizer Lock Relay (Pin 30) to Boom Switch Relay (Pin 87A) 9.86 9.
Electrical System Wire No. Page 9.84 or 9.86 9.85 or 9.87 9.85 or 9.87 9.85 or 9.87 9.84 or 9.86 9.85 or 9.
Electrical System Wire No. 152B1 152B2 Page Gauge Color From Function To 9.86 16 BLK/WHT § Male Connector to Splice 152B 9.86 16 BLK/WHT § Splice 152B to Park Brake Switch Connector (Pin 3) 9.84 or 153 16 GRY/WHT Park Brake Disconnect Relay (Pin 30) to Shifter Connector (Pin 9) 9.86 9.84 or 153A 16 GRY/WHT Transmission Fuse to Park Brake Disconnect Relay (Pin 30) 9.86 9.84 or 154 16 BLU/WHT Instrument Panel Connector (Pin J14) to Roadlights Connector (Option) (Main Beam) 9.86 9.
Electrical System 23 12C J2 J10 22 21C ROAD/ WORKLIGHT OPTION 154 155 152 12B 12B 30 86 85 87A 12A 26A 7.5 HEADLIGHT SWITCH RELAY C D E A B C D E 10.0 85 WIPER/ WASHER 32 OPTION WIPER/ WASHER 10.0 86 OPTION 87A LIGHT SWITCH RELAY A 87 2KK 12A E 2DD B 7 11 11 58 O S P R 15 O S P R 50 O 30 2DD 7 7 30 8 1 16 E 3 9 24A 10 38 6 8 41 10.0 114B 46 STEER SELECT SWITCH 24 85 52 10.0 52 HEATER 7.5 12 87A 87 2CC 42 INSTR. PANEL 10 48 30 86 15.
Electrical System 10054 (13198 - 16782, w/o Lighting Package) 47 ENGINE HARNESS MALE CONNECTOR A3 B3 A1 28 28B 28 47 BATTERY + 47B 47A 28B 28A 2K 40 47 C5 2P + - + - + - + - + - 3 12B 4B + BRN STABIL-TRAK CYLINDER SOLENOIDS 40 4A 27C + - + - + - 2L 28A 27 A B A B 35 2M GND C C 2T 16 5 B5 C1 C2 A2 C3 + + - B4 C4 158 + - A5 M STARTER 38 B2 106 30 50 5 152 10 18 24A 27 BLU BLK 12A + - BATTERY GRND - 27D 28 - BOOM SENSOR 2N + - 47A B1
Electrical System 30 85 87A 152A 7.5 26A HEADLIGHT SWITCH RELAY 10.0 OPTION 86 OPTION 85 WIPER/ WASHER 32 OPTION WIPER/ WASHER 87A C D E A B C D E LIGHT SWITCH RELAY A 2KK 12A E 2DD B 1 11B 10.0 2 11A 9 24A 10.0 42A 10 38 6 26 114B 85 52 HEATER 30 40.0 40.0 2CC 100 85 87A 20.
Electrical System 10054 (13198 - 16782, w/Light Package & 16783 -19079) 47 ENGINE HARNESS MALE CONNECTOR A3 B3 A1 28 28B 28 47 BATTERY + 47B 47A 28B 28A 2K 40 47 C5 2P + - + - + - + - + - 3 12B 4B + - BRN STABIL-TRAK CYLINDER SOLENOIDS 40 4A 27C + - + - + - 2L 28A 27 A B A B 35 2M GND STARTER C C 2T 16 5 C4 B5 C1 C2 A2 C3 + + - B4 158 + - A5 M 10 18 24A 106 30 50 5 152 38 B2 27 BLU BLK 12A + - § BATTERY GRND 27D 28 - BOOM SENSOR 2N +
Electrical System 9.7.21 Wire No. 2 2A1 2A2 2A3 2B1 2B2 2B3 ‡ ~ 10054 Logic Harness & Boom Extend Interlock Harness Electrical Schematic Legend (SN 13198 Through 19079) Page 9.92, 9.93 or 9.94 9.92, 9.93 or 9.94 9.92, 9.93 or 9.94 9.92, 9.93 or 9.94 9.92 or 9.93 9.92, 9.93 or 9.94 9.92 or 9.
Electrical System Wire No. 2L2 3 3A 3B 3C 7 23 35 45A 45B 49 50A 50B Page 9.92, 9.93 or 9.94 9.92, 9.93 or 9.94 9.92, 9.93 or 9.94 9.92, 9.93 or 9.94 9.92, 9.93 or 9.94 9.92, 9.93 or 9.94 9.92, 9.93 or 9.94 9.92, 9.93 or 9.94 9.92, 9.93 or 9.94 9.92, 9.93 or 9.94 9.92, 9.93 or 9.94 9.92 or 9.93 9.92 or 9.
Electrical System Wire No.
Electrical System Wire No. Page 9.92, 9.93 or 9.94 9.92, 9.93 or 9.94 9.92, 9.93 or 9.94 9.92, 9.93 or 9.94 9.92, 9.93 or 9.
Electrical System J10 152 152A 86 70B 85 3A 2A 7 35 2 60E 51A 59A HORN/HEATER 85 85 68 30 86 87A 10.0 2A 30 87A LIGHTS 1 85 3A 2C2 60A 85 56A OPTION BOOM EXT.
Electrical System J10 152A3 OPTION 152A 3B 3C 3A 3 OUTRIGGER CYLINDERS 3 H 49 2 60B 70A 70B 3B 1 85 7.5 OPEN 87A 7 J4 PARK BRAKE INTERLOCK 87 RELAY 2L1 2 60E 60 8 1 60D UP 1 59B 59B 59A STEER SELECT SWITCH HORN/HEATER 85 68 30 86 15.0 85 87A 10.0 2A B2 30 87A 63 41A 2A1 51 23 50B 30 86 20.0 71 LIGHTS 1 85 85 85 2A BOOM EXT.
Electrical System J10 152A3 OPTION 152A 3B 3C 3A 3 OUTRIGGER CYLINDERS 3 H 49 70A 70B 3B 2 60B 85 7.5 OPEN 87A 2A PARK BRAKE INTERLOCK 87 RELAY J4 CAB HARNESS FEMALE CONNECTOR 60C UP 1 ENGINE HARNESS MALE CONNECTOR A3 A3 B3 B3 A1 A1 2G 62 2B 2F E 10.0 7 7 2L1 64 2 60E 51A 71B 68 71A STEER SELECT SWITCH HORN/HEATER 85 85 71B 30 86 15.0 C5 62 B2 87A 10.
Electrical System 9.7.25 Wire No. 1 2A 2AA 2B 2BB 2C 2CC 2D 2DD 2E 2EE 2F 2FF 2G 2GG 2H 2HH 2J 2JJ 2K 2KK 2L 2LL 2M 2MM 2N 2P 2R 2T 2X 3A 3B 3C 6 7 8 10054 Cab Harness, Engine Harness & ECM Cab Harness Electrical Schematic Legend (SN 19080 - 19987 And 0160002332 & After) Page 9.102 9.103 9.102 9.103 9.102 9.103 9.102 9.103 9.102 9.103 9.103 9.102 9.103 9.102 9.103 9.102 9.103 9.102 9.103 9.102 9.103 9.102 9.103 9.102 9.103 9.102 9.103 9.103 9.103 9.103 9.103 9.102 9.102 9.
Electrical System Wire No. 12 12A 12AA 12B 12C 15 16 17 18 20 20A 20B 20C 20D 20E 21C 22 Page 9.102 9.102 9.102 9.102 9.102 Gauge 18 12 12 12 16 Color DK BLU DK BLU DK BLU DK BLU DK BLU 9.102 18 LT BLU 9.103 16 LT BLU 9.102 18 BRN 9.103 16 BRN 9.102 18 GRY 9.103 16 GRY 9.102 18 GRN 9.103 9.102 9.103 9.102 9.103 9.103 9.103 9.103 9.103 9.102 9.102 16 12 12 12 12 12 12 12 12 16 16 GRN BLK BLK BLK BLK BLK BLK BLK BLK RED WHT 9.102 16 GRN 9.103 16 ORG/GRN 9.
Electrical System Wire No. 32 Page 9.102 Gauge 14 Color GRY/WHT 9.102 16 RED/BLK 9.103 16 RED/BLK 34 34A 35 38 39 40 40A 40B 41 41A 41B 42A 42B 45 45A2 45B 46 47 47A 47B 48 49 50 51 52 101 101A 101B 102 102A 102B 103 103A 103B 9.103 & 9.104 9.102 9.103 16 RED/WHT 16 16 BRN/WHT BRN/WHT 9.
Electrical System Wire No. 104 104A 104B 105 105A 105B 106 107A 107B 111 111A 112 112A 113 113A 113B 114A 114B Page Gauge 9.102 16 9.103 16 9.103 16 9.103 18 9.102 16 9.103 16 9.103 16 9.103 18 9.102 12 9.103 & 12 9.104 9.102 18 9.102 18 9.102 12 9.102 12 9.102 16 9.102 16 9.102 16 9.102 16 9.102 16 9.102 16 9.102 16 9.102 16 9.103 16 9.103 16 9.
Electrical System Wire No. Page Gauge Color BP 9.104 16 RED/GRN BP1 9.104 16 RED/GRN BPB 9.104 16 RED/WHT BPB1 9.104 16 RED/WHT BPC 9.104 16 RED/WHT BPC1 9.104 16 RED/WHT BPD 9.104 16 RED/WHT BPD1 9.104 16 RED/WHT BPM 9.104 14 RED/GRN BPM1 9.104 14 RED/GRN BPS 9.104 14 RED/GRN BPS1 9.
Electrical System Wire No. GH2 GH2A GH2B GH3 GH4 GHG GHG1 GHG2 GHG3 Page 9.104 9.104 9.104 9.104 9.104 9.104 9.104 9.104 9.
Electrical System Wire No. Page Gauge Color WL1 9.104 18 BRN WSL 9.104 18 BLK From Function To Engine Control Module Bulkhead, Male Connector (Pin E) to Engine Function Indicator Light, Female Connector, P15 (Pin 2B-) Engine Control Module Bulkhead, Female Connector (Pin G) to Engine Control Module, Female Engine Connector, P2 (Pin 11) These wires are not part of a wire harness. Refer to the appropriate Parts Manual for part number information. Model 8042, 10042, 10054 Legacy Rev. 10/03 9.
Electrical System 30 85 87A 152A 7.5 26A HEADLIGHT SWITCH RELAY 10.0 OPTION 86 OPTION 85 WIPER/ WASHER 32 OPTION WIPER/ WASHER 87A C D E A B C D E 2GG LIGHT SWITCH RELAY 12A A E 2KK 2DD B 1 11B 2 11A 24A HORN BUTTON C 10.0 42A 35 10 2MM 6 20A 38 20A 20A 114B 20A 85 52 HEATER 30 40.0 27F 27 27B 26 26 100 107B 27D 86 85 153A 7.
Electrical System 10054 (19080 & After) 47 ENGINE HARNESS MALE CONNECTOR A3 B3 A1 28 28 47 STARTER 12V BUSS BAR 47B + 47A 28B 2K 40 47 C5 B2 A5 B4 C4 B5 C1 A4 C2 A2 C3 2P BOOM SENSOR 2N AB AB AB AB AB AB + 28 3 12B 27C AB2 BRN STABIL-TRAK CYLINDER SOLENOIDS 40 4A 12A AB AB AB AB D+ B+ AG1 GND (-) AG2 W 2L 28A 6 BLU BLK A B C A B C 35 2M STARTER See Page 9.
Electrical System 9.7.27 10054 ECM Cab Harness & Engine Harness (SN 19080 - 19987 And 0160002332 & After) STARTER 12V BUSS BAR 7.5 OPEN 50 CNS4 DLP 51 CNS4 ENGINE BLOCK 10.0 OPTION WIPER/ WASHER CNS5 3 J87L J87H CNS2 CNL2 CNH2 BP BN G CNS1 F CNS E D C 10.0 A STABILIZER B C 10.0 B CNL4 CNH CNL CNS CNL A 2 P7 DIAGNOSTIC PLUG CNL1 CNH P3 FEMALE CONNECTOR STEER SELECT SWITCH 1 CNH4 15.0 A 10.0 B INSTR. PANEL C 7.5 CNH1 CNL1 CNS1 10 F 10 D E C See Page 9.
Electrical System 9.7.28 Wire No.
Electrical System Wire No. 62 63 64 65A 66 67 68 Gauge 16 16 16 16 16 16 16 Color PUR/WHT BRN/YEL GRY/PUR DK BLU ORG/GRY BRN/BLK RED/BLK 70A 16 ORG/BLK 70B 70C 71 71A 71B 16 16 16 16 16 ORG/BLK ORG/BLK ORG/WHT ORG/WHT ORG/WHT 9.106 Page 9.
Electrical System J10 152A3 OPTION 152A 3B 3C 3A 3 OUTRIGGER CYLINDERS 3 H 49 J8 J9 J6 J4 CAB HARNESS FEMALE CONNECTOR 1 60C UP 1 2 60B 8 A3 67 DOWN 3 70A 70B 3B 2G A3 B3 B3 A1 A1 62 2B 2F 85 7.5 OPEN 87A 2A PARK BRAKE INTERLOCK 87 RELAY 10.0 OPTION WIPER/ WASHER 7 E 35 STABILIZER 71B 10.0 71A 15.0 85 HORN/HEATER 85 71B 30 86 87A RIGHT OUTRIGGER LOCK 87 RELAY 2A 87A 2A3 10.
Electrical System 9.7.30 Wire No. 1 1A 1B 1C 1D 1E 1F 2 3 4 5 6 6A 6B 6C 6D 6E 6F 9 10 PUR PUR 1 2 3 4 5 9.108 Wiper/Washer & Heater Harness Electrical Schematic Legend Page Gauge Color 9.
Electrical System 9.7.31 Wiper/Washer & Heater Harness Electrical Schematic PUR 6B 6C 5 9 9 6 4 3 1 9 6 4 3 1 5 C Park 9 1 2 7 5 2 7 5 2 1B 6C M A GND Run SKYLIGHT WIPER MOTOR 1E SKYLIGHT WIPER SWITCH PUR 1E 1B 2 6B 10.0 OPTION WIPER/ WASHER 32 6F 30 6D 6E 8 6A 15.
Electrical System 9.7.32 Wire No. 1 1A 1B 1C 1D 1E 1F 1J 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 3A 4A 4B 4C 20 20A 20B 20C 20D 20F 21 21A 21B 21C 22 22A 22B 22C 23 23A 23B 23C 24 24A 24B 24C 25 26 26A 26B 27 28 28A 28B 31 32 33 2B 3D 9.110 Roadlight Harness Electrical Schematic Legend Page 9.111 9.
Electrical System 9.7.
Electrical System 9.7.34 Wire No. 1 1A 1B 1C 2A 2B1 2B2 2B3 2B4 2B5 2C 3A 3A1 3B 3C 3D 4A 4B 4C 2B 3D 9.112 Worklight Harness Electrical Schematic Legend Page 9.113 9.
Electrical System 9.7.35 Worklight Harness Electrical Schematic BOOM WORKLIGHT 3D LEFT FRONT WORKLIGHT 2B1 N RIGHT FRONT WORKLIGHT 3B P 3C P P Boom Worklight 3D Harness A 2B2 N 3C 3B 2B N 2B B A B 3D 2B4 3D 3 3 3A1 See Pages 9.38, 9.40, 9.50, 9.62, 9.64, 9.74, 9.84, 9.86, or 9.102 2B2 2B1 2 2B4 INSTRUMENT PANEL CONNECTOR BACK LIGHT (J2) 156 3A 3A1 3A 1A WORKLIGHT 8 SWITCH OFF 12 29 30 86 85 87A 1 LIGHT SWITCH RELAY LIGHT SWITCH RELAY 1A 12B 2DD 7.
Electrical System 9.7.36 Engine Start Circuit and Troubleshooting Schematic is drawn with the ignition switch in the START position. Except where noted, this schematic is taken from diagrams on pages 9.50, 9.52, 9.74, 9.76, 9.102 and 9.104. BATTERY + 3A - 7.5 § OPEN BATTERY GRND 10.0 OPTION WIPER/ WASHER 5 30 50 M 10.0 STABILIZER GND 10.0 STARTER 5 STEER SELECT SWITCH B+ 15.0 D+ HORN/HEATER 3C 10.0 INSTR. PANEL ALTERNATOR 26A 7.
Electrical System Engine will not crank or starter solenoid does not engage. Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. All connections relating to circuit are clean and tight. 2. On 10042 or 10054, if the vehicle is starting hard, make sure that both outrigger switches are in the neutral (center) position. Check that transmission gear select lever is in the NEUTRAL (N) position. If OK Check that parking brake switch is ENGAGED.
Electrical System 9.7.36 Engine Start Circuit and Troubleshooting (Continued) Schematic is drawn with the ignition switch in the START position. Except where noted, this schematic is taken from diagrams on pages 9.50, 9.52, 9.74, 9.76, 9.102 and 9.104. BATTERY + 3A - 7.5 § OPEN BATTERY GRND 10.0 OPTION WIPER/ WASHER 5 30 50 M 10.0 STABILIZER GND 10.0 STARTER 5 STEER SELECT SWITCH B+ 15.0 D+ HORN/HEATER 3C 10.0 INSTR. PANEL ALTERNATOR 26A 7.
Electrical System Continued from Page 9.115. With ignition switch in start position, check starter solenoid terminal, wire [ST2] (BLU) connection for battery voltage. Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: Not OK Check for power at wire [106] (BLU/ORG), Pin B2, at female bulkhead connector. If OK 1. All connections relating to circuit are clean and tight. Repair/replace engine harness. 2.
Electrical System 9.7.36 Engine Start Circuit and Troubleshooting (Continued) Schematic is drawn with the ignition switch in the START position. Except where noted, this schematic is taken from diagrams on pages 9.50, 9.52, 9.74, 9.76, 9.102 and 9.104. BATTERY + 3A - 7.5 § OPEN BATTERY GRND 10.0 OPTION WIPER/ WASHER 5 30 50 M 10.0 STABILIZER GND 10.0 STARTER 5 STEER SELECT SWITCH B+ 15.0 D+ HORN/HEATER 3C 10.0 INSTR. PANEL ALTERNATOR 26A 7.
Electrical System Continued from Page 9.117. Check for power at wire [112A] (GRY), Pin 86, at neutral start relay. Not OK Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: Check for power at wire [112] (GRY), Pin 4, at transmission shifter. If OK Repair/replace cab harness. Not OK Check for power at wire [113] (RED), Pin 1, at transmission shifter. If OK Replace transmission shifter. If OK Repair/replace cab harness. If OK Replace park brake switch.
Electrical System 9.7.37 Electronic Throttle Circuit and Troubleshooting (SN 8042, 18991 - 19987, 10042 19031 - 19987, 10054, 19080 - 19987 And 8042/10042/10054, 0160002332 & After) Schematic is drawn with the ignition switch in the RUN position. 7.5 OPEN 50 51 DLP OPTION 10.0 OPTION WIPER/ WASHER DLP 6 10.0 DLP3 OPTION DLP1 STABILIZER DLP2 10.0 STEER SELECT SWITCH P19 PREHEAT INDICATOR LIGHT 15.0 1A+ 2A+ 1 2 1B- 2B- P15 ENGINE FUNCTION INDICATOR LIGHT WL1 HORN/HEATER SL1 10.
Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. Fuses. 2. All connections relating to circuit are clean and tight. Engine speed drops to low idle and there is no response when the throttle pedal is depressed. At ECM power harness female bulkhead connector, at Pin B, wire [THP] (RED), check for 5 VDC. Not OK If OK Check for 5 VDC at throttle sensor female harness connector, at Pin C, wire [THP1] (RED).
Electrical System 9.7.38 Charging Circuit and Troubleshooting Schematic is drawn with the ignition switch in the RUN position. Except where noted, this schematic is taken from diagrams on pages 9.50, 9.52, 9.74, 9.76, 9.102 and 9.104. BATTERY + - § BATTERY GRND 5 30 50 M GND STARTER 5 B+ D+ ALTERNATOR FEMALE AND MALE BULKHEAD HARNESS CONNECTORS HOURMETER ALTERNAT0R INSTRUMENT PANEL CONNECTOR J3 J8 A3 A3 B3 B3 A1 A1 B1 B1 GND (-) See pages 9.39, 9.41, 9.63, 9.65, 9.85 or 9.87.
Electrical System Dash panel alternator indicator ON continuously. Check alternator at terminal “B+” for voltage output of 13.8 -14.2 volts. Not OK Check for proper, low resistance, ground at alternator. If OK If OK Replace alternator. Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: With engine running, check for battery voltage at alternator terminal "D+". Not OK Replace alternator. Not OK Repair/replace engine harness. Not OK Repair/replace cab harness.
Electrical System 9.7.39 Front Steer Circuit and Troubleshooting Schematic is drawn with the ignition switch in the RUN position. § FEMALE AND MALE BULKHEAD HARNESS CONNECTORS FEMALE AND MALE BULKHEAD HARNESS CONNECTORS See pages 9.38, 9.39, 9.40, 9.41, 9.62, 9.63, 9.64, 9.65, 9.84, 9.85, 9.86 or 9.87. A3 A3 B3 B3 A1 A1 B1 B1 C5 C5 B2 B2 See pages 9.50, 9.52, 9.74, 9.76, 9.102 and 9.104.
Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. Fuses. 2. All connections relating to circuit are clean and tight. Front-wheel steer mode does not function when the steer select switch is in the center position Disconnect both connectors at the steer select valve solenoids, wires [8], [2C] and [9], [2B]. Check for front-wheel steer Not OK Refer to Section 8.8.15, “Front-Wheel Steering Circuit (Left Turn) and Troubleshooting,” or Section 8.8.
Electrical System 9.7.40 Four-Wheel Steer Circuit and Troubleshooting Schematic is drawn with the ignition switch in the RUN position. § FEMALE AND MALE BULKHEAD HARNESS CONNECTORS FEMALE AND MALE BULKHEAD HARNESS CONNECTORS See pages 9.38, 9.39, 9.40, 9.41, 9.62, 9.63, 9.64, 9.65, 9.84, 9.85, 9.86 or 9.87. A3 A3 B3 B3 A1 A1 B1 B1 C5 C5 B2 B2 See pages 9.50, 9.52, 9.74, 9.76, 9.102 and 9.104.
Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. All connections relating to circuit are clean and tight. Four-wheel steer mode does not function with the steer select switch in the four-wheel steer mode position. Disconnect steer select valve solenoid male connector and check for battery voltage, across wires [9] (LT GRN/BLK) and [2B] (BLK). If OK Not OK Check for battery voltage at wire [9] (LT GRN/BLK) at bulkhead connector, Pin C3.
Electrical System 9.7.41 Crab Steer Circuit and Troubleshooting Schematic is drawn with the ignition switch in the RUN position. § FEMALE AND MALE BULKHEAD HARNESS CONNECTORS FEMALE AND MALE BULKHEAD HARNESS CONNECTORS See pages 9.38, 9.39, 9.40, 9.41, 9.62, 9.63, 9.64, 9.65, 9.84, 9.85, 9.86 or 9.87. A3 A3 B3 B3 A1 A1 B1 B1 C5 C5 B2 B2 See pages 9.50, 9.52, 9.74, 9.76, 9.102 and 9.104.
Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. All connections relating to circuit are clean and tight. Crab steer mode does not function with the steer select switch in the crab steer mode position. Disconnect steer select valve solenoid male connector and check for battery voltage, across wires [8] (LT GRN/WHT) and [2C] (BLK). If OK Not OK Check for battery voltage at wire [8] (LT GRN/WHT) at bulkhead connector, Pin C2.
Electrical System 9.7.42 10042 Outrigger Circuit and Troubleshooting Schematic is drawn with the ignition switch in the RUN position. 7.
Electrical System Note: No outrigger functions work or a single function fails to work . • If no outrigger functions work, the problem is most likely the main power to the outrigger circuit. Check battery voltage at 7.5 amp outrigger fuse, output side. • If a single outrigger function (up/down) does not work, the problem is most likely the switch or that individual circuit. Not OK Replace fuse. Not OK Repair/replace cab harness. Not OK Repair/replace cab harness.
Electrical System 9.7.43 10054 Outrigger Circuit and Troubleshooting For additional information on the 10054 Outrigger Circuit, refer to Section 10.7, “Stabil-TRAK™ Electrical Circuit Operation and Troubleshooting (8042/10042),” Section 10.9, “Stabil-TRAK™ Boom Interlock Electrical Circuit Operation and Troubleshooting (10054, 13198-17984),” or Section 10.10, “Stabil-TRAK™ Boom Interlock Electrical Circuit Operation and Troubleshooting (10054, 17985-19987 and 0160002332 & After).” 9.
Electrical System This Page Intentionally Left Blank Model 8042, 10042, 10054 Legacy Rev. 10/03 9.
Electrical System 9.7.44 Front Windshield Wiper Circuit and Troubleshooting (Option) 10.0 OPTION WIPER/ WASHER 32 6F 30 PUR 6 6A 3 4 2 9 6 4 3 1 9 6 4 3 1 3 L 4 1 2 3C TO IGNITION SWITCH RUN 7 5 2 7 5 2 1A 6A P 2 L H M P GND H FRONT WIPER MOTOR 1 FRONT WIPER SWITCH PUR 1 1A 2 1D CAB GROUND STUD MH5120 9.134 Model 8042, 10042, 10054 Legacy Rev.
Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: With front wiper switch in LOW or HIGH position, the wiper does not operate. Note: When troubleshooting the wiper circuit, verify and fix the LOW speed function before the HIGH speed function. 1. All connections relating to circuit are clean and tight. Check 10-amp wiper fuse. Not OK Replace fuse. Not OK Repair/replace cab harness. Not OK Repair/replace wiper harness.
Electrical System 9.7.45 Skylight Wiper Circuit and Troubleshooting (Option) 10.0 OPTION WIPER/ WASHER 32 6F 30 PUR 6B 6C 5 9 9 6 4 3 1 9 6 4 3 1 5 C Park 9 1 2 7 5 2 3C TO IGNITION SWITCH RUN 7 5 1B 6C Run M A GND SKYLIGHT WIPER MOTOR 1E SKYLIGHT WIPER SWITCH 2 PUR 1E 1B 2 1D CAB GROUND STUD MH5130 9.136 Model 8042, 10042, 10054 Legacy Rev.
Electrical System With skylight wiper switch in the RUN position, the wiper does not operate. Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. All connections relating to circuit are clean and tight. Check 10-amp wiper fuse. Not OK Replace fuse. Not OK Repair/replace cab harness. Not OK Repair/replace wiper harness. Not OK Replace skylight wiper switch. Not OK Repair/replace wiper harness. Not OK Replace skylight wiper switch.
Electrical System 9.7.46 Front Windshield & Skylight Washer Circuit and Troubleshooting (Option) 10.0 OPTION WIPER/ WASHER 32 6F 30 6D 6E 8 3 8 3 1 3C TO IGNITION SWITCH RUN 7 2 7 2 1C 10 POWER M FRONT WASHER SWITCH FRONT WASHER PUMP MOTOR GND 1F 1C 2 1D CAB GROUND STUD MH5140 9.138 Model 8042, 10042, 10054 Legacy Rev.
Electrical System Washer does not spray water on front windshield and skylight. Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. All connections relating to circuit are clean and tight. Check reservoir for washer fluid. Not OK Fill reservoir with Not OK washer fluid. Not OK Fix hose connections. Not OK Troubleshoot and fix. Not OK Repair/replace wiper harness. Not OK Replace front washer switch. Not OK Repair/replace wiper harness.
Electrical System 9.7.47 Heater Circuit and Troubleshooting (Option) 1 4 3 1 1 O L 4 4 3 3 M H C BLOWER B SWITCH 2 1 4 HEATER BLOWER MOTOR POWER BLOWER MOTOR RESISTOR PACK M GND 3 2 5 CAB GROUND STUD 2 15.0 HORN/HEATER 52 2 3C TO IGNITION SWITCH RUN MH5150 9.140 Model 8042, 10042, 10054 Legacy Rev.
Electrical System Heater fan does not operate. Check 15-amp heater fuse. Not OK Replace fuse. Not OK Repair/replace cab harness. Not OK Repair/replace heater harness. Not OK Replace blower switch. Not OK Repair/replace heater harness. Not OK Clean, tighten and recheck. If OK Check for battery voltage at fuse block female connector wire [52] (ORG). If OK Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1.
Electrical System 9.7.
Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. Fuses. 2. All connections relating to circuit are clean and tight. 3. If dipped beam headlights do not work, follow the steps listed at, Section 9.7.51, “Roadlights Side & Dipped Beam Lights Circuit and Troubleshooting (Option),” before troubleshooting the main beam circuit.
Electrical System 9.7.
Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: With ignition switch OFF, hazard indicator and all hazard lights remain OFF with the 4 way hazard switch in the ON position. 1. Fuses. 2. All connections relating to circuit are clean and tight. Disconnect connector at fuse block, wire [12C] to wire [32] on roadlight harness. Check for battery voltage at wire [12C] (DK BLU). 3.
Electrical System 9.7.
Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: With the ignition ON and the lighting control lever pushed up for left turn signal or down for right turn signal, turn signal indicator and turn signals remain OFF. 1. Fuses. With hazard switch OFF, check for battery voltage at Pin 8, wire [1B] (RED) on hazard switch. 2. All connections relating to circuit are clean and tight. 3.
Electrical System 9.7.
Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: With the ignition ON and the lighting control lever rotated to 1st position (Side Lights Only), side lights remain OFF. 1. Fuses. 2. All connections relating to circuit are clean and tight. 3. Before troubleshooting either the side lights circuit or the dipped beam lights circuit, verify that the worklight circuit is operating. If not, follow the steps listed at, Section 9.7.
Electrical System 9.7.
Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. Fuses. 2. All connections relating to circuit are clean and tight. 3. Before troubleshooting the brake lights circuit, verify that the worklight circuit is operating. If not, follow the steps listed at, Section 9.7.53, “Roadlights w/ Worklights Circuit and Troubleshooting (Option),” before troubleshooting the brake lights circuit.
Electrical System 9.7.
Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: Worklights remain OFF with the ignition ON position and the bottom of the worklight switch pushed in. Check for battery voltage at fuse block female connector wire [12AA] (DK BLU). 1. Fuses. 2. All connections relating to circuit are clean and tight. Not OK Check for battery voltage at light switch relay Pin 30, wire [29] (RED). Not OK Repair/replace cab harness.
Electrical System 9.7.54 Worklight (Without Roadlights) Circuit and Troubleshooting (Option) BOOM WORKLIGHT 3D LEFT FRONT WORKLIGHT 2B1 N RIGHT FRONT WORKLIGHT 3B P 3C P P Boom Worklight 3D Harness A 2B2 N 3C 3B 2B N 2B B A B 3D 2B4 3D 3 3 3A1 See Pages 9.38, 9.40, 9.50, 9.62, 9.64, 9.74, 9.84, 9.86, or 9.102 2B2 2B1 2 2B4 INSTRUMENT PANEL CONNECTOR BACK LIGHT (J2) 156 3A 3A1 3A 1A WORKLIGHT 8 SWITCH OFF 12 29 30 86 85 87A 12B 87 1A 12B 2DD 7.
Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: Worklights remain OFF with the ignition ON position and the bottom of the worklight switch pushed in. Check for battery voltage at fuse block female connector wire [12AA] (DK BLU). 1. Fuses. 2. All connections relating to circuit are clean and tight. Not OK Check for battery voltage at light switch relay Pin 30, wire [29] (RED). Not OK Repair/replace cab harness.
Electrical System 9.8 TRANSMISSION GEAR SELECTION TROUBLESHOOTING The following seven electrical circuit schematics address each transmission position. For additional troubleshooting information, refer to Section 9.14.6, “Transmission Shift Control Switch.” 9.156 Model 8042, 10042, 10054 Legacy Rev.
Electrical System 9.8.1 Transmission, Forward First Gear Circuit, (SN 8042, 13198 - 18990, 10042 13198 - 19030) 3A 1 8 7 6 2 E 3C 5 D 26A A B C D E A B C D E 30 7.5 LIGHT SWITCH RELAY A 3C 2 58 O S P R 15 O S P R 50 O IGNITION SWITCH B C 26 1 27C 27 40.
Electrical System 9.8.2 Transmission, Forward First Gear Circuit, (SN 10054, 13198 - 19079) 3A 1 8 7 6 2 E 3C 5 D 26A A B C D E A B C D E 2 30 7.5 LIGHT SWITCH RELAY A 3C B 85 C 1 8 5 D 26 27 40.
Electrical System 9.8.3 Transmission, Forward First Gear Circuit, (SN 8042, 18991 - 19987, 10042, 19031 - 19987 And 8042/10042, 0160002332 & After) 3A 3C 26A A B C D E A B C D E S P R 19 58 O S P R 15 O S P R 50 O IGNITION SWITCH 30 7.5 LIGHT SWITCH RELAY A 3C B 1 8 27 40.
Electrical System 9.8.
Electrical System 9.8.5 Transmission, Forward Second Gear Circuit, (SN 8042, 13198 - 18990, 10042 13198 - 19030) 3A 1 8 7 6 2 E 3C 5 D 26A A B C D E A B C D E 30 7.5 LIGHT SWITCH RELAY A 3C 2 58 O S P R 15 O S P R 50 O IGNITION SWITCH B C 26 1 27C 27 40.
Electrical System 9.8.6 Transmission, Forward Second Gear Circuit, (SN 10054, 13198 - 19079) 3A 1 8 7 6 5 D 26A A B C D E A B C D E 30 7.5 A 3C 2 B 85 C 1 8 26 5 D 26 27 40.
Electrical System 9.8.7 Transmission, Forward Second Gear Circuit, (SN 8042, 18991 - 19987, 10042, 19031 - 19987 And 8042/10042, 0160002332 & After) 3A 3C 26A A B C D E A B C D E S P R 19 58 O S P R 15 O S P R 50 O IGNITION SWITCH 30 7.5 LIGHT SWITCH RELAY A 3C B 1 8 27 40.
Electrical System 9.8.8 Transmission, Forward Second Gear Circuit, (SN 10054, 19080 - 19987 And 0160002332 & After) 3A 3C 26A A B C D E A B C D E S P R 19 58 O S P R 15 O S P R 50 O IGNITION SWITCH 30 A B 52 85 51A 1 8 3C 5 26A 3A D 51A PARK BRAKE SWITCH 51 51B 26 2 27C 27 100 27D D B 41B 1 TO STARTER 107A 9 FORWARD 2nd Gear 1 F 2 4 3 N C SHIFTER ZF TRANSMISSION 9 B+ 2HH 153 PARK BRAKE DIS.
Electrical System 9.8.9 Transmission, Forward Third Gear Circuit, (SN 8042, 13198 - 18990, 10042 13198 - 19030) 3A 1 8 7 6 2 E 3C 5 D 26A A B C D E A B C D E 30 7.5 LIGHT SWITCH RELAY A 3C 2 58 O S P R 15 O S P R 50 O IGNITION SWITCH B C 26 1 27C 27 40.
Electrical System 9.8.10 Transmission, Forward Third Gear Circuit, (SN 10054, 13198 - 19079) 3A 1 8 7 6 5 A B C D E A B C D E D 19 A B 85 1 8 26 5 D 51 51B 27 TO STARTER 27D 100 2 D 41 41B 1 B 41C 107A TRANSMISSION 9 FORWARD 3rd Gear 2 F 3 4 N R SHIFTER ZF TRANSMISSION C B+ B2 153 8 GEAR 8 150 7 GEAR 7 103 6 105 GEAR 6 5 GEAR 5 4 NEUTRAL 4 3 REVERSE 3 2 FORWARD 2 104 1 B+ 1 113 20 103 105 150 B1 See page 9.84.
Electrical System 9.8.11 Transmission, Forward Third Gear Circuit, (SN 8042, 18991 - 19987, 10042, 19031 - 19987 And 8042/10042, 0160002332 & After) 3A 3C 26A A B C D E A B C D E S P R 19 58 O S P R 15 O S P R 50 O IGNITION SWITCH 30 7.5 LIGHT SWITCH RELAY A 3C B 1 8 27 40.
Electrical System 9.8.
Electrical System 9.8.13 Transmission, Forward Fourth Gear Circuit, (SN 8042, 13198 - 18990, 10042 13198 - 19030) 3A 1 8 7 6 2 E 3C 5 D 26A A B C D E A B C D E 30 7.5 LIGHT SWITCH RELAY A 3C 2 58 O S P R 15 O S P R 50 O IGNITION SWITCH B C 26 1 27C 27 40.
Electrical System 9.8.14 Transmission, Forward Fourth Gear Circuit, (SN 10054, 13198 - 19079) 3A 1 8 7 6 3C 26A 2 E A B C D E A B C D E 5 D PARK BRAKE SWITCH 4 E 3 S P R 19 2 O S P R 15 O S P R 50 O IGNITION SWITCH 30 B C 87A 1 8 1 2 26 5 26 27C 27 40.
Electrical System 9.8.15 Transmission, Forward Fourth Gear Circuit, (SN 8042, 18991 - 19987, 10042, 19031 - 19987 And 8042/10042, 0160002332 & After) 3A 3C 26A A B C D E A B C D E S P R 19 58 O S P R 15 O S P R 50 O IGNITION SWITCH 30 7.5 LIGHT SWITCH RELAY A 3C B 1 8 27 40.
Electrical System 9.8.
Electrical System 9.8.17 Transmission, Reverse First Gear Circuit, (SN 8042, 13198 - 18990, 10042 13198 - 19030) 3A 1 8 7 6 5 D 26A A B C D E A B C D E 10.0 30 7.5 LIGHT SWITCH RELAY A 3C 2 58 O S P R 15 O S P R 50 O IGNITION SWITCH 24 HORN/HEATER 26 B C 1 1 27 40.
Electrical System 9.8.18 Transmission, Reverse First Gear Circuit, (SN 10054, 13198 - 19079) 3A 1 8 7 6 3C 26A B C D E A B C D E 5 D PARK BRAKE SWITCH 2 E A 4 E 3 S P R 19 O S P R 15 O S P R 50 O IGNITION SWITCH 10.0 30 24 HORN/HEATER 2 B C 87A 1 1 8 2 26 5 D 26 27C 27 40.
Electrical System 9.8.19 Transmission, Reverse First Gear Circuit, (SN 8042, 18991 - 19987, 10042, 19031 - 19987 And 8042/10042, 0160002332 & After) 3A 3C 26A A B C D E A B C D E 24 102B 19 10.0 58 O S P R 15 O S P R 50 O 24 HORN/HEATER 30 7.5 LIGHT SWITCH RELAY A 3C B 85 1 26 27 40.0 MAIN 3A 5 26 27C 100 27D 2 E D 107B PARK BRAKE SWITCH 2 D 4 85 107A 1 107B 2HH TRANSMISSION 9 F N 1 2 3 REVERSE R SHIFTER ZF TRANSMISSION PARK BRAKE DIS.
Electrical System 9.8.20 Transmission, Reverse First Gear Circuit, (SN 10054, 19080 - 19987 And 0160002332 & After) 3A 3C 26A A B C D E A B C D E S P R 19 10.
Electrical System 9.8.21 Transmission, Reverse Second Gear Circuit, (SN 8042, 13198 - 18990, 10042 13198 - 19030) 3A 1 8 7 6 2 E 3C 5 D 26A A B C D E A B C D E 10.0 30 7.5 LIGHT SWITCH RELAY A 3C 2 58 O S P R 15 O S P R 50 O IGNITION SWITCH 24 HORN/HEATER B C 26 1 27C 27 40.
Electrical System 9.8.22 Transmission, Reverse Second Gear Circuit, (SN 10054, 13198 - 19079) 3A 1 8 7 6 3C 26A B C D E A B C D E 5 D PARK BRAKE SWITCH 2 E A 4 E 3 S P R 19 O S P R 15 O S P R 50 O IGNITION SWITCH 10.0 30 24 HORN/HEATER 2 B 87A C 1 1 8 2 26 5 D 26 27C 27 40.
Electrical System 9.8.23 Transmission, Reverse Second Gear Circuit, (SN 8042, 18991 - 19987, 10042, 19031 - 19987 And 8042/10042, 0160002332 & After) 3A 3C 26A A B C D E A B C D E 24 102B 19 10.0 58 O S P R 15 O S P R 50 O 24 HORN/HEATER 30 7.
Electrical System 9.8.24 Transmission, Reverse Second Gear Circuit, (SN 10054, 19080 - 19987 And 0160002332 & After) 3A 3C 26A A B C D E A B C D E S P R 19 10.0 30 24 HORN/HEATER A B 52 86 IGNITION SWITCH 1 5 26A 2 27 MAIN 3A D 26 27C 100 51 51B D B 41B 1 9 F N 1 2 3 4 R SHIFTER ZF TRANSMISSION REVERSE 9 B+ C 87A 87 113B 2EE 107B 2HH 153 PARK BRAKE DIS.
Electrical System 9.8.25 Transmission, Reverse Third Gear Circuit, (SN 8042, 13198 - 18990, 10042 13198 - 19030) 3A 1 8 7 6 5 26A A B C D E A B C D E 10.0 30 7.5 LIGHT SWITCH RELAY A 3C 2 58 O S P R 15 O S P R 50 O IGNITION SWITCH 24 B C 26 1 27 40.
Electrical System 9.8.26 Transmission, Reverse Third Gear Circuit, (SN 10054, 13198 - 19079) 3A 1 8 7 6 3C 26A B C D E A B C D E 5 D PARK BRAKE SWITCH 2 E A 4 E 3 S P R 19 O S P R 15 O S P R 50 O IGNITION SWITCH 10.0 30 24 HORN/HEATER 2 B C 87A 1 1 8 2 26 5 D 26 27C 27 40.
Electrical System 9.8.27 Transmission, Reverse Third Gear Circuit, (SN 8042, 18991 - 19987, 10042, 19031 - 19987 And 8042/10042, 0160002332 & After) 3A 3C 26A A B C D E A B C D E 24 102B 19 10.0 58 O S P R 15 O S P R 50 O 24 HORN/HEATER 30 7.
Electrical System 9.8.28 Transmission, Reverse Third Gear Circuit, (SN 10054, 19080 - 19987 And 0160002332 & After) 3A 3C 26A A B C D E A B C D E S P R 19 10.0 30 24 HORN/HEATER A B 52 1 27 40.
Electrical System 9.8.29 Dash Panel Warning Indicator Troubleshooting The following troubleshooting flow charts discuss each instrument cluster panel indicator separately. Additional information for each indicator can be found by referring to the correct electrical legends and schematics on pages 9.30 through 9.103. The Instrument cluster light bulbs can be replaced. Bulb function should be checked before proceeding to each troubleshooting chart. Refer to Section 9.11.3, “Instrument Cluster.
Electrical System 9.8.30 Engine Alternator Charging Warning Indicator Troubleshooting Engine Alternator Charging Warning Indicator P 0000 00 MA7560 Engine alternator charging warning indicator stays ON while operating. Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: Check alternator belt tension. If OK 1. Fuses. 2. Battery for proper charge. 3. All connections relating to circuit are clean and tight. 4. Check instrument cluster bulb for proper function.
Electrical System 9.8.31 Engine Coolant Temperature Warning Indicator Troubleshooting P Engine Coolant Temperature Warning Indicator 0000 00 MA7570 Engine coolant temperature warning indicator stays ON while operating. Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: Check radiator coolant level, fan belt tension, radiator cap, thermostat, and for plugged condition or debris on radiator. Not OK Repair as needed. Not OK Repair as needed. If OK 1. Fuses. 2.
Electrical System 9.8.32 Transmission Temperature Warning Indicator Troubleshooting P Transmission Temperature Warning Indicator 0000 00 MA7580 Transmission temperature warning indicator stays ON while operating and alarm sounds. Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: Stop and idle vehicle for 1 minute to allow transmission oil to cool. 1. Fuses. 2. Battery for proper charge. 3. All connections relating to circuit are clean and tight. 4.
Electrical System 9.8.33 Hydraulic Oil Temperature Warning Indicator Troubleshooting P Hydraulic Oil Temperature Warning Indicator 0000 00 MA7590 Hydraulic oil temperature warning indicator stays ON while operating. Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: Stop and idle engine for 5 minutes to allow hydraulic oil to cool. 1. Fuses. 2. Battery for proper charge. 3. All connections relating to circuit are clean and tight. 4.
Electrical System 9.8.34 Park Brake Warning Indicator Troubleshooting P Park Brake Warning Indicator 0000 00 MA7600 Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: Park brake warning indicator stays ON with park brake disengaged. Check light bulb. 1. Fuses. 2. Battery for proper charge. 3. All connections relating to circuit are clean and tight. 4. Check instrument cluster bulb for proper function.
Electrical System 9.8.35 Engine Oil Pressure Warning Indicator Troubleshooting P Engine Oil Pressure Warning Indicator Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. Fuses. 2. Battery for proper charge. 0000 00 3. All connections relating to circuit are clean and tight. MA7610 4. Check instrument cluster bulb for proper function. Engine oil pressure warning indicator stays ON while operating. Check engine for oil pressure.
Electrical System 9.8.36 Fuel Level Indicator Troubleshooting P Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. Fuses. Fuel Level Indicator 2. Battery for proper charge. 3. All connections relating to circuit are clean and tight. 0000 00 MA7620 4. Check instrument cluster bulb for proper function. Fuel level indicator reads EMPTY while operating. Verify fuel quantity level in tank. Not OK Fill fuel tank.
Electrical System 9.8.37 Hourmeter Indicator Troubleshooting P Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. Fuses. 2. Battery for proper charge. 0000 00 3. All connections relating to circuit are clean and tight. 4. Check instrument cluster bulb for proper function. MA7640 Hourmeter Indicator Hourmeter indicator does not register operating hours. Check wire 38 (ORG) for battery voltage to instrument panel connector.
Electrical System 9.8.38 Stabil-TRAK™ Indicator Troubleshooting P 0000 00 Stabil-TRAK™ Indicator MH3430 Stabil-TRAK™ indicator stays ON with boom below 40°. Before troubleshooting this electrical circuit, ALWAYS begin by checking the following: 1. Boom below 40°. 2. Transmission shifter in NEUTRAL. 3. Park Brake OFF. Check circuit 40 (BRN/BLK) at solenoid 3 on Stabil-TRAK cylinder for battery voltage. If OK Check Stabil-Lock relay circuit 114B (BLU/ORG) for battery voltage.
Electrical System 9.9 ENGINE START CIRCUIT The purpose of the engine start circuit is to energize the starter solenoid and engage the starter motor to start the engine. To start the engine, the ignition key switch must be in the START (1) position, the park brake switch must be in the ON position and the transmission shift control switch (travel select lever) must be in the NEUTRAL (center) position.
Electrical System 9.9.2 The starter operates when the attached starter solenoid engages a gear on the starter pinion shaft to mesh with the flywheel, and the starter pinion and gear begin to spin, in turn rotating the flywheel, crankshaft and related components within the engine. Starter The starter (1 or 15) is located on the left side of the engine (the left side of the vehicle).
Electrical System c. Starter Removal Remove the starter only if it fails. To remove the starter: 3. For jump start protection, a protective plastic cover (18) is installed around the starter solenoid terminal and mounting screw. A removable, tethered cap (19) allows access to the terminal mounting screw. 20 16 17 MH4890 18 21 1. Unlock and open the rear engine door. 2. If the vehicle has one battery, disconnect the negative (-) battery cable at the negative (-) battery terminal (16).
Electrical System f. Applies To Serial Numbers: 8042, 18991 - 19987, 10042 19031 - 19987, 10054, 19080 - 19987 And 8042/10042/10054, 0160002332 & After Starter Installation Applies To Serial Numbers: 8042, 13198 - 18990, 10042 13198 - 19030, 10054, 13198 - 19079 1. Position the starter (1) in its mounting opening on the flywheel housing. Position the ground cable (2) over the correct starter mounting bolt (3). Secure the starter with the three fasteners (3). Torque fasteners to 32 lb-ft (43 Nm).
Electrical System 4. Insert the fork terminal of the blue/orange wire (16) into the protective cover (17) on the starter solenoid terminal. Use a small phillips screwdriver to tighten the screw (18) securely. 5. Snap the tethered cap back in place over the screw in the protective cover. 18 9.10 CHARGING CIRCUIT The purpose of the charging circuit is to maintain battery voltage between 13.8 and 14.2 volts.
Electrical System The negative (-) post of the battery is connected to the starter ground, a stud located on the starter housing. Other ground leads routed directly from the main chassis ground are provided to the alternator and fuel shut-off switch, and are spliced within the wiring harness to other electrical system grounds. 3 The alternator includes an internal voltage regulator that limits alternator voltage to a preset value and helps prevent circuit overloads, power surges, etc.
Electrical System 4. Verify that the alternator mounting hardware is tight. SN 8042, 18991 - 19987, 10042 19031 - 19987, 10054, 19080 - 19987 And 8042/10042/10054, 0160002332 & After 5. Run the engine and check the alternator for noise. A loose drive pulley, loose mounting hardware, worn or dirty internal alternator bearings, a defective stator or defective diodes can cause noise. Replace a worn or defective alternator. 6. For additional information on the charging circuit refer to Section 9.7.
Electrical System Applies To Serial Numbers: 8042, 18991 - 19987, 10042 19031 - 19987, 10054, 19080 - 19987 And 8042/10042/10054, 0160002332 & After SN 8042, 13198 - 18990, 10042 13198 - 19030, 10054, 13198 - 19079 6.
Electrical System Applies To All Vehicles b. Alternator Installation 1. Position the alternator and align with the upper alternator mount (7) on the engine bracket. Insert the upper (longer) mounting hardware (6) through the alternator mount. Thread the longer capscrew into the alternator front mount. DO NOT tighten completely at this time. 2. Align the lower alternator mount hole (5) with the lower mounting bracket on the engine, and insert the lower mounting capscrew (4).
Electrical System 6. If the vehicle has one battery, connect the negative (-) battery cable to the negative (-) battery terminal (1). If the vehicle has dual batteries, connect both negative battery cables to both negative (-) battery terminals (4). 3 a.
Electrical System b. Visual Inspection of the Battery Inspect for damage such as a cracked or broken case, or cover, that could permit loss of electrolyte. If obvious physical damage is noticed, replace the battery. Handle the battery with care. Determine the cause of battery damage and correct as needed before installing the new battery. c. Battery Load Test 1. If the vehicle has one battery, disconnect the negative (-) battery cable at the negative (-) battery terminal (1).
Electrical System The time required for a charge will vary due to the following conditions: • Size of battery: For example, a completely discharged, large, heavy-duty battery requires more than twice the recharging as a completely discharged small passenger car battery. • Temperature: For example, more time will be required to charge a battery at 0° F than at 80° F.
Electrical System h. Battery Inspection, Cleaning and Drying g. Battery Removal Note: The best time to clean the battery compartment is when the battery is removed from the vehicle. Applies To Serial Numbers: 8042, 13198 - 18990, 10042 13198 - 19030, 10054, 13198 - 19079 1. Disconnect the negative (-) battery cable (1), from the battery (2). Disconnect the positive (+) battery cable (3) from the battery. 2. Remove the battery retaining (hold-down) strap hardware (4 and 5) and the retaining strap (6). 3.
Electrical System 9.11 ELECTRICAL SYSTEM COMPONENTS b. Warning Indicator Lights (In Operator’s Instrument Cluster) Electrical components include warning devices such as the indicators in the operator’s instrument cluster, horn, back-up alarm, and other components such as the various solenoids and all accessories. Examine the appropriate wiring diagrams and schematics earlier in this section, to help understand the wiring circuits involved. 9.11.
Electrical System e. Hydraulic Oil Temperature Warning Indicator MA8290 This warning light (6) will activate when the hydraulic oil temperature is above 195° F (91° C). The vehicle should be stopped and the engine allowed to idle at high idle for five 10 9 minutes. If the light continues to illuminate after five minutes, the engine must be shut down to help avoid damage in the hydraulic system. For additional information refer to Section 9.8.
Electrical System b. Disassembly 9.11.3 DO NOT disassemble the back-up alarm. Replace a defective or faulty alarm with a new part. The information under this heading deals mainly with the description and function of each indicator in the operator’s instrument cluster. Appropriate service procedures for each circuit, as applicable, appear elsewhere in this section of the manual. c. Inspection and Replacement Inspect the wiring harness connector and alarm terminals for continuity and shorting.
Electrical System High-Beam Indicator (Optional) b. Normal Operating Lights The high-beam indicator (12) illuminates when the optional headlight switch is placed in the HIGH-BEAM position. After the engine starts, the operator’s instrument cluster (7) provides information via the following indicators: MA8260 Directional Light Indicator (Optional) Fuel Level Indicator The fuel level indicator (8) represents the quantity of fuel remaining in the fuel tank. For additional information, refer to Section 9.
Electrical System e. Operator’s Instrument Cluster Bulb Removal 1. If the vehicle has one battery, disconnect the negative (-) battery cable at the negative (-) battery terminal (1). 15 13 If the vehicle has dual batteries, disconnect both negative battery cables from both negative (-) battery terminals (2). 14 12 16 11 17 6 10 1 2 MH4890 2. Unscrew the plastic ring retainer from the back of the instrument cluster. Disconnect the harness plug connector from the back of the instrument cluster (3).
Electrical System a. Removal Operator’s Display Panel Test Check the following, as the key switch is placed in the RUN position (21): 1. If the vehicle has one battery, disconnect the negative (-) battery cable at the negative (-) battery terminal (1). If the vehicle has dual batteries, disconnect both negative battery cables from both negative (-) battery terminals (2). 21 2. Carefully pry the windshield wiper switch (22) and wire connector out of the mounting hole. 3.
Electrical System 9.12.2 7. Disconnect the washer hose (19) from hose connector (20). Windshield Wiper Motor a. Removal Note: It may be necessary to remove several hydraulic hoses from under the dash in order to remove and install the wiper motor housing. (Refer to Section 4.3.3, “Steering Column/Valve Replacement.”) 1. If the vehicle has one battery, disconnect the negative (-) battery cable at the negative (-) battery terminal (1).
Electrical System 3. Have an assistant insert gasket (15), panto adapter (14) onto to the motor shaft (7). Insert bolts (13) through front cab holes and thread into motor housing. Tighten bolts. 9.12.3 Skylight Wiper Switch 4. Install metal washer (12) and metal hex jam nut (11). Tighten metal hex jam nut. Install rubber cap (10) and knurled driver (9) onto the motor shaft.
Electrical System e. Installation and Testing a. Removal 1. Connect the skylight wiper switch to the cab harness connector. 2. Position the switch over the rectangular switch bezel and snap into position. 3. If the vehicle has one battery, connect the negative (-) battery cable to the negative (-) battery terminal (1). If the vehicle has dual batteries, connect both negative battery cables to both negative (-) battery terminals (2). 1.
Electrical System a. Removal 3. Install the wiper arm (3) onto the wiper motor shaft (4). 4. Install the screws (6) through the plastic motor cover (7) and into the top locknut plate (9), and tighten. 5. Connect washer hose to top hose fitting (5). 6. If the vehicle has one battery, connect the negative (-) battery cable to the negative (-) battery terminal (1). If the vehicle has dual batteries, connect both negative battery cables to both negative (-) battery terminals (2). 1.
Electrical System 9.12.6 Windshield/Skylight Washer Reservoir and Pump 3. Pull the washer reservoir (6) out and away from the mounting studs. The windshield washer motor and reservoir is a unit and cannot be serviced separately. 4. Rotate the washer reservoir, label and remove the cab harness connectors (7) from the washer reservoir connectors (8). a. Removal 5. Remove the windshield washer hose (9) from the reservoir. 1.
Electrical System 9.13 9.13.1 CAB HEATER AND FAN (OPTION) 8. Remove the control from the panel. Cab Heater Controls Note: If the suspect component is found to be within the heater box, the heater box must be removed as a complete unit and replaced. For additional information on the removal and installation of the heater box, refer to Section 4.4.4, a. “Heater Assembly Removal.” 15 12 10 11 b. Disassembly DO NOT disassemble the cab heater and fan controls. The controls are not serviceable.
Electrical System 9.14 SWITCHES AND SOLENOIDS Note: For information on the front windshield wiper, skylight wiper and windshield washer systems, refer to Section 9.12, “Window Wiper/Washer (Option).” 9.14.1 Ignition Key Switch The ignition key switch (1) is located on the lower right side of the front dash. It is a key-operated switch used to start the engine and to run the vehicle.
Electrical System 4. Reach up and under the dash to work the ignition switch and wiring out of the mounting hole. 5. Disconnect the ignition switch connectors from the cab harness connectors, and remove the switch from the vehicle. b. Disassembly DO NOT disassemble the ignition switch. Replace a defective switch with a new part. c. Inspection and Replacement d. Ignition Switch Installation 1. Connect the ignition key switch to the cab harness connectors. 2.
Electrical System e. Transmission Neutral Start Feature The transmission neutral start feature is a safety feature designed to prevent the engine from starting with the transmission in (F) FORWARD or (R) REVERSE. 4 Shifting into (N) NEUTRAL activates the neutral start relay (1) located in the relay and fuse panel (2). When the travel select lever is in (N) NEUTRAL, electrical power flows to the starter relay, allowing the starter to engage and start the engine. 3 OH17902 9.14.
Electrical System 2. Disconnect the wiring connector at the fuel shut-off solenoid lead (7), then remove the fuel shut-off solenoid (5) from the fuel injector pump. 3. Remove the two bolts securing the solenoid to the mounting plate. Remove the nut holding the linkage to the arm on the fuel injection pump. Save the hardware for later reuse. 6. Start the engine. If the engine starts, the fuel shut-off solenoid is functioning.
Electrical System Examine the fluid in the hydraulic oil sight glass (1) to check whether there is a sufficient amount of fluid in the system (the oil level should be at the bottom of the sight glass with all hydraulic cylinders retracted) and whether the fluid is contaminated. Replace the hydraulic oil filter as required. Explore other causes for excessive temperature, such as high air temperature, plugged oil cooler or lines, loose fan belt, plugged radiator, etc. (Refer to Section 9.8.
Electrical System c. Hydraulic Oil Temperature Switch Cleaning and Drying 7 DO NOT submerge the hydraulic oil temperature switch. Clean only with an approved solvent and dry with a clean, lint-free cloth. d. Hydraulic Oil Temperature Switch Inspection and Replacement Inspect switch wiring for continuity and shorting. Replace a defective or faulty switch with a new switch. OH18502 e. Installation and Testing 8 P 1. Thread the switch (5) into its fitting (6) on the hydraulic reservoir.
Electrical System a. Park Brake Switch Removal 1. If the vehicle has one battery, disconnect the negative (-) battery cable at the negative (-) battery terminal (1). If the vehicle has dual batteries, disconnect both negative battery cables from both negative (-) battery terminals (2). 1 3 2 MH4890 2. Carefully pry the park brake switch (3) and wiring out of the mounting hole. 4 P 3. Label and disconnect the wiring from the park brake switch. Remove the switch from the vehicle. b.
Electrical System 9.14.5 Outrigger Switches (10042/10054 Only) Inspect the switch terminals for continuity and shorting in both the non-depressed and depressed positions. Replace a defective or faulty switch with a new switch. 2. Remove the four fasteners (9) securing the right side access panel (10), and remove the panel. a. Left and Right Outrigger Switches The left and right outrigger switches (5 and 6) control the RAISE and LOWER movements of both outriggers.
Electrical System 9.14.6 Transmission Shift Control Switch a. Travel Select Lever The transmission shift control switch (travel select lever) (1) is located on the left side of the steering column. The switch has three positions: (F) FORWARD (2) (all the way up), (N) NEUTRAL (3) (center), and (R) REVERSE (4) (all the way down). The switch or lever must be in the (N) NEUTRAL (3) position to permit engine starting. b.
Electrical System 9.14.7 Transmission Solenoid Valves The transmission is shifted via six solenoids. Three solenoid valves (Y1, Y2 and Y3) are contained in an UPPER spool-type solenoid cartridge assembly (valve body) (6). 6 The remaining three solenoid valves (Y4, Y5 and Y6) are contained in the LOWER spool-type solenoid cartridge assembly (valve body) (7).
Electrical System a. Travel Select Lever and Wiring Harness Testing Note: An assistant will be required to operate the travel select lever, in order to perform the following test. 1. Remove the plug from the UPPER (1 and 3) and LOWER (2 and 5) transmission solenoid valve bodies. Turn the ignition key switch to the RUN position. 1 3. Check the harness side pin connections with a DMM for battery voltage corresponding to the direction and gear that has been selected. Refer to the chart that follows.
Electrical System b. Upper and Lower Transmission Valve Body Solenoid Testing 14 Inspect the solenoid connector plugs (7 and 12). Following the chart below, test each pin connection on the upper transmission valve body connector for continuity and shorting. Each solenoid should have between 25.0 and 30.0 ohms of resistance when testing with an ohm/volt meter. Replace a defective solenoid valve. (Refer to Section 9.14.7, c. “Transmission Upper Valve Body Solenoid Removal.
Electrical System 2. Remove the six capscrews (1) four hex-head capscrews (2), ten lockwashers (3 and 4) and protective cover plate (5) secured over the transmission solenoid cartridge valve (6). Inspect the protective cover gasket (7); replace if torn or missing. 8 3. Install the protective cover gasket (7) on the valve body. Position the protective cover plate (5) over the gasket.
Electrical System 2. Thoroughly clean the area around the upper and lower valve body housing. f. 3. Remove screws securing the upper valve housing to the transmission. Note: When installing the solenoid valve into the valve body, position the solenoid valve wires so they do not interfere with the protective cover plate. 4. Remove upper valve body housing from transmission, and set aside in a clean area, free of dirt, grease and oil. 5. Remove the upper valve housing flat gasket. 6.
Electrical System 9.14.8 Steering Certain steering functions are dependent upon electrical operations as described below. Consult the Owners/ Operators Manual for further information related to steering. a. Steer Select Switch The steer select switch (1) is located on the right side of the operator’s control panel. It is a three-position switch that is pressed or “snapped” into a rectangular switch bezel.
Electrical System c. Four-Wheel Steer Indexing Front-Wheel Steer Mode With the steer select switch (1) in the center position (3), the following condition must be met: OH2601 1. The front wheels (7) must steer in the direction that the steering wheel is turned. 8 7 If the vehicle does not drive “straight,” the steering may not be synchronized or is “out of phase.” Perform the fourwheel steer indexing procedure to synchronize the steering. 1.
Electrical System 9.14.9 Steer Select Switches For additional information, refer to Section 9.7.39, “Front Steer Circuit and Troubleshooting.” a. Steer Select Switch Removal 1. If the vehicle has one battery, disconnect the negative (-) battery cable at the negative (-) battery terminal (1). If the vehicle has dual batteries, disconnect both negative battery cables from both negative (-) battery terminals (2). b. Steer Select Switch Disassembly, Inspection and Replacement DO NOT disassemble the switch.
Electrical System 9.14.10 Steer Select Valve The steer select valve (6), is secured to the steer select manifold and frame with four capscrews and o-rings (7) on the inside wall of the vehicle frame. When the solenoid is de-energized, the control spool (10) is returned to its normal (centered) condition by the centering springs (11).
Electrical System 9.14.11 a. Engine Oil Pressure Sender Removal Engine Low Oil Pressure Sender The engine oil pressure sender (1) is located on the engine and is connected via the engine wiring harness, bulkhead connector and cab wiring harness to the front dash panel. 1. If the vehicle has one battery, disconnect the negative (-) battery cable at the negative (-) battery terminal (4).
Electrical System 9.14.12 Engine Coolant High Temperature Sender The engine coolant high temperature sender (6) is threaded into the engine block (7) and is connected to the operator’s instrument cluster via the engine wiring harness, bulkhead connector and cab wiring harness. When the engine coolant temperature is below 210° F (99° C), the contacts within the sending unit open and the instrument cluster indicator turns OFF. (Refer to Section 9.8.
Electrical System 2. If the vehicle has one battery, connect the negative (-) battery cable to the negative (-) battery terminal (1). If the vehicle has dual batteries, connect both negative battery cables to both negative (-) battery terminals (2). (SN 8042-13198 through 18990, 10042-13198 through 19030, 10054-13198 through 19079) 3. Check for proper coolant level. 3 4. Clear the area around the vehicle of personnel and any obstructions to vehicle travel. 4 1 2 5.
Electrical System a. Transmission Temperature Sender Removal 1. If the vehicle has one battery, disconnect the negative (-) battery cable at the negative (-) battery terminal (1). If the vehicle has dual batteries, disconnect both negative battery cables from both negative (-) battery terminals (2). 2. Unplug the sender connector (3) from the cab harness connector. 3. The sender (3) is threaded into the transmission housing or case (4). Remove the sender. 9.14.
Electrical System a. Engine Block Heater Removal 1. Level the vehicle, ground the attachment, place the travel select lever in (N) NEUTRAL, engage the park brake switch and shut the engine OFF. Remove the ignition key. 2. Secure accident prevention tags to the steering wheel and ignition switch. (Refer to Section 1.5, “Accident Prevention Tags.”) WARNING: DO NOT attempt this procedure when the engine is hot. Wait for the engine, muffler and tailpipes to cool down before proceeding.
Electrical System d. Engine Block Heater Testing (SN 8042, 18991 - 19987, 10042 19031 - 19987, 10054, 19080 - 19987 And 8042/10042/10054, 0160002332 & After) Note: The following test should be performed with a cold engine. The coolant heater unit (7) can be tested on the machine by plugging the 110-volt cord (6) into a 110 volt outlet. After 20 to 30 minutes, place your hand on the engine block (8) next to the heater. If the heater element is functioning properly, you will feel the heat at that location.
Electrical System 9.14.15 Fuel Level Indicator and Fuel Level Sender The fuel level indicator (1) can be found on the operator’s instrument cluster. The fuel level sender (2) consists of a resistance, floattype fuel level sender mounted in the top of the fuel tank (3) and the wiring (4) connecting it with the fuel indicator in the operator’s instrument cluster. P The resistance of the fuel level sender is 31 ohms for a full tank of fuel, 101 ohms for 1/2 tank and 255 ohms for an empty tank.
Electrical System b. Fuel Level Circuit Tests For additional information refer to Section 9.8.36, “Fuel Level Indicator Troubleshooting.” If the fuel level indicator is suspected of giving a false reading, perform the following checks: 1. Check for loose or defective wiring, faulty ground connections, and corrosion on the fuel tank sender and wiring lead. 2.
Electrical System 9.14.16 a. Boom Angle Sensor Removal Hourmeter The hourmeter (1) is a non-repairable instrument that records hours of vehicle engine operation in tenth of an hour increments and is located in the instrument cluster. 1. If the vehicle has one battery, disconnect the negative (-) battery cable at the negative (-) battery terminal (4). If the vehicle has dual batteries, disconnect both negative battery cables from both negative (-) battery terminals (5).
Electrical System b. Boom Angle Sensor Installation 1. Install boom angle sensor (2) through outside of boom frame. 2. Install inside locknut (6) onto sensor. 3. Measure the clearance between the sensor and frame, and adjust sensor distance (7) to .120" (3,05 mm) and tighten locknut (6). 4. If the vehicle has one battery, connect the negative (-) battery cable to the negative (-) battery terminal (4).
Electrical System 9.14.19 Service Brake Switch The service brake switch works in conjunction with the Stabil-TRAK™ system. With the boom above 40°, the transmission shifter in either forward or reverse, and the service brake depressed, the Stabil-TRAK™ system engages. If the Service Brake Switch is suspect in the proper operation of the Stabil-TRAK™ system, refer to Section 10.8, “Stabil-TRAK™ System Test.” a. Service Brake Switch Removal 1.
Electrical System c. Service Brake Switch Adjustment Note: The service brake switch adjustment will require two people. Enlist the help of an assistant before attempting to follow the adjustment procedure. 1. Remove lower access panel (14). 15 16 17 14 MA7060 OH1760 2. Loosen locknut (9) securing the switch body (10) to the service brake switch bracket (11). 3. Connect a 1000 psi (69 bar) pressure gauge to the test port (15) on the service brake valve (16).
Electrical System This Page Intentionally Left Blank 9.250 Model 8042, 10042, 10054 Legacy Rev.
Section 10 Stabil-TRAK™ System and Boom Interlock System Contents PARAGRAPH 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10 10.11 10.12 TITLE PAGE Stabil-TRAK™ System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . 10.3 Boom Extend Interlock System Component Terminology (10054 Only) . . . . . . 10.4 Stabil-TRAK™ Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 Stabil-TRAK™ Operation . . . . . . . . . . . . . . . . . . . .
Stabil-TRAK™ System and Boom Interlock System 10.13 10.2 10.12.15 Hydraulic Troubleshooting - LOCKED MODE, Will Not Frame Sway Left . Boom Extend System Hydraulic Circuit Operation and Troubleshooting . . . . . 10.13.1 Troubleshooting Symptom Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13.2 Hydraulic Circuit Operation - Extend Interlock Mode . . . . . . . . . . . . . . . . 10.13.3 Hydraulic Troubleshooting - Extend Interlock Mode . . . . . . . . . . . . . . . . . 10.13.
Stabil-TRAK™ System and Boom Interlock System 10.1 STABIL-TRAK™ SYSTEM COMPONENT TERMINOLOGY To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the Stabil-TRAK™ system. The following illustration identifies the components that are referred to throughout this section.
Stabil-TRAK™ System and Boom Interlock System 10.2 BOOM EXTEND INTERLOCK SYSTEM COMPONENT TERMINOLOGY (10054 ONLY) To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the boom extend interlock system. The following illustration identifies the components that are referred to throughout this section.
Stabil-TRAK™ System and Boom Interlock System 10.3 STABIL-TRAK™ DESCRIPTION The patented rear axle lock or Stabil-TRAK™ system works to stabilize the vehicle under various conditions. The appropriate Owners/Operators manual contains basic Stabil-TRAK™ information; a copy of the owners/ operators manual should always be available in the storage compartment located on the left inside wall of the cab, next to the seat support.
Stabil-TRAK™ System and Boom Interlock System 10.4 STABIL-TRAK™ OPERATION The rough terrain forklift rarely operates on ground that is a smooth, flat surface. As its name infers, the “Construction Rough Terrain Forklift” is typically found on worksites with numerous holes, trenches, rocks and slopes. To negotiate this type of terrain, rough terrain forklifts are designed with a free oscillating rear axle.
Stabil-TRAK™ System and Boom Interlock System The Model 10054 has an additional boom extend interlock system. This system prevents the boom from being extended beyond a point between the “E” and “F” boom extend letters (approximately 40' [12 m]), unless both outriggers have been lowered onto solid terrain. Once this system has been activated, the vehicle will automatically place the Stabil-TRAK™ system in the LOCKED MODE and apply the park brake.
Stabil-TRAK™ System and Boom Interlock System b. LOCKED Mode 10054 With the boom above 40° (1 or 4) and by activating one or more of the functions (as follows), the Stabil-TRAK™ system is in the LOCKED MODE (2 or 5) and the rear axle is locked so it is rigid with the frame.
Stabil-TRAK™ System and Boom Interlock System 10.4.2 8042/10042 8 Stabil-TRAK™ Solenoid Valves There are five Stabil-TRAK™ solenoid valves installed in the Stabil-TRAK™ manifold, attached to the stabilizer cylinder above the left side of the rear axle. 9 If a solenoid valve is suspected of malfunctioning, disconnect the coil wiring lead and test the coil for proper resistance (7-9 ohms) and for proper voltage from the harness (12 VDC). Replace the solenoid coil if open or shorted to ground.
Stabil-TRAK™ System and Boom Interlock System 10.4.3 Logic Wiring Harness (10054 Only) The Model 10054 uses an additional logic wiring harness, that includes all wiring, fuses and relays needed for the operation of the boom interlock, Stabil-TRAK™ and outrigger systems. The logic harness has a fuse panel (1) that is attached to the fuse panel (2) from cab harness.
Stabil-TRAK™ System and Boom Interlock System 4. The fuse block relays (3 through 10) are located in the fuse block and is mounted behind the right side console access panel (15). To gain access, remove the screws (16) that secure the right side panel in place. 17 86 87 18 87A 30 85 MN1820 87A 30 16 15 87 OH2430 5. Remove the suspect relay from the fuse panel. 6.
Stabil-TRAK™ System and Boom Interlock System 10.4.5 b. Removal Outrigger Pressure Switches (10054 Only) a. Testing If after checking the electrical system, a pressure switch is suspect, test the switch as follows: 1. Park the vehicle on a firm, level surface. Level the vehicle, ground the attachment, place the travel select lever in the (N) NEUTRAL position, place the neutral lock lever in the (N) NEUTRAL LOCK position and engage the parking brake switch. 2.
Stabil-TRAK™ System and Boom Interlock System 4. Place an Accident Prevention Tag on both the ignition key switch and steering wheel, stating that the vehicle should not be operated. (Refer to Section 1.5, “Accident Prevention Tags.”) WARNING: Hot hydraulic fluid can cause severe burns. Wait for hydraulic fluid to cool before servicing any hydraulic component. 5. Unlock and open the rear door. Allow the engine, transmission and hydraulic fluid to cool. 6.
Stabil-TRAK™ System and Boom Interlock System 10.5 BOOM EXTEND INTERLOCK SYSTEM DESCRIPTION Note: The boom interlock system is used only on the Model 10054. The boom extend interlock system is designed to provide additional stability, allowing the boom to be extended to its maximum limits. The appropriate owners/operators manual contains boom extend interlock basic information.
Stabil-TRAK™ System and Boom Interlock System 10.6 BOOM EXTEND INTERLOCK SYSTEM OPERATION (10054 ONLY) The ultimate purpose of this system is to add an extra measure of stability, allowing the boom to be extended to its maximum limits. The boom extend interlock system may operate in one of the two following modes: 10.6.
Stabil-TRAK™ System and Boom Interlock System 10.7 STABIL-TRAK™ ELECTRICAL CIRCUIT OPERATION AND TROUBLESHOOTING (8042/10042) IMPORTANT: Before using the 8042 and 10042 StabilTRAK System Troubleshooting chart and diagrams, complete the Section 10.8, “Stabil-TRAK™ System Test,” on page 10.20, to determine what part of the system is not functioning properly.
Model 8042, 10042, 10054 Legacy + Rev.
10.
Model 8042, 10042, 10054 Legacy + Rev.
Stabil-TRAK™ System and Boom Interlock System 10.8 STABIL-TRAK™ SYSTEM TEST IMPORTANT: The operator must know that the Stabil-TRAK™ system is active and functioning properly. To test the function of the Stabil-TRAK™ system, read the Stabil-TRAK™ System Test instructions and follow Steps 1 through 9 of Section 10.8.2, “Stabil-TRAK™ System Test Procedures.” 10.8.
Stabil-TRAK™ System and Boom Interlock System Stabil-TRAK System Test Procedures Step 1 a. Place the vehicle on a level surface with 0° sway. b. Have the boom fully retracted and horizontal. c. Place an 8" (203 mm) wood or cement block in front of the front left tire. d. Enter the vehicle. e. Fasten the seat belt. FREE PIVOT MODE f. Turn the key to the RUN position. g. Check to be sure the Stabil-TRAK™ light is OFF. OH2500 Step 2 a. Start the engine. b. Turn the parking brake switch OFF. c.
Stabil-TRAK™ System and Boom Interlock System Stabil-TRAK System Test Procedures Step 7 a. With the parking brake switch ON, move the travel select lever to the (N) NEUTRAL position. b. Lower the boom to exactly 45°. c. Frame sway the vehicle no more than 5° to the left. LOCKED MODE d. Frame sway the vehicle back to 0°. e. Frame sway the vehicle no more than 5° to the right. Note: Observe that frame sway will be slower than normal during this test. f.
Stabil-TRAK™ System and Boom Interlock System 10.9 STABIL-TRAK™ BOOM INTERLOCK ELECTRICAL CIRCUIT OPERATION AND TROUBLESHOOTING (10054, 13198-17984) IMPORTANT: Before using the 10054 Stabil-TRAK System Troubleshooting chart and diagrams, complete Section 10.8, “Stabil-TRAK™ System Test,” on page 10.20 and Section 10.11, “Boom/Outrigger Interlock System Test,” on page 10.34, to determine what part of the system is not functioning properly.
Stabil-TRAK™ System and Boom Interlock System Note: If an outrigger is raised or a pressure switch is defective, boom on the 10054 will not extend beyond the 42 Series extension limit. Definitions: Boom Retracted = Less than 42 Series extension limit DE = De-energized E = Energized C = Closed O = Open 42 Series Exte ns io PB = Park Brake n Boom Extended = Boom at 42 Series extension limit or greater (See Figure at Right). H G F E D it m C Li B A MH6110 10.24 Model 8042, 10042, 10054 Legacy Rev.
Model 8042, 10042, 10054 Legacy + Rev. 10/03 C O = = = = = = = R N F Secondary Function Manifold PB A Park Brake Solenoids 2K2 51D 51B 1 2 3 4 5 6 7 8 B+ 113 104 102A 112 101 105 103 150 153 45 45 30 87 111 112 113B Park Brake Disengage Relay E 111 113 113 113A To Back-Up Alarm 112 70C Back-Up Alarm Relay 24A To Horn 10A 31 87 24 30 87A 2BB 85 86 70B 45A 7.
10.
Model 8042, 10042, 10054 Legacy + Rev. 10/03 C O = = = = = = = REVERSE 6 7 1 2 3 4 5 LEGEND SHIFTER ZF TRANSMISSION R N F 8 9 GEAR GEAR GEAR GEAR B+ B+ FORWARD REVERSE NEUTRAL 107B 45A2 To Fuel Shutoff 3C 45 113 104 102A 112 101 105 103 150 153 7.5A 45 30 87 112 113B Park Brake Disengage Relay DE 111 111 113 113 70C 112 112A 113A To Back-Up Alarm Back-Up Alarm Relay 24A To Horn 10A 31 87 24 30 87A 2BB 85 86 70B 45A 7.
Stabil-TRAK™ System and Boom Interlock System This Page Intentionally Left Blank 10.28 Model 8042, 10042, 10054 Legacy Rev.
Stabil-TRAK™ System and Boom Interlock System 10.10 STABIL-TRAK™ BOOM INTERLOCK ELECTRICAL CIRCUIT OPERATION AND TROUBLESHOOTING (10054, 17985-19987 AND 0160002332 & AFTER) IMPORTANT: Before using the 10054 Stabil-TRAK System Troubleshooting chart and diagrams, complete Section 10.8, “Stabil-TRAK™ System Test,” on page 10.20 and Section 10.11, “Boom/Outrigger Interlock System Test,” on page 10.34, to determine what part of the system is not functioning properly.
Stabil-TRAK™ System and Boom Interlock System Boom Retracted = Less than 42 Series extension limit Boom Extended = Boom at 42 Series extension limit or greater (See Figure at Right). PB = Park Brake DE = De-energized O = Open 42 Series Exte ns io C = Closed n E = Energized H G F E D it m C Li B A MH6110 10.30 Model 8042, 10042, 10054 Legacy Rev.
Model 8042, 10042, 10054 Legacy + Rev.
10.
Model 8042, 10042, 10054 Legacy + Rev.
Stabil-TRAK™ System and Boom Interlock System 10.11 BOOM/OUTRIGGER INTERLOCK SYSTEM TEST Before performing the following Boom/Outrigger Interlock System Test, perform Section 10.8, “Stabil-TRAK™ System Test,” to determine if the Stabil-TRAK™ system is working properly. If necessary, repair the StabilTRAK™ system before testing the boom/outrigger interlock system. WARNING: DO NOT operate this vehicle unless you are in the seat with the seat belt fastened around you.
Stabil-TRAK™ System and Boom Interlock System Boom/Outrigger Interlock System Test Procedures BOOM EXTEND MODE 2 BOOM EXTEND MODE 1 Step 1 a. Place the vehicle with no load on a hard, level surface such as blacktop or concrete. b. Fasten your seat belt. Step 2 a. With the outriggers in the raised position and the boom in a horizontal position, extend the boom. The boom should extend until the letter “E” appears and then should STOP.
Stabil-TRAK™ System and Boom Interlock System 10.12 STABIL-TRAK™ HYDRAULIC CIRCUIT OPERATION AND TROUBLESHOOTING The hydraulic operation and troubleshooting information for each of these modes will be described on the following pages. The function of the Stabil-TRAK™ system varies under different operating conditions. The basic modes include the FREE PIVOT MODE, SLOW PIVOT MODE and LOCKED MODE. 10.12.
Stabil-TRAK™ System and Boom Interlock System 10.12.2 Stabil-TRAK™ Cylinder Oil Flow In the FREE PIVOT and SLOW PIVOT MODES, oil flow from the stabilizer cylinder will be in one of two directions; ROD OIL OUT or BASE OIL OUT. ROD OIL OUT flow will occur when the left side of the rear axle is lower than the right side (left wheel in a pothole, or the right wheel passing over an obstruction), causing the cylinder to extend (1).
Stabil-TRAK™ System and Boom Interlock System P IN T T AUX MAIN CONTROL VALVE FRAME SWAY ATTACH TILT FRAME SWAY CYLINDER LFT/LWR Hydraulic Circuit Operation - FREE PIVOT Mode, Rod Oil Out EXT/RET 10.12.3 BYPASS CHECK VALVE TM STABIL-TRAK CYLINDER G3 G2 FTR 3 V DE 2A .030 DIA. C 2B 12B E 4B 4A 12A DE DE E .060 DIA. .060 DIA.
Stabil-TRAK™ System and Boom Interlock System 10.12.4 Hydraulic Troubleshooting - FREE PIVOT Mode, Rod Oil Out Conditions: • Ignition ON, engine running • Boom angle is below 40° When frame swaying right, left front tire comes off the ground Check electrical wiring. • Travel select lever in (F) FORWARD or (R) REVERSE • Park brake OFF • Service brake DISENGAGED Not OK Refer to Section 10.7, “Stabil-TRAK™ Electrical Circuit Operation and Troubleshooting (8042/10042),” Section 10.
Stabil-TRAK™ System and Boom Interlock System P IN T T AUX MAIN CONTROL VALVE FRAME SWAY ATTACH TILT FRAME SWAY CYLINDER LFT/LWR Hydraulic Circuit Operation - FREE PIVOT Mode, Base Oil Out EXT/RET 10.12.5 BYPASS CHECK VALVE TM STABIL-TRAK CYLINDER G3 G2 FTR V 3 DE 2A .030 DIA. C 2B 12B E 4B 4A 12A DE DE E .060 DIA. .060 DIA.
Stabil-TRAK™ System and Boom Interlock System 10.12.6 Hydraulic Troubleshooting - FREE PIVOT Mode, Base Oil Out Conditions: • Ignition ON, engine running With boom below 40°, when frame swaying to the left, the right front tire comes off the ground. Not OK Refer to Section 10.7, “Stabil-TRAK™ Electrical Circuit Operation and Troubleshooting (8042/10042),” Section 10.9, “Stabil-TRAK™ Boom Interlock Electrical Circuit Operation and Troubleshooting (10054, 13198-17984),” or Section 10.
Stabil-TRAK™ System and Boom Interlock System P IN T T STABIL-TRAK CYLINDER AUX MAIN CONTROL VALVE FRAME SWAY ATTACH TILT FRAME SWAY CYLINDER LFT/LWR Hydraulic Circuit Operation - SLOW PIVOT Mode, Rod Oil Out EXT/RET 10.12.7 BYPASS CHECK VALVE TM G3 G2 FTR 3 V DE 2A .030 DIA. C 2B PSG G PLT P PS 1 12B 4B 4A 12A DE E E DE 2 .060 DIA. 3 5 .060 DIA.
Stabil-TRAK™ System and Boom Interlock System 10.12.8 Hydraulic Troubleshooting - SLOW PIVOT Mode, Rod Oil Out Conditions: • Ignition ON, engine running • Boom angle is above 40° • Travel select lever in (F) FORWARD or (R) REVERSE While traveling, ride feels spongy (riding on 3 wheels). Check electrical wiring. Not OK Refer to Section 10.7, “Stabil-TRAK™ Electrical Circuit Operation and Troubleshooting (8042/10042),” Section 10.
Stabil-TRAK™ System and Boom Interlock System P IN T T STABIL-TRAK CYLINDER AUX MAIN CONTROL VALVE FRAME SWAY ATTACH TILT FRAME SWAY CYLINDER LFT/LWR Hydraulic Circuit Operation - SLOW PIVOT Mode, Base Oil Out EXT/RET 10.12.9 BYPASS CHECK VALVE TM G3 G2 FTR V 3 DE 2A .030 DIA. C 2B PSG G PLT P PS 1 12B 4B 4A 12A DE E E DE .060 DIA. 4 5 2 .060 DIA.
Stabil-TRAK™ System and Boom Interlock System 10.12.10 Hydraulic Troubleshooting - SLOW PIVOT Mode, Base Oil Out Conditions: • Ignition ON, engine running • Boom angle is above 40° • Travel select lever in (F) FORWARD or (R) REVERSE • Park brake OFF • Service brake DISENGAGED While traveling, ride feels spongy (riding on 3 wheels). Check electrical wiring. Not OK Refer to Section 10.7, “Stabil-TRAK™ Electrical Circuit Operation and Troubleshooting (8042/10042),” Section 10.
Stabil-TRAK™ System and Boom Interlock System 10.12.11 Hydraulic Circuit Operation LOCKED MODE a. Conditions: • Boom angle is above 40° • Park brake ON, or service brake ENGAGED, or travel select lever in (N) NEUTRAL b. Operation: When the conditions are met, solenoids 4A, 4B, 12A and 12B are de-energized and solenoid 3 is energized. In the LOCKED MODE, oil is prevented from flowing through the Stabil-TRAK™ manifold due to check valves in solenoid-operated valves 4A (1), 4B (2), 12A (3), and 12B (4). 10.
Stabil-TRAK™ System and Boom Interlock System 10.12.13 Hydraulic Troubleshooting - LOCKED MODE, Will Not Frame Sway Right P IN T 11 STABIL-TRAK CYLINDER 10 TM G3 G2 FTR 7 6 3 2A E C 5 2B 12B 4B 4A 12A DE DE DE DE 2 .060 DIA. HYDRAULIC RESERVOIR PB SECONDARY FUNCTION MANIFOLD 1 4 T PLT PS 3 PBG PSG G P 8 .060 DIA. BYPASS CHECK VALVE V .030 DIA.
Stabil-TRAK™ System and Boom Interlock System 10.12.14 Hydraulic Circuit Operation LOCKED MODE, Frame Sway Left a. Conditions • Boom angle is above 40° • Park brake ON, or service brake ENGAGED, or travel select lever in (N) NEUTRAL b. Operation When the joystick control is placed in the frame sway mode, cables activate the frame sway valve in the main control valve assembly.
Stabil-TRAK™ System and Boom Interlock System STABIL-TRAK CYLINDER 4 3 TM G3 G2 FTR 7 8 3 2A E C 2B 4B 4A 12A DE DE DE DE 9 10 PLT PS 12B 12 PSG G P 11 .060 DIA. .060 DIA. BYPASS CHECK VALVE V .030 DIA. 5 6 P IN T 2 AUX T FRAME SWAY ATTACH TILT MAIN CONTROL VALVE 1 LFT/LWR FRAME SWAY CYLINDER EXT/RET 10.12.
Stabil-TRAK™ System and Boom Interlock System 10.13 BOOM EXTEND SYSTEM HYDRAULIC CIRCUIT OPERATION AND TROUBLESHOOTING The function of the boom extend interlock system varies under different operating conditions. The basic modes include the EXTEND INTERLOCK MODE and OUTRIGGER INTERLOCK MODE. The hydraulic operation and troubleshooting information for each of these modes will be described on the following pages. 10.13.
Stabil-TRAK™ System and Boom Interlock System This Page Intentionally Left Blank Model 8042, 10042, 10054 Legacy Rev. 10/03 10.
Stabil-TRAK™ System and Boom Interlock System 10.13.2 valve (5), causing it to close. This prevents oil flow to the extend/retract cylinder (6), preventing the boom from being extended further. Hydraulic Circuit Operation Extend Interlock Mode Operation: When the outriggers in the RAISED position, the outrigger pressure switches (1 and 2) are open. As the boom is extended past the boom extend switch, the switch opens, de-energizing the boom lockout solenoid (3).
Stabil-TRAK™ System and Boom Interlock System BOOM LOCKOUT VALVE EXTEND/RETRACT CYLINDER 8 5 C1 6 7 3 T 4 DE V1 P T OUTRIGGER VALVE AUX FRAME SWAY ATTACH TILT P BYPASS CHECK VALVE IN T LFT/LWR EXT/RET 9 T MAIN CONTROL VALVE HYDRAULIC RESERVOIR LS B2 A2 E A1 R 10 B1 E R PUMP HYDRAULIC OIL COOLER BYPASS CHECK VALVE 2 1 R.H. Pressure Return Suction Load Sense OUTRIGGER CYLINDER L.H.
Stabil-TRAK™ System and Boom Interlock System 10.13.4 As the boom extends past the boom extend switch, the switch opens. The boom extend lockout solenoid valve (3), remains energized by the circuit provided by the outrigger pressure switches. Hydraulic Circuit Operation Outrigger Interlock Mode Operation: When the outriggers are lowered onto firm terrain, pressure within the outrigger cylinders close the outrigger pressure switches (1 and 2), energizing the boom extend lockout solenoid valve (3). 10.13.
Stabil-TRAK™ System and Boom Interlock System BOOM LOCKOUT VALVE EXTEND/RETRACT CYLINDER 5 4 C1 E 3 T V1 P T MAIN CONTROL VALVE AUX FRAME SWAY ATTACH TILT P IN T LFT/LWR T EXT/RET OUTRIGGER VALVE BYPASS CHECK VALVE HYDRAULIC RESERVOIR LS B2 A2 E A1 R B1 E R PUMP HYDRAULIC OIL COOLER BYPASS CHECK VALVE 1 2 R.H. Pressure Return Suction Load Sense OUTRIGGER CYLINDER L.H. SOLENOID COIL STATE DE DE-ENERGIZED E Model 8042, 10042, 10054 Legacy ENERGIZED MH3201 Rev. 10/03 10.
Stabil-TRAK™ System and Boom Interlock System This Page Intentionally Left Blank 10.56 Model 8042, 10042, 10054 Legacy Rev.
Section 11 Index A Access Panels and Covers Replacement.............................4.34 Accident Prevention Tags ...............1.4 After Service Startup and Checks Axle Service ..............................2.36 Boom Service............................2.36 Brake System Service...............2.35 Electrical Component Service ...................................2.34 Engine Service..........................2.36 Fuel System Service .................2.35 Hydraulic Component Service .............................
Index D Dash Panel Troubleshooting Engine Alternator Charging Warning Indicator................. 9.186 Engine Coolant Temperature Warning Indicator................. 9.187 Engine Oil Pressure Warning Indicator................. 9.191 Fuel Level Indicator ................ 9.192 Hourmeter Indicator ................ 9.193 Hydraulic Oil Temperature Warning Indicator................. 9.189 Park Brake Warning Indicator ............................... 9.190 Stabil-TRAK Indicator ............. 9.
Index General Anti-Corrosion............. 2.30 Hydraulic System ..................... 2.29 Lubrication Points (Grease Fittings).................... 2.29 Paint ......................................... 2.32 Thread Locking Compound ...... 2.32 Transmission ............................ 2.28 Wheel Ends .............................. 2.28 Fuel System Diesel Fuel ................. 7A.18, 7B.22 Fuel Filter ................... 7A.24, 7B.28 Fuel Injectors.............. 7A.24, 7B.28 Fuel Level Sender and Gauge......
Index O Open Cab Components Auxiliary Hydraulic Joystick Assembly Replacement ........4.17 Brake Pedal and Valve .............4.10 Electrical Components..............4.19 Joystick Assembly Replacement..........................4.14 Miscellaneous Cab Components ..........................4.20 Seat/Seat Belt............................. 4.4 Steering Column/Valve Replacement............................ 4.6 Steering Wheel, Column and Shifter ...................................... 4.5 Throttle Pedal Replacement .
Index T Torques Bolts and Nuts ............................ 2.5 Fasteners ................................... 2.5 Training Mechanics as Operators... 1.3 Transmission Gear Selection Troubleshooting Forward First Gear Circuit ..... 9.157, 9.158, 9.159, 9.160 Forward Fourth Gear Circuit.. 9.169, 9.170, 9.171, 9.172 Forward Second Gear Circuit 9.161, 9.162, 9.163, 9.164 Forward Third Gear Circuit.... 9.165, 9.166, 9.167, 9.168 Reverse First Gear Circuit..... 9.173, 9.174, 9.175, 9.
Index 11.6 Model 8042, 10042, 10054 Legacy Rev.
Accident Prevention Tags Accident Prevention Tags 8990403 Origin 5/00 OS2180
Accident Prevention Tags 8990403 Origin 5/00 OS2180
