Sky Trak MANUAL PDF

Models: 8042, 10042, 10054
S/N 13198 thru 19987 and 0160002332 thru 0160029592
OH2462
SERVICE MANUAL
8990396 C
Printed in U.S.A. 02/07
SECTION CONTENTS
Section Subject Page
Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.2 Owners/Operators Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.3 Training Mechanics as Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.4 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.5 Accident Prevention Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.6 Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.7 Emergency Exit Rear Window (Enclosed Cabs Only) . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
1.8 Hazard/Emergency Information Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.1 8042, 10042, 10054 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.3 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2.4 Metric Conversion Factors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
2.6 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
2.7 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
2.8 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
2.9 Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
2.10 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
2.11 Pressure Testing and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
2.12 After Service Startup and Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
Section 3
Boom ........................................................... 3.1
3.1 Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.2 Boom System - Three Section Booms (8042 and 10042). . . . . . . . . . . . . . . . . . . . . . . 3.4
3.3 Boom Assembly Maintenance (8042 and 10042) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
3.4 Boom Chains - Three Section Boom (8042 and 10042) . . . . . . . . . . . . . . . . . . . . . . . . 3.46
3.5 Boom System - Four Section Boom (10054). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.64
3.6 Boom Assembly Maintenance (10054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.64
3.7 Boom Chains - Four Section Boom (10054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.121
3.8 Hose Carrier Assembly - Four Section Boom (10054) . . . . . . . . . . . . . . . . . . . . . . . . . 3.151
3.9 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.168
3.10 Quick Attach Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.171
3.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.174
 2003 JLG Industries, Inc.

Model 8042, 10042, 10054 Legacy Rev. 10/03 i
Section 4
Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.1 Operator’s Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
4.2 Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.3 Open Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
4.4 Enclosed Cab (Optional) Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
4.5 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27
4.6 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.31
4.7 Access Panels and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.34
Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3 Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.4 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29
Section 6
Transmission: ZF 4 WG-98 TC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
6.2 Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.3 Transmission Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.4 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.5 Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
6.6 Transmission Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
6.7 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
6.8 Towing a Disabled Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
6.9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
Section 7A
Engine: Cummins 4BT3.9 and 4BTA3.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.1
7A.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.4
7A.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.6
7A.3 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.8
7A.4 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.8
7A.5 Standard Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.8
7A.6 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.9
7A.7 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.17
7A.8 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.18
7A.9 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.26
7A.10 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.28
7A.11 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.29
7A.12 Engine Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.38
7A.13 Engine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.42
7A.14 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.43
ii Model 8042, 10042, 10054 Legacy Rev. 10/03

Section 7B
Engine: Cummins QSB4.5T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.1
7B.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.4
7B.2 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.6
7B.3 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.8
7B.4 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.8
7B.5 Standard Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.8
7B.6 Engine Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.9
7B.7 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.20
7B.8 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.22
7B.9 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.31
7B.10 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.32
7B.11 Engine Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.33
7B.12 Engine Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.42
7B.13 Engine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.45
7B.14 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.46
Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
8.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
8.4 Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
8.5 Hoses, Tube Lines, Fittings, Etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
8.6 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
8.7 Hydraulic System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
8.8 Hydraulic Circuits and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
8.9 Four-Wheel Steer Indexing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.67
8.10 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.68
8.11 Hydraulic System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.70
8.12 Valves and Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.76
8.13 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.110
Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
9.2 Service Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
9.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
9.4 Effective Ground Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
9.5 Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
9.6 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
9.7 Electrical System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
9.8 Transmission Gear Selection Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.156
9.9 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.195
9.10 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.199
9.11 Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.208
9.12 Window Wiper/Washer (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.213
9.13 Cab Heater and Fan (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.219
9.14 Switches and Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.220
Model 8042, 10042, 10054 Legacy Rev. 10/03 iii

Section 10
Stabil-TRAK™ System and Boom Interlock System . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
10.1 Stabil-TRAK™ System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
10.2 Boom Extend Interlock System Component Terminology (10054 Only) . . . . . . . . . . . . 10.4
10.3 Stabil-TRAK™ Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
10.4 Stabil-TRAK™ Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
10.5 Boom Extend Interlock System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
10.6 Boom Extend Interlock System Operation (10054 Only) . . . . . . . . . . . . . . . . . . . . . . . . 10.15
10.7 Stabil-TRAK™ Electrical Circuit Operation and Troubleshooting (8042/10042) . . . . . . 10.16
10.8 Stabil-TRAK™ System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
10.9 Stabil-TRAK™ Boom Interlock Electrical Circuit Operation and Troubleshooting
(10054, 13198-17984) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
10.10 Stabil-TRAK™ Boom Interlock Electrical Circuit Operation and Troubleshooting
(10054, 17985-19987 and 0160002332 & After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
10.11 Boom/Outrigger Interlock System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
10.12 Stabil-TRAK™ Hydraulic Circuit Operation and Troubleshooting. . . . . . . . . . . . . . . . . . 10.36
10.13 Boom Extend System Hydraulic Circuit Operation and Troubleshooting . . . . . . . . . . . . 10.50
Section 11
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
Accident Prevention Tags
iv Model 8042, 10042, 10054 Legacy Rev. 10/03

Section 1
Safety Practices
Contents
PARAGRAPH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.2 Owners/Operators Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.3 Training Mechanics as Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.4 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.4.1 Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.4.2 Hazard Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.5 Accident Prevention Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
1.7 Emergency Exit Rear Window (Enclosed Cabs Only) . . . . . . . . . . . . . . . . . . . . . 1.6
1.8 Hazard/Emergency Information Decal Locations. . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Model 8042, 10042, 10054 Legacy Rev. 10/03 1.1

Safety Practices
1.1 INTRODUCTION Many factors contribute to unsafe conditions: carelessness,

fatigue, overload, inattentiveness, unfamiliarity, even
JLG Industries, Inc. (hereafter, JLG) products meet all drugs and alcohol, among others. Although equipment
applicable industry safety standards. JLG actively damage can usually be repaired in a brief period of time,
promotes safe practices in the use and maintenance of its death and irreparable injury are permanent. For optimal
products through training programs, instructional safety, encourage everyone to think, and to act, safely.
manuals and the pro-active efforts of all employees Appropriate service methods and proper repair
involved in engineering, design, manufacture, marketing procedures are essential for the safety of the individual
and service. doing the work, for the safety of the operator, and for the
This manual is designed to provide service technicians safe, reliable operation of the vehicle. All references to
with complete information on the maintenance and repair the right side, left side, front and rear are given from the
of the Sky Trak 8042, 10042 and 10054 Legacy operator’s seat looking in a forward direction.
Telescopic Material Handler. Provisions for supplementary information are made by
Particular effort has been made to produce a manual to JLG in the form of Service Bulletins, Service Campaigns,
serve as a reference handbook for the experienced Service Training Schools, the JLG website, other
service technician, but also provides essential step-by- literature, and through updates to the manual itself.
step procedures for the professional development of the Comments and suggestions for improvement are
less experienced person. Remember, even the best welcome and encouraged.
manual in the world is no substitute for an appropriate All information, illustrations and specifications contained
education, skill development that comes through in this manual are based on the latest product information
experience alone, safety, wise and judicious available at the time of publication approval. JLG
discernment, and ultimately, proper performance of reserves the right to make changes and improvements to
service procedures. its products, and to discontinue the manufacture of any
This service manual provides general directions for product, at its discretion at any time without public notice
accomplishing service and repair procedures with tested, or obligation.
effective techniques. Following the procedures in this
manual will help assure safety and equipment reliability. 1.2 OWNERS/OPERATORS MANUAL
Read, understand and follow the information in this
manual, and obey all locally approved safety practices, The vehicle must be driven and operated as a consequence
procedures, rules, codes, regulations and laws. Prior to of, or when performing, service, maintenance and test
performing any maintenance on the vehicle, consider all procedures. The service technician must, therefore,
factors, circumstances and conditions which can have an thoroughly read, understand, and follow the Sky Trak
effect upon the safety of personnel and equipment, and 8042, 10042 and 10054 Legacy Telescopic Material
take appropriate action to ensure the safety of all Handler Owners/Operators Manual.
involved. An owners/operators manual is supplied with each vehicle
These instructions cannot cover all details or variations in and must be kept in the owners/operators manual
the equipment, procedures, or processes described, nor holder (1).
provide directions for meeting every possible contingency
during operation, maintenance, or testing. When additional
information is desired to satisfy a situation not covered 1
sufficiently, consult the local Sky Trak distributor or the JLG
Service Department at 1-877-554-5438 or
1-717-485-6657.
MH0770
In the event that the owners/operators manual is missing,

consult the local Sky Trak distributor or the JLG Service
Department before proceeding.
1.2 Model 8042, 10042, 10054 Legacy Rev. 10/03

Safety Practices
1.3 TRAINING MECHANICS AS 1.4 SAFETY INFORMATION

OPERATORS
The following information provides general safety
Because it is necessary to move the vehicle to service or instructions, including examples of hazard statements
maintain the vehicle, it is necessary that all mechanics with signal words, notification of hazards, methods to
are OSHA trained and certified as operators. A mechanic help avoid hazards, and the consequences of failing to
trained in the proper operation of the vehicle can better follow the safety information. To avoid possible death or
determine whether all functions are operating correctly. injury, carefully read and follow all safety messages. Fully
understand the potential causes of death and injury.
At the time of original purchase, the purchaser of this
vehicle was instructed by the seller on its proper use. In the event of an accident, know where to obtain medical
When this vehicle is to be serviced or maintained by assistance and how to use a first-aid kit and fire
someone other than the purchaser, make certain that the extinguisher/fire suppression system. Keep emergency
mechanic is trained, in accordance with the OSHA telephone numbers (fire department, ambulance, rescue
regulations listed in the NOTICE below, and reads and squad/paramedics, police department, etc.) nearby. If
understands the SKY TRAK Model 8042, 10042 and working alone, check with another person routinely to
10054 Legacy Telescopic Material Handler Owners/ help assure personal safety.
Operators Manual before operating or maintaining the The information in this manual does not replace any other
vehicle. safety rules or proper judgement. Governmental
NOTICE: Under OSHA rules, it is the responsibility of the authorities and employers also have their own sets of
employer to provide operator training. Successful rules, codes, regulations and laws. Before starting work
completion and certification of Safety Training for Rough at a site, check with the supervisor or safety coordinator
Terrain Forklifts is required. Operator Training Kits are and ask about the safety policy. Learn the safety
available by calling the Ken Cook Company at requirements in effect before operating, maintaining,
414-466-6060. An order form for these kits is available testing or servicing the vehicle. Safety depends on
through our website, http://www.jlg.com. following safety requirements.
In addition, make sure that the mechanic has completed
a walk-around inspection of the vehicle, is familiar with all
1.4.1 Safety Alert Symbol
decals and/or decal plates on the vehicle, and has The exclamation mark within a triangle is the Safety Alert
demonstrated the correct use of all controls. Symbol. This symbol is used to indicate a potential
personal injury hazard only. The symbol will not be
used to indicate property-damage-only hazards.
MC0700
This symbol means “Attention! Become Alert! Your

Safety is Involved!” The symbol is used to attract
attention to safety hazards found on the vehicle safety
decals and throughout this manual.
Model 8042, 10042, 10054 Legacy Rev. 10/03 1.3

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.
Explanations of the types of hazard statements are as
follows:
DANGER:
The signal word “DANGER” indicates an imminently
hazardous situation which, if not avoided, will result in
death or serious injury.
MC0690
WARNING: Before beginning any maintenance or service, place an

Accident Prevention Tag (1) on both the starter key
The signal word “WARNING” indicates a potentially switch (2) and the steering wheel (3), stating that the
hazardous situation which, if not avoided, could result in vehicle should not be operated. Actual Accident
death or serious injury. Prevention Tags, which can be punched out and used,
are included as the last page in this manual. Retain these
Accident Prevention Tags for reuse at a later date.
CAUTION:
3
The signal word “CAUTION” indicates a potentially
hazardous situation which, if not avoided, may result in
minor or moderate injury.
CAUTION: DANGER
The signal word “CAUTION,” used without the safety DAN

GER
1
alert symbol, indicates a potentially hazardous situation
which, if not avoided, may result in property damage.
For safe maintenance of the vehicle, read, understand
2
and follow all DANGER, WARNING and CAUTION
information. OH1720
1.4 Model 8042, 10042, 10054 Legacy Rev. 10/03

Safety Practices
1.6 SAFETY INSTRUCTIONS 1.6.2 Equipment Hazards

OWNERS/OPERATORS MANUAL: Before operating the
Following are general safety statements to consider before
vehicle, carefully read, understand and follow the owners/
performing maintenance procedures on a vehicle.
operators manual.
Additional statements related to specific tasks and
procedures are located throughout this manual and are OPERATIONAL PROTECTION: Before operating the
listed prior to any work instructions to provide safety vehicle, or returning it for operational use, check that the
information before the potential of a hazard occurs. Operator’s Protective Structure is intact, undamaged,
unmodified and secure.
For all safety messages, carefully read, understand and
follow the instructions before proceeding. LIFTING OF EQUIPMENT: Before using any lifting
equipment (chains, slings, brackets, hooks, etc.), verify
1.6.1 Personal Hazards that it is of the proper capacity, in good working order, and
is properly attached.
HAIR and CLOTHING: DO NOT wear loose clothing or
jewelry. Tie up or restrain hair. Wear the correct safety NEVER stand or otherwise become positioned under a
equipment for the job (including, but not limited to: hard suspended load or under raised equipment. The load or
hat; safety shoes; safety glasses, goggles, or face shield; equipment could fall or tip.
heavy gloves; hearing protection; reflective clothing; wet- DO NOT use a hoist, jack or jack stands only to support
weather gear; respirator or filter mask). equipment. Always support equipment with the proper
EYE PROTECTION: Always wear appropriate eye capacity blocks or stands properly rated for the load. A
protection when chiseling, grinding, sanding, welding, hoist or jack failure can allow the equipment to tip or fall.
painting, repairing hydraulic systems, or checking, testing COMPRESSED AIR: Before and during the use of
or charging the battery. compressed air, wear eye protection and advise all other
BREATHING PROTECTION: Wear respiratory protection personnel in the work area that compressed air is about
when grinding or painting. to be used.
HEARING PROTECTION: Always wear hearing protection HAND TOOLS: Always use the proper tool for the job;
in a high noise area. keep tools clean and in good working order, and use
special service tools only as recommended.
FOOT PROTECTION: Wear protective footwear with
reinforced toe caps and slip-resistant soles.
LIFTING: NEVER lift a heavy object without the help of at
least one assistant or a suitable sling and hoist.
Model 8042, 10042, 10054 Legacy Rev. 10/03 1.5

Safety Practices
1.6.3 General Hazards FLUID PRESSURE: Before loosening any hydraulic or

diesel fuel component, hose or tube, turn the engine
SOLVENTS: Only use approved solvents, and solvents
OFF. Wear heavy, protective gloves and eye protection.
that are known to be safe for use.
NEVER check for leaks using any part of your body; use
HOUSEKEEPING: Keep the work area and operator’s a piece of cardboard or wood instead. If injured, seek
cab clean, and remove all hazards (debris, oil, tools, etc.). medical attention immediately. Diesel fluid leaking under
FIRST AID: Immediately clean, dress and report all injuries pressure can explode. Hydraulic fluid and diesel fuel
(cuts, abrasions, burns, etc.), no matter how minor the leaking under pressure can penetrate the skin, cause
injury may seem. Know the location of a First Aid Kit, and infection, gangrene and other serious personal injury.
know how to use it. Relieve all pressure before disconnecting any
CLEANLINESS: Wear eye protection, and clean all component, part, line or hose. Slowly loosen parts and
components with a high-pressure or steam cleaner allow release of residual pressure before removing any
before attempting service. part or component. Before starting the engine or applying
pressure, use components, parts, hoses and pipes that
When removing hydraulic components, plug hose ends
are in good condition, connected properly and are
and connections to prevent excess leakage and
tightened to the proper torque. Capture fluid in an
contamination. Place a suitable catch basin beneath the
appropriate container and dispose of in accordance with
vehicle to capture fluid run-off.
prevailing environmental regulations.
1.6.4 Operational Hazards PRESSURE TESTING: When conducting any test, only
use test equipment that is correctly calibrated and in good
OPERATIONAL CONSIDERATIONS: Before operating condition. Use the correct equipment in the proper
the vehicle, carefully read, understand and follow the manner, and make changes or repairs as indicated by the
Owners/Operators manual. test procedure to achieve the desired result.
ENGINE: Stop the engine before performing any service. LEAVING VEHICLE: Lower the attachment to the ground
DANGEROUS START: Place Accident Prevention Tags before leaving the vehicle.
on the ignition key switch and the steering wheel before TIRE PRESSURE: Always keep tires inflated to the
attempting to perform any service or maintenance. proper pressure to help prevent dangerous travel and
Disconnect battery leads. Place a warning sign on a load-handling situations. DO NOT over-inflate tires.
vehicle that is dangerous to start, if leaving vehicle
unattended.
1.7 EMERGENCY EXIT REAR WINDOW
VENTILATION: Avoid prolonged engine operation in (ENCLOSED CABS ONLY)
enclosed areas without adequate ventilation.
RADIATOR CAP: Always wear steam-resistant, heat The rear window in the enclosed cab can be used as an
protective gloves when opening the radiator cap. Cover emergency exit by removing the latch pin (1) located on
the cap with a clean, thick cloth and turn slowly to the first the window latch (2). Once the latch pin is removed, the
stop to relieve pressure. window is free to swing open.
SOFT SURFACES AND SLOPES: NEVER work on a
vehicle that is parked on a soft surface or slope (inclined 1 1.
2.
ground or hills). The vehicle must be on a hard level 3.
surface, with the wheels blocked when performing any

1
service. Obtain assistance, block all wheels, and add

9
7
9
0
1
4
2
supports if necessary before beginning any work.
SUPPORTS AND STRAPS: Install safe, stable supports, OH1730
slings or straps beneath or around a component or

structural member before beginning any work.
1.6 Model 8042, 10042, 10054 Legacy Rev. 10/03

Safety Practices
This Page Intentionally Left Blank
Model 8042, 10042, 10054 Legacy Rev. 10/03 1.7

Safety Practices
1.8 HAZARD/EMERGENCY clean.

INFORMATION DECAL LOCATIONS If a replacement decal is needed, refer to the Owners/
Operators manual or parts manual for the latest part
Locations of vehicle hazard and other emergency number and ordering information, or, contact JLG Parts
information decals are shown on this page and the Department directly at:
following pages. As part of routine maintenance, check
that ALL hazard and emergency information decals on
1-717-485-6472
the vehicle are present and readable. Keep all decals
Model 8042 (S/N 13198 thru 18990)
3 5
1. Read operator's manual

3. Allow no riders. DANGER
before operating.
AVOID CRUSHING
if vehicle tips.
2. Fasten seat belt.

4. Use a compliant
work platform to lift
Jumping can
result in death
6
or lower personnel. or serious
injury.
DO NOT JUMP.
Brace yourself.
Stay in cab.
2 Keep seat belt on.
4
WARNING
AVOID
CRUSHING,
falling off
vehicle can
cause death
or serious
injury
1
Allow no riders OH17431
1. 4110188 No Riders Warning (1)

2. 4110188 Vehicle Rollaway Warning (1)
3. 4108991 Electrocution Danger (1)
4. 7139071 Load Chart Booklet (1)
5. 4110137 Tipover Danger (1)
6. 4110187 Do Not Jump Danger (1)
7. 4110188 Safety Instructions (1)
1.8 Model 8042, 10042, 10054 Legacy Rev. 10/03

Safety Practices
12
13
10 11
MH4180
8. 4110184 Moving Parts Warning (2)

9. 4110172 Explosive Gases Warning (1)
10. 4110389 Carrying Personnel Warning (1)
11. 4107442 Boom Extend Letters (1)
12. 4105262 Boom Angle Indicator (1)
13. 4109791 Emergency Exit - Enclosed Cab Only (1)
Model 8042, 10042, 10054 Legacy Rev. 10/03 1.9

Safety Practices
Model 10042 (S/N 13198 thru 19030)
3 5

before operating. 3. Allow no riders. DANGER
AVOID CRUSHING
if vehicle tips.
4. Use a compliant
2. Fasten seat belt. work platform to lift
or lower personnel.
Jumping can
result in death
or serious
6
injury.
DO NOT JUMP.
Brace yourself.
Stay in cab.
Keep seat belt on.
2
WARNING 4
AVOID
CRUSHING,
falling off
vehicle can
cause death
or serious
injury
DANGER
VEHICLE TIPOVER, outriggers ALWAYS fully lower outriggers
over holes or voids can cause onto solid surfaces.
1
Allow no riders
4107971
OH2733
8

8. 4107971 Outrigger Over Holes Danger (1)
1.10 Model 8042, 10042, 10054 Legacy Rev. 10/03

Safety Practices
10
13
14
11 12
MH4190

Model 8042, 10042, 10054 Legacy Rev. 10/03 1.11

Safety Practices
Model 10054 (S/N 13198 thru 19079)
3 5

AVOID CRUSHING
if vehicle tips.
4. Use a compliant Jumping can
2. Fasten seat belt. work platform to lift result in death
injury.
2 DO NOT JUMP.
Brace yourself.
Stay in cab.
Keep seat belt on.
4
WARNING
AVOID
CRUSHING,
falling off
vehicle can
cause death
1 or serious
injury
DANGER
Allow no riders
4107971
OH2733

1.12 Model 8042, 10042, 10054 Legacy Rev. 10/03

Safety Practices
10
13
14
11 12
MH4190

Model 8042, 10042, 10054 Legacy Rev. 10/03 1.13

Safety Practices
Model 8042 (S/N 18991 & After)
3 5
6
2
3. Allow no riders. DANGER
before operating.
AVOID CRUSHING
if vehicle tips.
2. Fasten seat belt. work platform to lift result in death
injury.
DO NOT JUMP.
Brace yourself.
Stay in cab.
Keep seat belt on.
WARNING
AVOID
4
CRUSHING,
falling off
vehicle can
cause death
or serious
injury
1
Allow no riders OH17431

1.14 Model 8042, 10042, 10054 Legacy Rev. 10/03

Safety Practices
14
12 13
8
OH2894
10
11

14. 4110460 Ether Starting Warning (2)
Model 8042, 10042, 10054 Legacy Rev. 10/03 1.15

Safety Practices
Model 10042 (S/N 19031 & After)
5
3

AVOID CRUSHING
if vehicle tips.
2 or lower personnel.
result in death
or serious
injury.
DO NOT JUMP.
Brace yourself.
Stay in cab.
Keep seat belt on.
6
WARNING
AVOID 4
CRUSHING,
falling off
vehicle can
cause death
or serious
injury
1 DANGER
Allow no riders
4107971
OH2733

1.16 Model 8042, 10042, 10054 Legacy Rev. 10/03

Safety Practices
15
10
9
13
14
11
12
OH1754

Model 8042, 10042, 10054 Legacy Rev. 10/03 1.17

Safety Practices
Model 10054 (S/N 19080 & After)
5
3

AVOID CRUSHING
if vehicle tips.
2 or lower personnel.
result in death
or serious
injury.
DO NOT JUMP.
Brace yourself.
Stay in cab.
Keep seat belt on.
6
WARNING
AVOID 4
CRUSHING,
falling off
vehicle can
cause death
or serious
injury
1 DANGER
Allow no riders
4107971
OH2733

1.18 Model 8042, 10042, 10054 Legacy Rev. 10/03

Safety Practices
15
10
9
13
14
11
12
OH1754

Model 8042, 10042, 10054 Legacy Rev. 10/03 1.19

Safety Practices
1.20 Model 8042, 10042, 10054 Legacy Rev. 10/03

Section 2
General Information and Specifications
Contents

2.1 8042, 10042, 10054 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.2.1 Service Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.2.2 The Owners/Operators Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.2.3 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . 2.4
2.2.4 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.3 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2.3.1 Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2.3.2 Bolts and Nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2.3.3 SAE Flat Face O-Ring Seal Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . 2.5
2.3.4 SAE 37° Flare Hydraulic Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
2.4 Metric Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.4.1 Approximate American to Metric Conversions . . . . . . . . . . . . . . . . . . . . . 2.9
2.4.2 Approximate Metric to American Conversions . . . . . . . . . . . . . . . . . . . . . 2.10
2.5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
2.5.1 Vehicle Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
2.5.2 Vehicle Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
2.5.3 Attachment Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
2.5.4 Performance Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
2.5.5 Hydraulic Cylinder Performance Specifications . . . . . . . . . . . . . . . . . . . . 2.20
2.5.6 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
2.5.7 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
2.5.8 Fluid and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
2.5.9 Hydraulic Relief Valve Settings (8042 and 10042) . . . . . . . . . . . . . . . . . . 2.25
2.5.10 Hydraulic Relief Valve Settings (10054) . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
2.5.11 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
2.5.12 Miscellaneous Specifications (All Models) . . . . . . . . . . . . . . . . . . . . . . . . 2.27
2.5.13 Tamper Proofing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
2.5.14 Fork Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
Model 8042, 10042, 10054 Legacy Rev. 10/03 2.1

2.6 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

2.6.1 Axle (Differential Housing). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
2.6.2 Axle Wheel Ends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
2.6.3 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
2.6.4 Lubrication Points (Grease Fittings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
2.6.5 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
2.6.6 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
2.6.7 Drive Shaft Splines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
2.6.8 General Anti-Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
2.6.9 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
2.6.10 Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
2.6.11 Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
2.7 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
2.8 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
2.9 Hoses and Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
2.9.1 Hose and Tube Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
2.9.2 Hose and Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
2.10 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
2.10.1 Bearing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
2.10.2 Bearing Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
2.10.3 Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
2.11 Pressure Testing and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
2.12 After Service Startup and Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
2.12.1 After Service Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
2.12.2 After Electrical Component Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
2.12.3 After Hydraulic Component Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35
2.12.4 After Brake System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35
2.12.5 After Fuel System Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35
2.12.6 After Transmission Service or Replacement . . . . . . . . . . . . . . . . . . . . . . . 2.35
2.12.7 After Tire and Wheel Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36
2.12.8 After Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36
2.12.9 After Boom Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36
2.12.10 After Axle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36
2.2 Model 8042, 10042, 10054 Legacy Rev. 10/03

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.
Model 10054 Shown
Stabil-TRAK™
Cylinder (On
Left Side Of Boom Assembly
Frame)
Carriage Assembly
Lift/Lower
Cylinders
Slave
Cylinders
Extend/Retract
Cylinder
Right Side Engine Operator’s Protective

Compartment Door Structure
(Left Side Not Shown)
Frame Sway Cylinder
MH3031
Hydraulic Oil Reservoir/Fuel Tank Outrigger Assembly

(10042 and 10054 Only)
Model 8042, 10042, 10054 Legacy Rev. 10/03 2.3

2.2 INTRODUCTION The vehicle serial number plate (1) is located at the front
of the vehicle, on the frame sway cylinder upright.
2.2.1 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. Following them will assure reliability.
There are many variations in procedures, techniques,
tools and parts for servicing vehicles, as well as work 1
skills. This manual cannot possibly anticipate all such
variations and provide advice or cautions for each one.
Accordingly, anyone who intends to depart from the
instructions in this Manual must first consider personal
safety and then vehicle integrity. OH0280
IMPORTANT: JLG recommends the use of IMPORTANT: The replacement of any part on this
environmentally sound waste storage and disposal vehicle with any other than an JLG authorized
practices. NEVER drain fluids on the ground or into a replacement part can adversely affect the performance,
sewer or catch basin. Use suitable collection containers, durability, or safety of the vehicle, and will void the
then store and/or dispose of waste products in an warranty. JLG disclaims liability for any claims or
approved and safe manner. Check and obey all Federal, damages, whether regarding property damage, personal
State and/or Local regulations regarding waste storage, injury or death arising out of the use of unauthorized
disposal and recycling. replacement parts.
A warranty registration form must be filled out by the Sky
2.2.2 The Owners/Operators Manual
Trak distributor, signed by the purchaser and returned to
The Owners/Operators Manual provides information you JLG when the vehicle is sold and/or put into use.
need to properly operate and maintain this vehicle.
Registration activates the warranty period and helps to
IMPORTANT: Before you operate this vehicle, read the assure that warranty claims are promptly processed. To
manual completely and carefully, so that you will guarantee full warranty service, verify that the distributor
understand the safety instructions and the operation of has returned the business reply card of the warranty
the controls and safety equipment. You must comply registration form to JLG.
with all Danger, Warning and Caution notices. They are
for your benefit. 2.2.4 Disclaimer
JLG reserves the right to make changes to and to add
2.2.3 Replacement Parts and Warranty
improvements upon its product at any time, without public
Information
notice or obligation. JLG also reserves the right to
For reference when ordering replacement parts or making discontinue manufacturing any product at its discretion at
service inquiries about the vehicle, the vehicle serial any time.
number is required to help assure the provision of correct
parts and information. Before ordering parts or initiating
service inquiries, make note of the serial number.
2.4 Model 8042, 10042, 10054 Legacy Rev. 10/03

2.3 TORQUES 3. Apply clean petroleum based oil to the male thread.
4. Place the flat surface of the female connector (2) in
2.3.1 Fasteners full contact with the o-ring (4) in the male connector.
All fasteners (nuts, bolts, washers, etc.) are equal to SAE 5. Finger tighten the nut (5) onto the fitting.
Grade 5 (PC8.8) and are plated, unless otherwise specified. 6. Complete the joint by tightening the nut to the torque
specified in the table. For hoses and swivel fittings
2.3.2 Bolts and Nuts use a second wrench to keep the female connector
Unless otherwise specified, the following values apply for from moving during tightening.
Grade 5 (PC8.8) nuts and bolts:
O-Ring Boss Fittings To
Size Torque Size Torque Flat Face Fittings
SAE Size Torque lb-ft (Nm)
Inch lb-ft Nm mm Nm lb-ft
4 19 ± 5 (26 ± 7)
1/4 9 12 6,0 10 7 6 35 ± 5 (47 ± 7)
5/16 17 24 8,0 25 18 8 52 ± 7 (70 ± 10)
10 83 ± 17 (112 ± 23)
3/8 31 42 10,0 50 37
12 120 ± 20 (163 ± 27)
7/16 50 68 -- -- -- 16 165± 35 (224 ± 47)
1/2 75 102 12,0 80 59 20 215 ± 65 (292 ± 88)
24 252 ± 77 (342 ± 104)
9/16 110 150 14,0 130 95
5/8 150 203 16,0 200 146
3/4 250 340 20,0 360 263
7/8 380 515 22,0 510 372
1.0 585 793 24,0 650 475
4 2
2.3.3 SAE Flat Face O-Ring Seal Hydraulic
Fittings
3
a. Assembly Procedure 5
Improper assembly of this type of joint will result in
leaking joints. Under tightening will result in the joint MA10,0800
loosening during normal usage. Foreign material on
either seal surfaces will cause damage to one or both
mating parts when the joint is tightened resulting in a
leaking joint. The absences of the fitting o-ring will cause
the joint to leak.
1. Inspect both the male (2) and female (3) sealing
surfaces for burrs, scratches, dents, other damage,
or foreign material. If any damage is found on either
surface, the part is to be rejected as unusable. Clean
off any foreign material from the sealing surfaces
before assembly.
2. Inspect the male fitting for the presence of the seal
o-ring (4). Inspect the o-ring for any sign of damage.
If the o-ring is missing or damaged replace it.
Model 8042, 10042, 10054 Legacy Rev. 10/03 2.5
b. Straight O-Ring Boss Fittings To c. Adjustable (Angle) O-Ring Boss Fittings To

O-Ring Boss Ports O-Ring Boss Ports
Improper assembly of this joint will result in leaking joints. Improper assembly of this joint will result in a leaking joint.
Under tightening of the fitting will result in the fitting Failure to position the locknut properly will result in
loosening during normal operation and the joint leaking. damage to the o-ring. Under tightening of the fitting will
Damaging the o-ring during assembly will result in result in the fitting loosening during normal operation and
immediate joint leakage. the joint leaking. Damaging the o-ring during assembly
1. Inspect components to ensure that male and female will result in immediate joint leakage.
port threads and sealing surfaces are free of burrs, 1. Inspect components to ensure that male and female
nicks, or scratches, or any foreign material. If any port threads and sealing surfaces are free of burrs,
damage is found the bad part must not be used. nicks, or scratches, or any foreign material. If any
Clean any foreign material from the mating parts damage is found the bad part must not be used.
before assembly. Clean any foreign material from the mating parts
2. Lubricate the o-ring and male thread with a clean before assembly.
petroleum based lubricant.
3. Screw the fitting into the port. A C
1
4. Torque the fitting to the values found in table.
3
2
O-Ring Boss Fittings To
O-Ring Boss Ports
B D
4 15 ± 1 (20 ± 1)
6 25 ± 1 (34 ± 1)
8 55 ± 5 (75 ± 7)
4
10 76 ± 5 (103 ± 7)
MA10,0820
12 130 ± 5 (176 ± 7)
16 210± 10 (285 ± 14) 2. Back off the locknut as far as possible (1). Make sure
20 245 ± 35 (332 ± 47) the back-up washer is not loose. If the back-up
24 315 ± 45 (427 ± 61) washer is loose the fitting must be rejected.
3. Lubricate the o-ring (2) and male thread with clean
petroleum based lubricant.
4. Screw the fitting into the port as far as possible by
hand (B & C).
5. To align the tube end (3) of the fitting to accept the
mating tube or hose, unscrew the fitting as required
but not more than one turn.
6. Using two wrenches, hold the fitting in the desired
position and tighten the locknut (4) to the appropriate
torque value listed in the table in Section 2.3.3, b.
“Straight O-Ring Boss Fittings To
O-Ring Boss Ports.”
2.6 Model 8042, 10042, 10054 Legacy Rev. 10/03

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 1.5 to 2 turns in a
clockwise direction when viewed from the pipe
thread end. With any sealant the first 1 to 2 threads
should be left uncovered to avoid system
contamination.
3. Screw the connector into the port finger tight.
4. Wrench tighten the fitting to the appropriate Turns
From Finger Tight (TFFT) from following table. Make
sure that angle fittings are aligned with the mating
tube or hose within the listed number of turns. Never
back off (loosen) pipe thread connectors to achieve
alignment.
Pipe Fittings To Pipe Ports

Pipe Thread Size Turns From Finger Tight
(T.F.F.T.)
1/8" 2-3
1/4" 2-3
3/8" 2-3
1/2" 2-3
3/4" 2-3
1" 1-1/2 - 2-1/2
1-1/4" 1-1/2 - 2-1/2
1-1/2" 1-1/2 - 2-1/2
2" 1-1/2 - 2-1/2
Model 8042, 10042, 10054 Legacy Rev. 10/03 2.7

2.3.4 SAE 37° Flare Hydraulic Fittings 4. Using a permanent type ink marker, make a mark (2)
on one of the flats on the nut and continue it onto the
a. Assembly Procedure static fitting or port.
Follow these steps when tightening hose ends, tube ends 5. Complete the joint by wrench tightening (3) the nut
and fitting swivel ends onto fitting male end connections the number of flats (4) specified in the table for the
size and type of fitting. This assembly procedure is
Improper assembly of this type of joint will result in
referred to as Flats From Finger Tight (FFFT).
leaking joints. Over tightening can result in cracking of the
female swivel seat or deformation of the male fitting 6. A less desirable tightening method is nut torque.
tapered seat. Under tightening will result in the joint First follow steps 1 & 2. Apply clean petroleum
loosening during normal usage. Foreign material on based oil to the male thread. Finger tighten the nut
either seal surfaces will cause damage to one or both onto the fitting. Torque the nut to the value listed in
mating parts when the joint is tightened, resulting in a the table.
leaking joint.
1. Inspect both the male and female sealing cone Hose Ends, Tube Ends and Fitting Swivel Ends
surfaces for burrs, scratches, dents, other damage, To Fitting Male Ends
or foreign material. If any damage is found on the
SAE Tube Swivel Nut Torque lb-ft (Nm)
seat the part is to be rejected as unusable. Clean off
Size Conn. or w/Oiled
any foreign material from the sealing surfaces before
(FFFT) Hose Conn. Threads
assembly.
(FFFT)
2. Align the mating parts and check to see that the flare 4 2 2 16 ± 3 (22 ± 4)
seats properly on the nose of the fitting.
5 2 2 19 ± 4 (26 ± 5)
3. Finger tighten the nut onto the fitting. If necessary a
6 1-1/2 1-1/4 25 ± 5 (34 ± 7)
wrench may be used to snug the nut against the
fitting (30 lb-in maximum torque). This is considered 8 1-1/2 1 49 ± 10 (66 ± 14)
the “finger tight” (1) condition. 10 1-1/4 1 74 ± 11 (100 ± 15)
12 1-1/4 1 103 ± 15 (140 ± 20)
14 1 1 121 ± 18 (164 ± 24)
1 3 16 1 1 135 ± 35 (183 ± 47)
20 1 1 166 ± 33 (225 ± 45)
24 1 1 210 ± 40 (285 ± 54)
32 1 1 314 ± 54 (426 ± 73)
2
4 Straight & Adjustable O-Ring

Boss Fittings To
O-Ring Boss Ports
MA10,0810
4 14 ± 1 (19 ± 1)
6 23 ± 1 (31 ± 1)
8 41 ± 1 (56 ± 1)
10 45 ± 3 (61 ± 4)
12 72 ± 3 (98 ± 4)
16 118± 5 (160 ± 7)
20 154 ± 7 (209 ± 9)
24 162 ± 8 (220 ± 11)
2.8 Model 8042, 10042, 10054 Legacy Rev. 10/03

2.4 METRIC CONVERSION FACTORS When this is known Multiply by To find

VOLUME
2.4.1 Approximate American to Teaspoons (tsp) 5 Milliliters (ml)
Metric Conversions Tablespoons (Tbsp) 15 Milliliters (ml)
When this is known Multiply by To find Cubic inches (in ) 3
16 Milliliters (ml)
TORQUE Fluid ounces (fl oz) 30 Milliliters (ml)
(moment of force)
Cups (c) 0.24 Liters
Pound/feet (lb-ft) 1.356 Newton meters (Nm)
Pints (pt) 0.47 Liters
Pound/inches (lb-in) 0.113 Newton meters (Nm)
Quarts (qt) 0.95 Liters
POWER
Gallons (gal) 3.8 Liters
Horsepower (hp) 745.7 Watts 3
Cubic feet (ft ) 0.03 Cubic meters (m3)
SPEED (velocity)
Cubic yards (yd3) 0.76 Cubic meters (m3)
Miles per hour (mph) 1.609 Kilometers per hour
(km/hr; kph) AIR PRESSURE
LENGTH (distance) Pounds per

square inch (psi) 6.895 Kilopascals (kPa)
Inches (in) 25.4 Millimeters (mm)
HYDRAULIC PRESSURE
Inches (in) 2.5 Centimeters (cm)
Pounds per
Feet (ft) 30.5 Centimeters (cm) square inch (psi) 0.069 Bar
Feet (ft) 0.305 Meters (m) TEMPERATURE (exact)
Yards (yd) 0.9 Meters (m) To determine degrees Celsius (° C), subtract 32, then
Miles (mi) 1.6 Kilometers (km) multiply by 0.56; (° F -32) x 0.56 = ° C.
AREA
Square inches (in2) 6.5 Square centimeters (cm2)
Square feet (ft2) 0.09 Square meters (m2)
Square yards (yd2) 0.8 Square meters (m2)
Square miles (mi2) 2.6 Square kilometers (km2)
Acres 0.4 Hectares (ha)
MASS (weight)
Ounces (oz) 28.3 Grams (g)
Pounds (lb) 0.4536 Kilograms (kg)
Short tons (2000 lb) 0.9 Metric ton (t)
Model 8042, 10042, 10054 Legacy Rev. 10/03 2.9

2.4.2 Approximate Metric to When this is known Multiply by To find

American Conversions AREA
When this is known Multiply by To find Square centimeters
TORQUE (cm2) 0,4 Square inches (in2)
(moment of force) Square meters (m2) 1,1 Square yards (yd2)
Newton meters (Nm) 0,738 Pounds/feet (lb-ft) Square kilometers
Newton meters (Nm) 8,85 Pounds/inches (lb-in) (km2) 0,6 Square miles (mi2)
POWER Hectares (10000 m2) 2,5 Acres
Watts 0,0013 Horsepower (hp) MASS (weight)
SPEED (velocity) Grams (g) 0,035 Ounces (oz)
Kilometers per Kilograms (kg) 2,2 Pounds (lb)
hour (km/hr; kph) 0,621 Miles per hour (mph) Metric ton
LENGTH (distance) (1000 kg) (t) 1,1 Short tons
Millimeters (mm) 0,0394 Inches (in) VOLUME
Centimeters (cm) 0,394 Inches (in) Milliliters (ml) 0,03 Fluid ounces (fl oz)
Meters (m) 3,281 Feet (ft) Milliliters (ml) 0,06 Cubic inches (in3)
Meters (m) 1,1 Yards (yd) Liters 2,1 Pints (pt)
Kilometers (km) 0,621 Miles (mi) Liters 1,06 Quarts (qt)
Liters 0,26 Gallons (gal)
3) Cubic feet (ft3)
Cubic meters (m 35
Cubic meters (m3) 1,3 Cubic yards (yd3)
AIR PRESSURE
Kilopascals (kPa) 0,145 Pounds per square
inch (psi)
HYDRAULIC PRESSURE
Bar 14,5 Pounds per square
inch (psi)
TEMPERATURE (exact)
To determine degrees Fahrenheit (° F), multiply degrees
Celsius (° C) by 1.8, then add 32; (° C x 1.8) + 32 = ° F.
2.10 Model 8042, 10042, 10054 Legacy Rev. 10/03

Model 8042, 10042, 10054 Legacy Rev. 10/03 2.11

2.5 SPECIFICATIONS
2.5.1 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" (4.021 mm)
(I) Maximum Lift Height, Boom Extended 41' 11" (12,8 m)
(J) Maximum Lift Height, Boom Retracted 21' 6" (6,5 m)
(K) Maximum Below Grade Depth, Boom Extended 3' 8" (1.105 mm)
(L) Maximum Reach, from Front of Front Tires 26' 8" (8,1 m)
(M) Maximum Reach at Maximum Lift Angle, 58.0" (1,7 m)
Boom Extended
(N) Maximum Reach at Maximum Lift Angle, -36.5" (-927 mm)
Boom Retracted
(O) Maximum Reach at Minimum Lift Angle, 25' 7" (7,8 m)
Boom Extended
(P) Maximum Boom Lift Angle 68.5°
(Q) Minimum Boom Lift Angle -8.0°
(R) Angle of Departure 26°
Attachment Tilt Angle:
(S) At Minimum Boom Angle - UP 11.9°
(T) At Minimum Boom Angle - DOWN -102.0°
(U) At Maximum Boom Angle - UP 88.4°
(V) At Maximum Boom Angle - DOWN -25.5°
Frame Sway Angle (Not Shown):
Right 10.0°
Left 10.0°
2.12 Model 8042, 10042, 10054 Legacy Rev. 10/03

UM
I
J
N
0.0 Q P
C
S
R F
24.0" D
K A
T
L O
B E
H
G
MH07802
Model 8042, 10042, 10054 Legacy Rev. 10/03 2.13

b. Model 10042 (With Standard 12-ply, 17.5-25

Tires)
Description
(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" (4.323 mm)
(J) Maximum Lift Height, Boom Extended 42' 1.5" (12,8 m)
(K) Maximum Lift Height, Boom Retracted 23' 3" (7,1 m)
(L) Maximum Below Grade Depth, Boom Extended 3' 2" (965 mm)
(M) Maximum Reach, from Front of Front Tires 26' 6" (8,1 m)
(N) Maximum Reach at Maximum Lift Angle, 56.3" (1.430 mm)
Boom Extended
(O) Maximum Reach at Maximum Lift Angle, -29.2" (-742 mm)
Boom Retracted
(P) Maximum Reach at Minimum Lift Angle, 25' 4" (7.7 m)
Boom Extended
(Q) Maximum Boom Lift Angle 68.5°
(R) Minimum Boom Lift Angle -8.0°
(S) Angle of Approach 25.1°
(T) Angle of Departure 26°
(U) At Minimum Boom Angle - UP 11.9°
(V) At Minimum Boom Angle - DOWN -102.0°
(W) At Maximum Boom Angle - UP 88.4°
(X) At Maximum Boom Angle - DOWN -25.5°
Right 10.0°
Left 10.0°
2.14 Model 8042, 10042, 10054 Legacy Rev. 10/03

WN
J
K
O
0.0 R Q
D
U S
T G
24.0" E
L A
V
M P
C B F
I
H
MH07902
Model 8042, 10042, 10054 Legacy Rev. 10/03 2.15

c. Model 10054 (With Standard 12-Ply, 17.5-25

Tires)
Description
(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" (4.323 mm)
(J) Maximum Lift Height, Boom Extended 53' 2" (16,2 m)
(K) Maximum Lift Height, Boom Retracted 22' 11" (6,9 m)
(L) Maximum Below Grade Depth, Boom Extended 4' 11" (1.499 mm)
(M) Maximum Reach, from Front of Front Tires 38' 9" (11,8 m)
(N) Maximum Reach at Maximum Lift Angle, 113" (2.870 mm)
Boom Extended
(O) Maximum Reach at Maximum Lift Angle, -30.8" (-782 mm)
Boom Retracted
(P) Maximum Reach at Minimum Lift Angle, 37' 6" (11.43 m)
Boom Extended
(Q) Maximum Boom Lift Angle 68.5°
(R) Minimum Boom Lift Angle -8.0°
(S) Angle of Approach 25.1°
(T) Angle of Departure 26°
(U) At Minimum Boom Angle - UP 11.9°
(V) At Minimum Boom Angle - DOWN -102.0°
(W) At Maximum Boom Angle - UP 88.4°
(X) At Maximum Boom Angle - DOWN -25.5°
Right 10.0°
Left 10.0°
2.16 Model 8042, 10042, 10054 Legacy Rev. 10/03

W
N
J
X
Q
0.0 R
U D
S
G
E T
A
24.0"
L
X
M
P
CBF
I
H
MH08002
Model 8042, 10042, 10054 Legacy Rev. 10/03 2.17

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" (1.219 mm) pallet forks,
full fuel tank, and standard bias ply tires [no hydrofill]):
Open Cab:
Front Axle 8,344 lb (3.785 kg) 9,317 lb (4.226 kg) 10,325 lb (4.683 kg)
Rear Axle 17,021 lb (7.720 kg) 17,006 lb (7.714 kg) 16,998 lb (7.710 kg)
Total (Open Cab) 25,365 lb (11.505 kg) 26,323 lb (11.940 kg) 27,323 lb (12.393 kg)
Enclosed Cab:
Front Axle 8,442 lb (3.829 kg) 9,414 lb (4.270 kg) 10,423 lb (4.728 kg)
Rear Axle 17,123 lb (7.767 kg) 17,109 lb (7.759 kg) 17,100 lb (7.756 kg)
Total (Enclosed Cab) 25,565 lb (11.596 kg) 26,523 lb (12.031 kg) 27,523 lb (12.484 kg)
2.18 Model 8042, 10042, 10054 Legacy Rev. 10/03

2.5.3 Attachment Weights

Note: Attachments listed below are for all models, except where specified.
Std 48" Carriage with Shaft 456 lb (205 kg)

48" Side Tilt Carriage with Shaft and Cylinders 687 lb (312 kg)
52" Swing Carriage with Shaft and Cylinders 950 lb (428 kg)
72" Swing Carriage with Shaft and Cylinders 1,135 lb (511kg)
Bucket, 1.125 yd3 (0,860 m3) 760 lb (345 kg)
Broom, 8 ft (2,4 m) 1,100 lb (499 kg)
Pallet Forks (8042 only) 278 lb (127 kg)
2" x 4" x 48" (5 x 10 x 122 cm), quantity: 2
Pallet Forks (10042 and 10054) 312 lb (141 kg)
2.25" x 4" x 48" (5,7 x 10 x 122 cm), quantity: 2
Block Forks 2" x 2" x 48" (5 x 5 x 122 cm), quantity: 6 480 lb (218 kg)
Lumber Forks, 1.75" x 7" x 60" (4 x 18 x 152 cm), 466 lb (211 kg)
quantity: 2
12 ft Truss Boom (8042 only) 470 lb (213 kg)
15 ft Truss Boom (10042 and 10054) 525 lb (238 kg)
Auger Drive Unit 285 lb (129 kg)
Auger Mounting Frame 180 lb (82 kg)
Auger (Various Sizes Available) Varies
Auger Extension (Various Sizes Available) Varies
Model 8042, 10042, 10054 Legacy Rev. 10/03 2.19

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)
2.5.5 Hydraulic Cylinder Performance Specifications

Note: Vehicle with no load, engine at full throttle, hydraulic oil above 130° F (54° C) minimum, engine at operating
temperature.
Function Approximate Times, in Seconds

8042 10042 10054
Boom Extend Less than 19.0 Less than 19.0 Less than 19.0
Boom Retract Less than 17.0 Less than 17.0 Less than 17.0
Boom Lift Retracted Less than 17.5 Less than 17.5 Less than 17.5
Boom Lower Retracted Less than 15.5 Less than 15.5 Less than 15.5
Attachment Tilt - UP Less than 8.0 Less than 8.0 Less than 8.0
Attachment Tilt - DOWN Less than 11.0 Less than 11.0 Less than 11.0
Frame Sway Left to Right with Boom 5.5-12.0 5.5-12.0 3-6
Down
Frame Sway Left to Right with Boom 23.0-33.0 23.0-33.0 23.0-33.0
Above 40° and Emergency Brake
Engaged
Frame Sway Right to Left with Boom 4.0-8.0 4.0-8.0 4.0-8.0
Down
Frame Sway Right to Left with Boom 26.0-52.0 26.0-52.0 26.0-52.0
Above 40° and Emergency Brake
Engaged
Outrigger - Left or Right, UP or DOWN — 4.0-9.0 4.0-9.0
Outrigger - Left and Right, UP or DOWN — 4.0-10.0 4.0-10.0
2.20 Model 8042, 10042, 10054 Legacy Rev. 10/03

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 1,000 Cold Cranking Amps @ 0° F (-18° C)
Engine)
Reserve Capacity (Cummins QSB4.5T Engine) 850 Cold Cranking Amps (Each Battery)
Group/Series (Cummins 4BT3.9 & 4BTA3.9 Engine) C31XH
Group/Series (Cummins QSB4.5T Engine) Series 27
Alternator 12V, 95 Amps
Fuses - Standard Blade Style:
7.5 Amps Light Switch Relay, Transmission, Outriggers (10042
and 10054), Boom/Outrigger Interlock (10054 Only)
ECM Indicator Light (Cummins QSB4.5T Engine Only),
ECM System Fuses (Cummins QSB4.5T Engine Only)
10 Amps Instrument Cluster, Steer Select Switch, Stabil-TRAK
System, Washer/Wipers (Optional), ECM System Fuses
(Cummins QSB4.5T Engine Only)
15 Amps Horn/Heater
20 Amps Optional Lights
40 Amps Main, Optional Road/Work Lights
Fuses - Mega Bolt Down Style:
125 Amps Cold Start Grid Heater (Cummins QSB4.5T Engine
Only)
Model 8042, 10042, 10054 Legacy Rev. 10/03 2.21

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 Interlock (10054 Only) 12 Volt
Right Outrigger Lock (10054 Only) 12 Volt
Left Outrigger Lock (10054 Only) 12 Volt
2.22 Model 8042, 10042, 10054 Legacy Rev. 10/03

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 Cummins 4BTA3.9 Cummins 4BTA3.9
Turbo Aftercooled Turbo Aftercooled Turbo
Displacement 239 in3 (3,9 liters) 239 in3 (3,9 liters) 239 in3 (3,9 liters)
Low Idle 1050 ±50 rpm 1050 ±50 rpm 1050 ±50 rpm
High Idle 2750 ±100 rpm 2750 ±100 rpm 2750 ±100 rpm
Horsepower 110 HP @ 2500 rpm 116 HP @ 2500 rpm 116 HP @ 2500 rpm
Peak Torque 278 lb-ft @ 1500 rpm 300 lb-ft @ 1500 rpm 300 lb-ft @ 1500 rpm
Fuel Delivery Fuel Injection Fuel Injection Fuel Injection
Average Fuel Consumption, 2 gal/hr (1,67 Imp gal/ 2 gal/hr (1,67 Imp gal/ 2 gal/hr (1,67 Imp gal/
Depending on Load/Duty hr or 7,57 liters/hr) hr or 7,57 liters/hr) hr or 7,57 liters/hr)
Air Cleaner Dry Type, Dry Type, Dry Type,
Replaceable Primary Replaceable Primary Replaceable Primary
and Safety Elements and Safety Elements and Safety Elements
Model 8042 (S/N 18991 & After), 10042 (S/N 19031 & After) & 10054 (S/N 19080 & After)
Description 8042, 10042, 10054

Engine Make/Model Cummins QSB4.5T
Displacement 275 in3 (4,5 liters)
Low Idle 950 ±50 rpm
High Idle 2650 ±100 rpm
Horsepower 110 HP @ 2500 rpm
Peak Torque 305 lb-ft @ 1500 rpm
Fuel Delivery Fuel Injection
Average Fuel Consumption, 2 gal/hr (1,67 Imp gal/hr or 7,57 liters/hr)
Depending on Load/Duty
Air Cleaner Dry Type, Replaceable Primary and Safety Elements
Model 8042, 10042, 10054 Legacy Rev. 10/03 2.23

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 35.6 gal (135 liters)
Type of Fuel Above 32° F (0° C) Standard #2 Diesel (Refer to Section 2.6.6, “Engine.”)
Type of Fuel Below 32° F (0° C) 50/50 Mix of #1 and #2 Diesel Fuels
Cooling System:
Capacity w/o Heater 4.0 gal (15 liters)
(including 1.5 qt [1,4 liters] for overflow bottle)
Overflow Bottle Capacity 3.0 qt (2,8 liters)
Type of Fluid 50/50-mix of ethylene glycol and water
Transmission:
Capacity w/Filter Change 3.0 gal (11,8 liters)
Filter Capacity 1.5 qt (1,4 liters)
Type of Oil Universal Tractor Fluid
(Refer to Section 2.6.3, “Transmission.”)
Axle (Differential Housing):
Capacity Front Axle - 9.5 qt (9,0 liters)
Rear Axle - 10.6 qt (10,0 liters)
Type of Oil Universal Tractor Fluid. Refer to Section 2.6.1, “Axle
(Differential Housing).”
2.24 Model 8042, 10042, 10054 Legacy Rev. 10/03

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.”)
2.5.9 Hydraulic Relief Valve Settings (8042 and 10042)
Port Relief Attachment Tilt (Both Sides) 3,250 ±100 psi (224,0 ±6,9 bar)
Port Relief Auxiliary Hydraulics 3,250 ±100 psi (224,0 ±6,9 bar)
Pressure Reducing Relieving Valve, Stabilizer 75/150 psi (5,2/10,3 bar)
Pressure Reducing Valve, Park Brakes 500-600 psi (34,5-41,4 bar)
Pressure Reducing Valve, Steering 2,500 ±100 psi (172,4 ±6,9 bar)
Relief Valve, Park Brake 650/700 psi (44,8/48,3 bar)
Main Valve Back-up Relief 3,500 ±100 psi (241,3 ±6,9 bar)
Main Valve Unloader Relief at Valve Inlet 3,000 ±100 psi (206,8 ±6,9 bar)
Main Pump Standby Pressure at Pump Outlet 550-600 psi (34-41 bar)
Main Pump Compensator at Pump Outlet 3,300-3,400 psi (228-234 bar)
2.5.10 Hydraulic Relief Valve Settings (10054)
Port Relief Attachment Tilt (Both Sides) 3,250 ±100 psi (224,0 ±6,9 bar)
Pressure Reducing Relieving Valve, Stabilizer 200 ±25 psi (13.7 ±1.8 bar)
Pressure Reducing Valve 500-600 psi (34,5-41,4 bar)
Model 8042, 10042, 10054 Legacy Rev. 10/03 2.25

2.5.11 Tires
Description 8042 10042 10054

Wheel Lug Nut Torque 430-470 lb-ft 430-470 lb-ft 430-470 lb-ft
(583-637 Nm) (583-637 Nm) (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) — —
17.5R25 One Star Radial — 73 psi (503 kPa) 73 psi (503 kPa)
Foam Filled 13.00-24, 12 ply 775 lbs (351 Kg) — —
Tire Ballast (Minimum per Tire)
Foam Filled 17.5-25, 12 ply — 1,075 lbs (488 Kg) 1,075 lbs (488 Kg)
Tire Ballast (Minimum per Tire)
Tire Footprint Area (area is established under maximum tip load):
Vehicle with Rated Load 150 in2 (968 cm2) — —
13.00-24, 12-ply Tires @ 70 psi (483 kPa)
Vehicle with Rated Load & Optional 212 in2 (1368 cm2) — —
15.5-25, 12-ply Tires @ 70 psi (483 kPa)
Vehicle with Rated Load & Optional Rock 212 in2 (1368 cm2) — —
15.5-25, 12-ply Tires @ 70 psi (483 kPa)
Vehicle with Rated Load — 244 in2 (1.574 cm2) —
17.5-25, 12-ply Tires @ 60 psi (414 kPa)
Vehicle with Rated Load — — 244 in2 (1.574 cm2)
17.5-25, 12-ply Tires @ 60 psi (414 kPa)
Maximum Ground Pressure (max. ground pressure at tip = (machine weight + load) / (2 x footprint area):
Vehicle with Rated Load 111 psi (765 kPa) — —
13.00-24, 12-ply Tires @ 70 psi (483 kPa)
Vehicle with Rated Load & Optional 79 psi (545 kPa) — —
15.5-25, 12-ply Tires @ 70 psi (483 kPa)
Vehicle with Rated Load & Optional Rock 79 psi (545 kPa) — —
15.5-25, 12-ply Tires @ 70 psi (483 kPa)
Vehicle with Rated Load — 74 psi (510 kPa) —
17.5-25, 12-ply Tires @ 60 psi (414 kPa)
Vehicle with Rated Load — — 77 psi (531 kPa)
17.5-25, 12-ply Tires @ 60 psi (414 kPa)
2.26 Model 8042, 10042, 10054 Legacy Rev. 10/03

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) 24,500 lb (11.113 kg)
2.5.13 Tamper Proofing 2.5.14 Fork Ratings

A tamper-proof means is in place on the following All approved forks for this vehicle are marked with a
adjustable components prior to machine shipment. This maximum load capacity rating. This rating is stamped on
can either be tamper-proof paint or a steel tamper-proof the left edge of the fork (1), just below the fork pivot shaft
cap. DO NOT attempt to defeat, bypass or alter any (2). The rating is listed in U.S. pounds and based on a 24"
tamper-proof device. (610 mm) load center (3).
• Main Valve Port Relief Valves (5) Standard, or (7) This rating specifies the maximum load capacity that the
Auxiliary Hydraulics individual fork can safely carry at a maximum load center
• Steering Relief Valve (1) of 24" (610 mm).
• Attachment Tilt Cylinder Counterbalance Valve (1) Since forks are always used in multiples, the total rating
of any combination of forks is the sum of their rated
• Lift/Lower Cylinder Counterbalance Valves (2) capacities.
• Extend/Retract Cylinder Counterbalance Valve (1) Other than block forks, use all forks in matched pairs. Use
• Main System Relief Valve (1) block forks in matched sets.
• Parking Brake Relief (1)
• Pump Pressure Compensating Valve (1)
3
XXXX - 24
XXXX - 24
2
OU0131
Model 8042, 10042, 10054 Legacy Rev. 10/03 2.27

2.6 FLUIDS, LUBRICANTS AND DO NOT add additional friction modifier to factory-filled
CAPACITIES wheel ends. All wheel ends are factory-filled by the
manufacturer with oil. If a wheel end is drained for service, it
should be refilled with the gear oils listed.
2.6.1 Axle (Differential Housing)
Note: DO NOT use synthetic oil without the express
a. Axle Differential Housing Lubricants written consent of the manufacturer.
In general, use a Universal Tractor Fluid that meets the b. Axle Wheel End Capacity
following specifications:
The capacity listed below is for one wheel end
Nominal viscosity at 104° F (40° C)....................... 55 cSt
Axle wheel end (front axle)................... 1.7 qt (1,6 liters)
Minimum viscosity at 212° F (100° C) .................. 9.1 cSt
Axle wheel end (rear axle) ................... 1.3 qt (1,2 liters)
Pour point (Maximum) ..............................-32° F (-36° C)
Flash point (Minimum) ............................ 392° F (200° C) 2.6.3 Transmission
Minimum viscosity index............................................ 135
a. Transmission Lubricants
Products known to meet these requirements include:
• JOHN DEERE: JDM J20C (HY-GARD) In general, use a Universal Tractor Fluid that meets the
• FORD/NEW HOLLAND: ESN-M2C134-D
(Hydraulic Oil 134) Nominal viscosity at 10° F (40° C) ........................ 55 cSt
• MASSEY-FERGUSON: M-1141 Minimum viscosity at 212° F (100° C) .................. 9.1 cSt

(PERMANTRAN III) Pour point (Maximum).............................. -32° F (-36° C)
• CHEVRON: CHEVRON 1000 THF Flash point (Minimum).............................392° F (200° C)
Minimum viscosity index ............................................135
b. Axle Differential Housing Capacity
Axle differential housing (front axle) ........9.5 qt (9 liters)
• JOHN DEERE: JDM J20C (HY-GARD)
Axle differential housing (rear axle) .....10.6 qt (10 liters)
(Hydraulic Oil 134)
2.6.2 Axle Wheel Ends
• MASSEY-FERGUSON: M-1141
a. Axle Wheel End Lubricants (PERMANTRAN III)
In general, use a Universal Tractor Fluid that meets the • CHEVRON: CHEVRON 1000 THF
b. Transmission Capacity
Nominal viscosity at 104° F (40° C)....................... 55 cSt
Capacity w/filter change ...................... 3 gal (11,8 liters)
Minimum viscosity at 212° F (10° C) .................... 9.1 cSt
Filter ........................................................ 1 qt (0,9 liters)
Pour point (Maximum) ..............................-32° F (-36° C)
Flash point (Minimum) ............................ 392° F (200° C)
Minimum viscosity index............................................ 135
• JOHN DEERE: JDM J20C (HY-GARD)
(Hydraulic Oil 134)
• MASSEY-FERGUSON: M-1141
(PERMANTRAN III)
• CHEVRON: CHEVRON 1000 THF
2.28 Model 8042, 10042, 10054 Legacy Rev. 10/03

2.6.4 Lubrication Points (Grease Fittings) SAE 10W MOTOR OIL

• CASTROL/DEUSOL CRD
a. Lubricants
• ESSO ESSOLUBE D-3HP
When lubricating any component via the grease fittings,
use multi-purpose, lithium-based grease with EP • ESSO ESSOLUBE XD-3
additives that meets NLGI Grade-2 specifications. • CASTROL AGRICASTROL HDD
Products known to meet these requirements include: • SHELL RIMULA CT
• AMOCO AMOLITH EP2 • SHELL RIMULA X
• ARCO LITHOLINE EP2 • SHELL RIMULA TX
• BENZ MOLY-SERVICE EP2
Note: For -30° F to +70° F (-34° C to +21° C), 5W20
• CHEVRON DUROLITH EP2 motor oil with -50° F (-45° C) pour point can be substituted.
• CITGO H EP2 However, above 70° F (21° C), hydraulic system oil must
be changed to ISO-46 hydraulic oil or SAE 10W motor oil.
• GULF GULFCROWN EP2
• MOBILE MOBILUX EP2 b. Hydraulic System Capacity
• SHELL ALVANIA EP2 Model 8042:
• SUN PRESTIGE 742EP System Capacity ............................. 57.5 gal (218 liters)
• TEXACO MULTIFAX EP2 Reservoir Capacity to FULL Mark ... 32.2 gal (122 liters)
Note: Refer to the appropriate Owners/Operators Model 10042 and 10054:
manual for the maintenance schedule and checklist for
System Capacity ................................ 64 gal (242 liters)
lubrication intervals and grease fitting locations.
Reservoir Capacity to FULL Mark ... 32.2 gal (122 liters)
2.6.5 Hydraulic System
2.6.6 Engine
a. Hydraulic Fluids
a. Engine Fluids and Lubricants
The hydraulic system is factory-filled with ISO Grade 46
anti-wear hydraulic oil. When filling the hydraulic system, 1. Engine Oil:
use an anti-wear hydraulic oil meeting ISO Grade 46 with
-40° F (-40° C) pour point/ASTM viscosity SUS 215 at Diesel Engine Oil, SAE 15W40
100° F (38° C), or a 10W motor oil that meets the In general, use a premium-quality, 15W40 diesel engine
requirements of U.S. ordinance specification MIL-L-2104C. (motor) oil. Additives are not necessary. For most climates,
Products known to meet these requirements include: use 15W40 motor oil that at least meets the
manufacturers minimum recommended oil specifications
ISO-46 HYDRAULIC OIL as defined in their operator manual. In cold climates
• GULF HARMONY 46 AW where ambient (outside air) temperatures are
consistently below 32° F (0° C), refer to the engine
• AMOCO RYKON 46 manufacturers operator manual for alternative oils.
• MOBIL DTE-25
• ARCO DURO AW S-215 2. Cooling System (engine coolant):
• SHELL TULLUS 46 In general, use a 50/50 mix of premium-quality ethylene
glycol (commonly referred to as “anti-freeze/anti-boilover”)
• BENZ PETRAULIC 46-7C
and water. Additives are not necessary.
• SUN SUNVIS 821 WR
• CHEVRON AW HYDRAULIC OIL 46
• TEXACO RANDO HD 46
• CITGO PACEMAKER XD-46
Model 8042, 10042, 10054 Legacy Rev. 10/03 2.29

3. Fuel: Contact:
Aldrich Chemical Co., Inc.
In general, use #2 diesel fuel. From November 15 to
P.O. Box 335
March 15, when operating in cooler climates where
Milwaukee, WI 53201 USA
ambient (outside air) temperatures are consistently at or
Phone: (414) 273-3850
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 DOW CORNING, INC.
filter regularly. Additives are not necessary. Product name: MOLYKOTE® 77 Paste
Contact:
b. Engine Capacities Dow Corning Corporate Center
P.O. Box 994
1. Engine Oil Capacity: Midland, MI 48686-0994 USA
Phone: (517) 496-4400
Crankcase Capacity (4BT3.9 & 4BTA3.9 Engine)
With filter change.................................11 qt (10,4 liters) 2.6.8 General Anti-Corrosion
Filter Capacity..........................................1 qt (0,9 liters)
a. Anti-Corrosion Compound
Crankcase Capacity (QSB4.5T Engine Only)
For general anti-corrosion protection, use a wax film rust
With filter change.................................10.5 qt (10 liters)
inhibitor that provides a protective film two ten-thousandths
Filter Capacity...................................0.85 qt (0,80 liters) of an inch (0.0002" or 0,00005 mm) thick. One such rust
inhibitor that is specifically formulated for this purpose is
2. Cooling System Capacity (w/o heater): LPS 3. It is marketed by:
Cooling System Capacity .......................4 gal (15 liters) LPS Laboratories, Inc.
Overflow Bottle Capacity .........................3 qt (2,8 liters) 4647 Hugh Howell Rd.
Tucker, GA 30085-5052
3. Fuel Tank Capacity: Phone: 1-800-241-8334
Fax: (770) 493-9206
Total Capacity.....................................37 gal (140 liters)
Note: Anti-corrosion protection is especially important in
Usable Capacity ..............................35.6 gal (135 liters) frame and stabilizer cylinder pin support bores for
protection from corrosion wear.
2.6.7 Drive Shaft Splines
IMPORTANT: DO NOT disassemble any of the drive b. Anti-Corrosion Need Areas
shafts (refer to Section 5, “Axles, Drive Shafts, Wheels Coat all unplated pins and all bores for cylinder pins,
and Tires,” of this manual for information covering drive attachment pivot pins, chain sheave pins, the quick
shafts and U-joints). To help ensure optimum performance, attach lock pin and all quick attach lock pin bores. On the
the drive shaft assemblies are specially balanced as a boom, coat the fork shaft and unpainted boom slide
unit at the factory. When servicing any flange yoke, slip pathways.
yoke or drive shaft tube, order a complete assembly.
Refer to the appropriate parts manual for ordering 2.6.9 Electrical
information.
Respective of the above statement, should it become a. Basic Ratings
necessary to coat the transmission input drive shaft
Battery Rating ....................... 12V DC Negative Ground
splines, use molybdenum disulfide grease. Molybdenum
disulfide grease is specifically formulated for this purpose Battery Type......................................Maintenance-Free
and is marketed by several manufacturers under various 4BT3.9 & 4BTA3.9 Engine .. 1,000 Cold Cranking Amps
names, including: QSB4.5T Engine ........ 850 Cold Cranking Amps (Each)
Aldrich Chemical Co., Inc. Battery Series (4BT3.9 & 4BTA3.9 Engine) ....Series 31
Product name: Aldrich MOLYBDENUM (IV) SULFIDE Battery Series (QSB4.5T Engine) ...................Series 27
Catalog Number: 23,484-2
Number of Batteries (4BT3.9 & 4BTA3.9 Engine)... One
Package Size: 5 g (0.175 oz)
100 g (3.5 oz) Number of Batteries (QSB4.5T Engine).................. Two
500 g (17.5 oz) Alternator Rating ..............................................65 Amps
2.30 Model 8042, 10042, 10054 Legacy Rev. 10/03

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
Optional Lights ...................................................20 Amp
Instrument Cluster ............................................. 10 Amp
Optional Road/Work Lights ................................40 Amp
Horn/Heater ....................................................... 15 Amp
Transmission.....................................................7.5 Amp
Steer Select Switch ........................................... 10 Amp
Boom/Outrigger Interlock ..................................7.5 Amp
Stabil-TRAK System.......................................... 10 Amp
Grid Heater (QSB4.5T Engine Only)................125 Amp
Optional Washer/Wipers ................................... 10 Amp
ECM System (QSB4.5T Engine Only) ..............7.5 Amp
Optional Lights .................................................. 20 Amp
ECM System (QSB4.5T Engine Only) ...............10 Amp
Optional Road/Work Lights ............................... 40 Amp
Transmission .................................................... 7.5 Amp c. Relay Ratings
ECM Indicator Light (QSB4.5T Engine Only) ... 7.5 Amp Model 8042 and 10042:
Grid Heater (QSB4.5T Engine Only) ............... 125 Amp Park Brake Disengage .............................................12V
ECM System (QSB4.5T Engine Only).............. 7.5 Amp Optional Headlight Switch ........................................12V
ECM System (QSB4.5T Engine Only)............... 10 Amp Light Switch..............................................................12V
Model 10042: Neutral Start .............................................................12V
Main................................................................... 40 Amp Stabil-TRAK Lock.....................................................12V
Light Switch Relay ............................................ 7.5 Amp Boom Switch ............................................................12V
Instrument Cluster ............................................. 10 Amp Back-up ....................................................................12V
Horn/Heater ....................................................... 10 Amp Model 10054:
Steer Select Switch ........................................... 10 Amp Park Brake Disengage .............................................12V
Stabil-TRAK System.......................................... 10 Amp Optional Headlight Switch ........................................12V
Optional Washer/Wipers ................................... 10 Amp Light Switch..............................................................12V
Outriggers (4BT3.9 & 4BTA3.9 Engine) ........... 7.5 Amp Neutral Start .............................................................12V
Outriggers & ECM Indicator Light Stabil-TRAK Lock.....................................................12V
(QSB4.5T Engine Only).................................... 7.5 Amp
Boom Switch ............................................................12V
Optional Lights .................................................. 20 Amp
Back-up ....................................................................12V
Optional Road/Work Lights ............................... 40 Amp
Park Brake Interlock.................................................12V
Transmission .................................................... 7.5 Amp
Boom Extend Lockout ..............................................12V
Grid Heater (QSB4.5T Engine Only) ............... 125 Amp
Stabil-TRAK Interlock...............................................12V
ECM System (QSB4.5T Engine Only).............. 7.5 Amp
Stabil-TRAK Lock Up ...............................................12V
ECM System (QSB4.5T Engine Only)............... 10 Amp
Boom Extend Interlock .............................................12V
Model 10054:
Right Outrigger Lock ................................................12V
Main................................................................... 40 Amp
Left Outrigger Lock ..................................................12V
Light Switch Relay ............................................ 7.5 Amp
Outrigger Lockout (S/N 13198 thru 17984 Only)......12V
Instrument Cluster ............................................. 10 Amp
Horn/Heater ....................................................... 15 Amp
Steer Select Switch ........................................... 10 Amp
Stabil-TRAK System.......................................... 10 Amp
Model 8042, 10042, 10054 Legacy Rev. 10/03 2.31

2.6.10 Paint 2.6.11 Thread Locking Compound

Unless otherwise specified, paint components as For general thread locking purposes, Loctite® products,
indicated in the following sections. manufactured by Loctite Corporation, are recommended.
Contact:
a. Orange Paint
LOCTITE Corporation
Durable, premium Sky Trak Orange paint is available in 1001 Trout Brook Crossing
both a convenient 16 ounce (480 ml) spray can for touch- Rocky Hill, CT 06067 USA
ups and in a production size, one gallon (3,8 liter) Phone: 1-800-LOCTITE (1-800-562-8483)
container for extensive repainting. Consult the appropriate Fax: (860) 571-2460
parts manual for the applicable part number and ordering Internet: http://www.loctite.com
information. Use orange paint on all vehicle components
LOCTITE® is a registered trademark of Loctite
except as specified in paragraphs 2.6.10 B and C.
Corporation.
b. Black Paint
2.7 CLEANING
Durable, premium Sky Trak Black paint is available in
both a convenient 16 oz (480 ml) spray can for touch-ups Dirt and abrasive dust reduce the efficient working life of
and in a production size, one gallon (3,8 liter) container parts and systems and lead to the costly replacement of
for extensive repainting. The following components are components. To help increase the service life of parts,
painted Black: clean the exterior of all parts before beginning any
• Boom Angle Indicator Pointer repairs.
• Brake Pedal Use cleaning fluids and solvents suitable for cleaning
parts that do not create safety hazards. Certain types of
• Radiator cleaning fluid can cause skin irritation and can damage
• Radiator Shroud components (such as rubber, electrical parts, etc.).
• Oil Cooler Servicing the hydraulic system in particular requires
• Axles cleanliness of the work area, as well as the components
on the vehicle.
• Drive Shafts
Follow these suggestions before attempting to service
• Transmission any hydraulic component:
• Forks 1. Flush hose and tube assemblies with a solvent
• Quick Attach (Current Production) compatible with hose materials. Blow excess solvent
• Carriages (Current Production, refer to appropri- away with shop air.
ate Parts Manual for correct paint part number) 2. Plug or cap hydraulic fittings, hoses and tube
• Mirrors and Mirror Brackets assemblies, and protect the threads until time of
installation. Clean up any spilled hydraulic fluid
• Air Cleaner (4BT3.9 & 4BTA3.9 Engine Only) immediately.
• Steering Column 3. Flush the hydraulic oil reservoir or fuel tank with a
• Outriggers (10042 and 10054) suitable solvent to remove paint, metal chips, etc.
• Outrigger Cylinders (10042 and 10054) 4. Protect hydraulic system components from airborne
contaminants. Plug or cap all cylinder, valve,
c. White Paint reservoir, tank and pump openings until time of
installation.
Durable, premium Sky Trak White paint is available in
both a convenient 16 oz (480 ml) spray can for touch-ups 5. Use clean, filtered oil when filling the system.
and in a production size, one gallon (3,8 liter) container Maintain the hydraulic system at a minimum
for extensive repainting. The following components are cleanliness level of ISO code 18/15-particle ration
painted White: count.
• Boom Extend Cylinder
• Wheels
2.32 Model 8042, 10042, 10054 Legacy Rev. 10/03

2.8 REPLACEMENT 2.9.2 Hose and Tube Installation

1. When installing a new hose, loosely connect each
ALWAYS use the correct tool when removing or replacing
end to verify that the hose takes up the designed
any part or performing any service.
position, and is free of twists and unnecessary
Some procedures may require the use of specialized bends before tightening completely. Tighten any
tools. If needed, many of these tools can be obtained support clamps sufficiently in order to hold the hose
through Snap-On® tool distributors. in position without crushing it, preventing movement
Contact: and chafing of the hose.
Snap-On Incorporated 2. If a hose is replaced on a part that moves, move the
P.O. Box 1410 part through its entire range of motion to verify that
Kenosha, WI 53141-1410 USA the hose will not make contact with any component.
Phone: (262)-656-5200 Adjust the hose as necessary.
Internet: http://www.snapon.com
3. When installing any hose, be sure that the hose
Snap-On® is a registered trademark of Snap-On does not become kinked or twisted.
Technologies, Inc.
4. NEVER allow free-moving or unsupported hoses to
Replace o-rings, seals and gaskets whenever they are contact each other or any other components. Such
disturbed. NEVER mix new and old seals or o-rings, contact causes chafing and reduces hose life.
regardless of apparent visual condition. ALWAYS
lubricate new seals and o-rings with hydraulic oil before 2.10 BEARINGS
installation.
ALWAYS replace elastic locknuts with new elastic 2.10.1 Bearing Removal
locknuts to help ensure proper fastening.
ALWAYS refer to the Parts Manual for proper 1. NEVER remove bearings unless absolutely
replacement of appropriate size, type and grade of ALL necessary! ALWAYS use the recommended size
fasteners. and type of bearing puller to reduce the risk of
damage to the bearing or related components.
2.9 HOSES AND TUBES 2. When bearings or bushings are removed, verify that
the bearing or bushing is free of discoloration, nicks,
scuffing or signs of overheating. If in doubt, replace
2.9.1 Hose and Tube Inspection the bearing or bushing.
1. Damaged, dented, crushed or leaking hoses, tubes
or fittings restrict oil flow and operation of the system 2.10.2 Bearing Cleaning
being served. Fittings that show any signs of
ALWAYS wear safety glasses. Clean the bearings that
movement from their original positions have failed
are acceptable for service in a suitable solvent. NEVER
and must be replaced. ALWAYS replace the entire
spin-dry a bearing with compressed air; this can cause
hose or tube assembly if the fittings are damaged.
metal-to-metal contact and damage the bearing.
2. Hoses must remain in good condition. Obvious signs Compressed air can also cause a bearing to come apart.
of external hose wear, or hydraulic fluid leaking or After cleaning a bearing, immerse the bearing in clean
weeping indicate the need to replace the hose lubricating oil until needed.
assembly. If in doubt, replace the hose.
3. Replace a hose or tube assembly if any of the
following conditions exist:
• Ballooning (replace hose immediately!)
• Kinking, crushing, stretching or deforming
• Concealed corrosion of wire reinforcement
• Chafed outer cover
Model 8042, 10042, 10054 Legacy Rev. 10/03 2.33

2.10.3 Bearing Installation 2.12 AFTER SERVICE STARTUP AND

1. Always install bearings carefully to help avoid CHECKS
damaging their delicate surfaces.
2. Install bearings using one of the following methods: 2.12.1 After Service Startup
• PRESS FIT for installation on rotating parts such Note: Refer to the Owners/Operators manual for engine
as shafts and gears cold start procedures.
• PUSH FIT into static locations such as reduction 1. Check ALL fluid levels, and add fluid as required.
gear housings.
2. Connect the negative (-) battery cable or cables to
3. Always install the bearing into the rotating part first, the negative (-) battery terminal or terminals if the
whenever possible. cable or cables were disconnected.
4. Use a press or the proper installation tools when 3. Start and idle the engine. Check for leaks from the
installing a bearing or bushing. hydraulic components, engine, radiator, axles,
5. In the absence of a press or proper installation tools, transmission and brakes. Check for leaks from the
carefully heat the casing and/or bearing in hot oil to hydraulic oil reservoir plugs or fittings; tighten as
assist in the installation. required. Check the levels of all fluids and lubricants.
4. Purge the hydraulic system of air by operating all
2.11 PRESSURE TESTING AND vehicle functions through their entire range of
ADJUSTMENT motion. Operate all functions several times to ensure
all air is purged from the system.
Prior to pressure testing or adjustment, verify that all 5. Check for proper and smooth operation of all
hoses and tubes are in good condition and that all fittings components.
are tight.
6. Retract all cylinders fully. Turn the engine OFF and
Use pressure gauges with the proper pressure range and check the hydraulic oil level in the hydraulic oil
rating to measure the specified pressures. reservoir. Allow the oil to cool and recheck the level.
Use correct test procedures to help prevent personal Add oil as required to bring the oil level up to the
injury, and damage to the system or test equipment. proper level.
Verify that the hydraulic oil is at the proper operating
temperature, 80°-120° F (27°-49° C), before testing any 2.12.2 After Electrical Component Service
pressures or making any adjustments to any valves. If 1. Check the torque of all fasteners securing replaced
necessary, operate the vehicle to raise the oil temperature up electrical/electronic components.
to the operating temperature. In the absence of a
2. Check wire connections to electrical components.
temperature gauge, the oil can be checked by placing
your hand against the side or the bottom of the hydraulic 3. Verify that wiring components are dry and free of
oil reservoir. If the tank is too hot to keep your hand in moisture.
contact with the tank, the oil should be within the proper 4. Check connectors for broken, frayed or loose wires.
range.
5. Check wires and wire harnesses for brittle or frayed
wire shielding.
6. Connect the negative (-) battery cable or cables to
the negative (-) battery terminal or terminals if the
cable or cables were disconnected.
7. Start the engine and purge the hydraulic system of
air.
8. Check the operation of the replaced electrical
component(s).
2.34 Model 8042, 10042, 10054 Legacy Rev. 10/03

2.12.3 After Hydraulic Component Service 3. Check the torque on the drive shaft yoke retaining
strap bolts:
1. Check the torque of all fasteners on replaced
hydraulic components. • Upper driveshaft 35 lb-ft (47 Nm)
2. Check that the hoses and tubes are properly • Lower driveshaft 60 lb-ft (81 Nm)
attached, properly positioned and that all the fittings 4. Refer to the ZF 4WG98 TC Transmission Repair
are properly tightened. Manual, P/N 8990455 (ZF P/N 5871 135 002) for
3. If a hydraulic component failed and contaminated servicing the transmission after overhaul or repair.
the system: 5. Wear suitable eye protection. When an overhauled
• Drain the hydraulic oil reservoir or repaired transmission is installed, thoroughly
clean the oil cooler lines to and from the
• Flush the system using clean hydraulic oil
transmission.
• Prime the pump
6. Drain and flush the entire system.
• Clean the hydraulic oil reservoir
7. Disconnect and clean all transmission lines.
• Change the hydraulic oil filter Whenever it is possible, remove the transmission
4. After normal hydraulic component maintenance, lines from the vehicle for cleaning.
check the hydraulic oil level and add oil as required. 8. Thoroughly clean transmission filter screens and
5. Start the engine and purge the hydraulic system of cases, and replace transmission filter elements.
air. Operate all boom functions through their full
range of motion several times. Cycle the hoist and CAUTION: DO NOT exceed 165 psi
extend cylinders to purge air from the system. (11,4 bar) when back flushing the oil cooler.
Visually check for leaks. Applying too much pressure may damage the
oil cooler/radiator.
6. Check operation of all systems in the hydraulic
circuit by operating the controls through all the 9. “Back flush” the transmission oil cooler with oil and
functions several times. compressed air until all foreign material is removed.
Flushing in the direction of normal flow does not
2.12.4 After Brake System Service adequately clean the cooler. If needed, remove the
1. Check the oil level in the axle and replenish with transmission oil cooler assembly from the vehicle.
Universal Tractor Fluid as required. DO NOT use flushing compounds for cleaning
purposes.
2. Bleed the air from the brake system.
10. Reassemble all components and fill the transmission
3. Check the brake pressure.
with clean, fresh Universal Tractor Fluid through the
4. Check the brakes for proper operation. filler opening until the fluid reaches the FULL mark
on the transmission dipstick.
2.12.5 After Fuel System Service 11. Run the engine at idle for several minutes to help
1. Drain and flush fuel tank, if it was contaminated, with prime the torque converter and fill the transmission
clean fuel. cooling lines.
2. Replace all the fuel filters. 12. Recheck the level of the fluid in the transmission with
3. Fill the fuel tank with fresh, clean fuel as required. the engine running at idle.
4. Bleed the fuel system of air. 13. Add Universal Tractor Fluid as necessary to bring
the fluid level up to the FULL mark on the
2.12.6 After Transmission Service or transmission dipstick. Install the oil dipstick. Recheck
Replacement the fluid level when it reaches an operating
temperature 180-200° F (83-94° C).
1. Check transmission oil level and add Universal
14. Recheck all drain plugs, lines, connections, etc., for
Tractor Fluid. Refer to Section 2.6.3, “Transmission,”
leaks, and tighten as required.
for types of transmission lubricants.
2. Replace transmission filter.
Model 8042, 10042, 10054 Legacy Rev. 10/03 2.35

2.12.7 After Tire and Wheel Service 4. Check for proper operation by operating all boom
functions through their full range of motion several
1. Check the air pressure in the tires. Maintain proper
times.
air pressure at all times. Refer to proper tire size as
follows:
2.12.10 After Axle Service
Standard Tires
1. Check the fluid levels in the axle and wheel ends.
• 8042 (13.00-24, 12 ply) 70 psi (483 kPa)
2. Check the torque on the driveshaft flange yoke
• 10042/10054 (17.5-25, 12 ply) 60 psi (414 kPa) retaining strap bolts. Torque these bolts to 60 lb-ft
Optional Tires - 8042 (81 Nm).
• 15.5 - 25, 12 ply 70 psi (483 kPa) 3. Check the torque on the wheel nuts. Torque to 430-
• 15.5 - 25, 12 ply, (Rock) 70 psi (483 kPa) 470 lb-ft (583-637 Nm).
• 15.5R25 One Star (Radial) 75 psi (517 kPa) 4. Check and adjust the toe-in if required.
Optional Tires - 10042/10054 5. Apply grease to all lubrication points (grease fittings).
• 17.5R25 One Star (Radial) 73 psi (503 kPa) Note: Refer to the appropriate Owner/Operators manual
for the grease fitting locations.
2. Check the wheel nut torque. Torque the wheel nuts
to 450 lb-ft (610 Nm). 6. Refer to the axle manufacturer’s maintenance
manual for further information.
2.12.8 After Engine Service
Consult a qualified service agent (manufacturer’s
representative and/or service manual) for proper procedures
before engine startup.
2.12.9 After Boom Service

1. Check wear pads.
2. Check chain tension, and adjust as required.
3. Apply grease to all lubrication points (grease fittings).
Note: Refer to the appropriate Owners/Operators
manual for the grease fitting locations.
2.36 Model 8042, 10042, 10054 Legacy Rev. 10/03

Section 3
Boom
Contents

3.1 Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.2 Boom System - Three Section Booms (8042 and 10042) . . . . . . . . . . . . . . . . . . 3.4
3.2.1 Boom System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
3.2.2 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
3.3 Boom Assembly Maintenance (8042 and 10042) . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
3.3.1 Inner Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
3.3.2 Intermediate Boom Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
3.3.3 Outer Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
3.3.4 Outer Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
3.3.5 Intermediate Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30
3.3.6 Inner Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
3.4 Boom Chains - Three Section Boom (8042 and 10042) . . . . . . . . . . . . . . . . . . . . 3.46
3.4.1 Boom Chain Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46
3.4.2 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54
3.4.3 Boom Chain Tension Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54
3.4.4 Boom Chain Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.55
3.4.5 Boom Extend and Retract Chains Removal and Replacement. . . . . . . . . 3.58
3.5 Boom System - Four Section Boom (10054). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.64
3.5.1 Boom System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.64
3.5.2 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.64
3.6 Boom Assembly Maintenance (10054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.64
3.6.1 Inner Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.65
3.6.2 Secondary Intermediate Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . 3.76
3.6.3 Primary Intermediate Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.80
3.6.4 Outer Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.84
3.6.5 Outer Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.90
3.6.6 Primary Intermediate Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3.97
3.6.7 Secondary Intermediate Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . 3.102
3.6.8 Inner Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.108
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.1

Boom
3.7 Boom Chains - Four Section Boom (10054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.121

3.7.1 Boom Chain Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.121
3.7.2 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.134
3.7.3 Boom Chain Tension Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.134
3.7.4 Intermediate Boom Chains Tension Adjustment . . . . . . . . . . . . . . . . . . . . 3.134
3.7.5 Inner Boom Chain Tension Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . 3.137
3.7.6 Boom Extend and Retract Chains Removal and Replacement. . . . . . . . . 3.139
3.8 Hose Carrier Assembly - Four Section Boom (10054) . . . . . . . . . . . . . . . . . . . . . 3.151
3.8.1 Hose Carrier Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.151
3.8.2 Hose Carrier Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.158
3.9 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.168
3.9.1 Wear Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.168
3.9.2 Boom Wear Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.168
3.9.3 Boom Wear Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.171
3.10 Quick Attach Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.171
3.10.1 Disconnecting from an Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.171
3.10.2 Connecting to an Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.172
3.10.3 Quick Attach Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.172
3.10.4 Quick Attach Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.173
3.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.174
3.2 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
3.1 BOOM SYSTEM COMPONENT

TERMINOLOGY
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
referred to throughout this section.
Boom Extend Chains Intermediate Boom Section Outer Boom

SectionBoom Pivot
Inner Boom Section Boom Retract Chain
w/Gooseneck Boom Angle Pin
Indicator
FRONT
Auxiliary Wear
Hydraulic Pads
Boom Proximity
Couplers Sensor
Attachment
Tilt Cylinder Boom Extend/
Boom Slave
Retract Cylinder
Boom Lift / Lower Cylinder
Cylinder
Quick Attach Three Section Boom (8042 and 10042)
Intermediate Boom Secondary Intermediate Intermediate Boom

Inner Boom
Extend Chains Boom Section Retract Chain
Extend Chain
Primary Intermediate Outer Boom
Inner Boom Boom Section Section
Inner Boom Section Retract Chain
w/Gooseneck Boom Pivot
Boom Angle Pin
Indicator
FRONT
Auxiliary Wear
Hydraulic Pads
Couplers Boom Extend Boom Proximity
Interlock Sensor Sensor
Boom Extend/ Boom Slave

Attachment Boom Lift /
Retract Cylinder Cylinder
Tilt Cylinder Lower Cylinder
Quick Attach Four Section Boom (10054)
MH4350
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.3

Boom
3.3 BOOM ASSEMBLY MAINTENANCE

WARNING: DO NOT service the vehicle (8042 AND 10042)
without following all safety precautions as
outlined in the “Safety Practices” section of this The boom assembly consists of the inner, intermediate
manual. Failure to follow the safety practices and outer booms and supporting hardware.
may result in death or serious injury.
IMPORTANT: Boom replacement must be completed in
sequence, one boom section at a time, as described in
3.2 BOOM SYSTEM - THREE SECTION these instructions. Replacement of two or more boom
BOOMS (8042 AND 10042) sections as a unit requires special considerations that
are not covered in these instructions.
3.2.1 Boom System Description IMPORTANT: Before removing the inner boom, the
The boom operates via an interchange among the electrical, carriage or any other attachment must be removed from
hydraulic and mechanical systems. Components the quick attach.
involved include the joystick, Attachment Tilt cylinder, The inner, intermediate and outer boom removal
Extend/Retract cylinder, Lift/Lower cylinder, Slave instructions must be completed in sequence. The inner
cylinders, electronic sensors, extend and retract chains, boom must be removed before removing the intermediate
various pivots, supporting hardware and other boom. The inner boom and intermediate boom must be
components. removed one at a time before removing the outer boom.
Before beginning, conduct a visual inspection of the
3.2.2 Boom System Operation vehicle, work area and task about to be undertaken.
The three section boom assembly consists of inner, Read, understand and follow these instructions.
intermediate, and outer boom assemblies with double top After servicing the boom, perform the following:
boom extend chains and a single retract chain. Boom
extension and retraction is accomplished via hydraulic 1. Check wear pads. (Refer to Model 8042 Legacy
power and chain movement. Owners/Operators Manual or Model 10042 Legacy
Owners/Operators Manual.)
As the Extend/Retract hydraulic cylinder, which is
anchored at the rear of the intermediate boom and the 2. Check chain wear and tension adjustment. (Refer to
rear of the outer boom, begins to extend, it forces the Section 3.4.1, “Boom Chain Inspection,” and Section
intermediate boom out of the outer boom. 3.4.3, “Boom Chain Tension Check.”)
The inner and outer booms are connected by extend and 3. Apply grease at all lubrication points (grease fittings).
retract chains. These chains are routed around sheaves (Refer to Model 8042 Legacy Owners/Operators
on the intermediate boom. As the intermediate boom is Manual or Model 10042 Legacy Owners/Operators
forced out, the extend chain pulls the inner boom out of Manual.)
the intermediate boom. 4. Check for proper operation by operating all boom
As hydraulic pressure is applied to the retract port on the functions through their full range of motion several
Extend/Retract cylinder, the intermediate boom is pulled times.
back into the outer boom, and the retract chain pulls the
inner boom back into intermediate boom.
This mechanical linkage formed by the chains and
supporting hardware extends and retracts the intermediate
and inner booms at the same rate.
The outer boom does not extend or retract, but lifts and
lowers via action of the Lift/Lower cylinder.
3.4 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
3.3.1 Inner Boom Removal 6. Move the Attachment Tilt joystick in both directions
to relieve any trapped pressure in the Attachment Tilt
1. Remove any attachment from the quick attach
system. If your vehicle is equipped with optional
assembly. (Refer to Section 3.10.1, “Disconnecting
auxiliary hydraulics, move the auxiliary hydraulic
from an Attachment.”)
joystick in both directions to relieve any trapped
Note: If you are replacing the inner boom with a new pressure in the auxiliary hydraulic system.
inner boom, remove the quick attach from the inner
boom. (Refer to Section 3.10.3, “Quick Attach Removal.”)
WARNING: Hydraulic fluid leaking under
pressure can penetrate the skin, cause infection,
WARNING: Wear protective footwear gangrene, and death or serious personal
with reinforced toe caps and slip-resistant injury. If injured, see a doctor immediately.
soles. Failure to comply can result in foot or Relieve all pressure before disconnecting any
other bodily injury from crushing, slipping or component, part, line or hose. Slowly loosen
falling. parts and allow release of residual pressure
before removing any parts or component.
WARNING: NEVER lift a heavy object
without the help of at least one assistant or a WARNING: Wait for the hydraulic fluid
suitable sling and hoist. Failure to comply can to cool before servicing any hydraulic component.
result in death or serious personal injury. Hot hydraulic oil can cause severe burns.
Note: This procedure will require a clear space of 7. Locate the two hoses (1) attached to the base of the
approximately 16 feet at the front of the vehicle. Attachment Tilt cylinder (2) inside the gooseneck (3).
1. Park the vehicle on a hard, level surface. Move the 8. Label and remove the hoses (1) from the fittings (4)
boom to a horizontal (level) position. Extend (or on the Attachment Tilt cylinder. Plug the hose ends
Retract) the boom until the boom is extended and cap the fittings on the Attachment Tilt cylinder to
approximately 2 feet (610 mm). Move the quick prevent dirt and debris from entering the hydraulic
attach to the horizontal position. Place the travel system and/or cylinder.
select lever in the (N) NEUTRAL position, place the
neutral lock lever in the (N) NEUTRAL LOCK
position, engage the parking brake and shut the
engine OFF.
2. Return to the cab, fasten your seat belt and start the
engine. Retract the boom slightly until slack is 3
noticed in the extend chain. Shut the engine OFF.
3. 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.”)
4. Unlock and open the engine compartment cover.
Allow the engine, transmission and hydraulic fluid to 1
cool before proceeding.
5. Disconnect the battery negative (-) cable at the
battery negative (-) terminal to prevent the engine
from starting accidentally. 4
2
MH0830
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.5

Boom
9. If your vehicle is equipped with optional auxiliary 8 7

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.
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
MH0850
11. With auxiliary hydraulics: Inside the inner boom,

loosen but DO NOT remove the two capscrews (9)
securing the left side wear pad and hose clamp
3
support bracket (10) to the top of the inner boom.
12. Remove the two capscrews (11), two
lockwashers (12) and two flat washers (13) holding
the stack clamps (14) and hose clamp support
2 1
bracket (10) to the left side of the inner boom.
Remove the clamps and the clamp support bracket
from the inner boom.
2
10
13
MH0840 12
11
10. 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 10
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. 14
9
MH2840
3.6 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
13. Without optional auxiliary hydraulics: Inside the 15. At the front of the intermediate boom (22), remove
inner boom, remove the two capscrews (15) and two the capscrews (23) and lockwashers (24) holding the
lockwashers (16) holding the stack clamps (17) to top wear pads (25) and spacers (26) to the inside of
the left side wall of the inner boom. Remove the the intermediate boom. Label the wear pads and
clamp cover plate (18) and all the clamps. spacers as “Top Left” and “Top Right” sides. Save
the spacers, capscrews, lockwashers and wear pad
inserts (27).
17 24
23
16
24
15
18
26
25 22
MH0860
27 MH0890
14. Pull the free ends of the Attachment Tilt hoses (19)
and (optional) auxiliary hydraulic hoses (20) from 16. At the front of the intermediate boom (28), remove
inside the inner boom and out the rear of the the capscrews (29), lockwashers (30) and flat
boom (21). Allow the hoses to hang from the rear of washers (31) holding the side wear pads (32) and
the boom. shims (33) to the inside of the intermediate boom.
Label the wear pads and shims as “Left Upper/Lower”
and “Right Upper/Lower.” Save the shims, capscrews,
flat washers, lockwashers and wear pad inserts (34).
34 32
20
28
33 31 30 29 MH0900
19 21
20
MH0870
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.7

Boom
17. At the rear of the boom, measure the amount of Note: Record the location of the shoulder bolt (10) to
threads protruding beyond each elastic locknut (1) ensure correct installation.
and record that measurement for reassembly.
19. At the rear of the boom, locate the retract chain (11)
Remove the two elastic locknuts (1) and flat
on the right side of the boom. In front of the retract
washers (2) holding both extend chain clevis’ (3) to
chain sheave, locate the shoulder bolt (10) which
the anchor plate (4) on the inner boom (5). Save the
holds the retract chain to the anchor plates on the
flat washers and discard the elastic locknuts.
inner boom. Remove the elastic locknut (12) from
the shoulder bolt and remove the shoulder bolt. Save
2
1 the shoulder bolt and discard the elastic locknut. Allow
the retract chain to hang out the rear of the boom.
10
11
3
4
5
MH0911
12
18. At the front of the intermediate boom (6), pull both
extend chains (7) out from between the inner and
intermediate boom sections. The extend chains can 11
remain anchored between the yoke plates (8) on the MH2550
outer boom. Loop both chains over the top of the
chain sheave (9) and lay the chains on top of the Note: If replacing the inner boom assembly with a new
outer boom. inner boom, the quick attach assembly and the Attachment
Tilt cylinder should be removed at this time.
7
If the inner boom is not to be replaced, the quick attach
assembly and Attachment Tilt cylinder can remain in
place. Proceed to Step 29.
20. 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.
8
21. Support the rod end of the Attachment Tilt
cylinder (17). Use a brass punch and a rawhide
hammer to remove the rod end pin (15) from the
9
quick attach assembly.
22. Inspect the pin (15) for nicks or surface corrosion.
6 MH0920 Use fine emery cloth to fix minor nicks or corrosion.
If damaged and if it cannot be repaired, the pin must
be replaced.
3.8 Model 8042, 10042, 10054 Legacy Rev. 03/04

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).
27. Inspect the pin for nicks or surface corrosion. Use
17 14 fine emery cloth to repair minor nicks or corrosion. If
damaged and if it cannot be repaired, the pin must
13 be replaced.
16
~
15 MH0940

24
holding the quick attach pivot pin (20) to the quick
attach assembly (21). Save the capscrew and
discard the elastic locknut. Place a support under 26
the quick attach assembly to prevent it from dropping
when the pivot pin is removed.
25
24. Use a brass punch and a rawhide hammer to
remove the quick attach pivot pin (20) from the quick
attach assembly and the bushings in the gooseneck.
Record the location and quantity of the shim
washers (22 and 23) as the pin is being removed.
Save the washers (22 and 23) from each side of the 27
MH0960
quick attach.
25. Inspect the pin for nicks or surface corrosion. Use 28. Lower the Attachment Tilt cylinder (27) with the hoist
fine emery cloth to repair minor nicks or corrosion. If and remove from the backside of the gooseneck.
damaged and if it cannot be repaired, the pin must Place the Attachment Tilt cylinder on a clean, level
be replaced. surface.
29. Pull the inner boom straight out of the intermediate
boom. Reposition the slings as needed so the inner
boom balances when removed from the intermediate
boom. Set the inner boom down on a hard, level
21 surface. Support the boom as needed to prevent it
from tipping over.
18
~
23
22
20
19
22
23 MH0950
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.9

Boom
30. At the rear of the inner boom (1), remove the 33. Carefully lower the inner boom onto suitable
capscrews (2) and lockwashers (3) holding the top supports or to the ground.
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
WARNING: NEVER weld or drill the
boom. The structural integrity of the boom will
spacers, shims, capscrews, lockwashers and wear
be impaired if subjected to any repair involving
pad inserts (7).
welding or drilling. Failure to comply can result
31. Remove the capscrews (8), lockwashers (9) and flat in death or serious personal injury.
washers (10) holding the side wear pads (11) and
shims (12) to the sides of the inner boom. Label the 34. Inspect the boom and welds. Consult the local Sky
wear pads and shims as “Left Side Upper/Lower” Trak distributor or the JLG Service Department at
and “Right Side Upper/Lower.” Save the shims, 1-877-554-5438 or 1-717-485-6657, if structural
capscrews, lockwashers, flat washers and wear pad damage is detected.
inserts (13). 35. Inspect hoses, hardware, wear pads, mounting
32. Remove the capscrews (14) and lockwashers (15) points, chains and other components visible with the
holding the bottom wear pad (16) and spacer (17) to inner boom removed. Replace if damaged.
the bottom of the inner boom. Label the wear pad 36. Inspect all wear pads for wear. (Refer to Section
and spacer as “Bottom.” Save the spacer, 3.9.1, “Wear Pad Inspection.”)
capscrews, lockwashers and wear pad inserts (18).
7 4
5
14
6
15
3 8
1 9
2
10
12
11
17
13
16 18 MH0970
3.10 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
3.3.2 Intermediate Boom Removal 3. At the front of the outer boom (25), remove the
capscrews (26), lockwashers (27) and flat washers (28)
WARNING: Wear protective footwear
holding the side wear pads (29) and shims (30) to
the inside of the outer boom. Label the wear pads as
with reinforced toe caps and slip-resistant “Left Side Upper/Lower” and “Right Side Upper/Lower.”
soles. Failure to comply can result in foot or Save the capscrews, lockwashers, flat washers,
other bodily injury from crushing, slipping or shims and wear pad inserts (31).
falling.

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.”
2. At the front of the outer boom (19), remove the 28
capscrews (20), lockwashers (21) and flat 27
washers (22) holding the top wear pads (23) to the
inside of the outer boom. Label the wear pads as 31
“Top Left” and “Top Right” sides. Save the 26
25
capscrews, lockwashers, flat washers and wear pad
inserts (24). 29
30 MH0990
20
19 21 4. Remove the capscrews (32) and lockwashers (33)
holding the center wear pad spacer mount (34) to
22 the front of the outer boom. Save the capscrews and
the lockwashers.
23
34
24 MH0980
33
32 MH1000
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.11

Boom
5. If replacing the intermediate boom with a new 9. At the rear of the intermediate boom, remove the
boom section: Remove the lower wear pads at the capscrews (10), lockwashers (11) and flat
front of the boom. Remove the capscrews (1) and washers (12) holding the hose reel assembly (13),
lockwashers (2) holding the lower wear pads (3) and lower wear pad (14) and spacer (15) to the lower
spacers (4) to the inside of the boom. Label the wear plate on the intermediate boom. Reassemble the
pads and spacers as “Left” or “Right” sides. Save the capscrews, lockwashers and flat washers to hold the
capscrews, lockwashers, spacers and wear pad lower wear pad in place for intermediate boom removal.
inserts (5).
13
10
11
12
14
3 15 MH1030
4 10. Remove the capscrews (16), lockwashers (17) and flat

2 washers (18) holding the hose reel side plate (19), lower
1 MH1010 left side wear pad (20) and shims (21) to the side of
the intermediate boom. Save the capscrews,
6. At the rear of the intermediate boom, remove the lockwashers, flat washers, shims and wear pad
capscrew (6) and lockwasher (7) holding the retract inserts (22). Watch for the six washers (23) to fall out
chain sheave pin (8) to the mounting plate inside the from between the side plate of the hose reel
boom. assembly and the side plate of the intermediate boom.
7. Remove the retract chain sheave pin (8) from the
mount and the retract chain sheave (9). Remove the 22 21
retract chain sheave from the intermediate boom. 19
8. Inspect the bushings inside the sheave. Replace the
bushings if there are any signs of wear. Inspect the 23
pin for wear or damage. Replace the pin if showing 20 18
signs of wear. 17
16
9
MH1040
7
6
MH1020
3.12 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
11. Pull the hose reel, with hoses, out the back of the
intermediate boom. Allow the hose reel assembly to 32 35
slide down the hoses and rest it on the floor. 36
12. Label and remove the hoses from the hose reel. The 33
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). While pulling the shoulder bolt out,
catch the spacers (28) from between the plates
as the bolt is removed. Pull the bolt out far 37
enough to remove the hoses from the hose reel.
b. After the hoses are removed from behind the
lower retaining bolt, insert the shoulder bolt (27)
through the plates, inserting the spacers (28) 34
35
between the plates as the bolt is inserted.
Reassemble the flat washer (26) and elastic
locknut (25) to hold the shoulder bolt in place. DO 32
NOT fully tighten at this time.
c. Remove the elastic locknut (29) from the upper
retaining capscrew (30). While pulling the 36
MH1450
33
capscrew out, catch the spacers (31) from
between the plates as the capscrew is removed.
Pull the capscrew out far enough to remove the 15. Pull the hose ends out from between the
hoses from the hose reel. intermediate boom and the outer boom and out the
rear of the boom.
d. After the hoses are removed, insert the
capscrew (30) through the plates, inserting the 16. Support the front of the Extend/Retract cylinder.
spacers (31) between the plates as the capscrew 17. Remove the retaining ring (38) from one side of the
is inserted. Reassemble the elastic locknut (29)
Extend/Retract cylinder rod end mounting pin (39).
to hold the capscrew in place.
Use a brass punch and a rawhide hammer to
remove the rod end pin from the mounting ears (40)
31
on the intermediate boom.
18. Inspect the pin (39) for wear or damage. Use fine
29 emery cloth to repair minor nicks or corrosion. If the
pin is damaged, replace it. Save the retaining ring.
25
26
30
24
28 27 MH1490
13. With auxiliary hydraulics: Label and remove the 38

auxiliary hoses (32 and 33) from the bottom tube
assemblies (34) at the mounting plate. Cap the hose
ends. 39
40
14. Without auxiliary hydraulics: At the front of the
outer boom, label and remove the Attachment Tilt
hoses (35 and 36) from the top tube assemblies (37) 40 MH1050
at the mounting plate. Cap the hose ends.
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.13

Boom
19. Pull the intermediate boom straight out of the outer b. Remove the capscrews (7), lockwashers (8) and
boom. Reposition the slings as needed so the flat washers (9) holding the upper wear pads (10)
intermediate boom balances when removed from the and shims (11) to the intermediate boom. Label
outer boom. Set the intermediate boom down on the wear pads and shims as “Top Left,” “Top
blocks on a hard, level surface. Center” or “Top Right.” Save the capscrews,
lockwashers, flat washers, shims and wear pad
inserts (12).
boom. The structural integrity of the boom will 12
be impaired if subjected to any repair involving 10
in death or serious personal injury.
11
20. Inspect the boom and welds. Contact the local Sky
Trak distributor or the JLG Service Department at
1-877-554-5438 or 1-717-485-6657, if structural 9
damage is detected.
21. Inspect all wear pads for wear. (Refer to Section
8
3.9.1, “Wear Pad Inspection.”)
7
22. Inspect hoses, hardware, mounting points, chains
and other components visible with the intermediate
boom removed. Replace if damaged.
23. If you are replacing the intermediate boom with a
new boom section, the following items need to be
removed from the intermediate boom:
MH1070
a. Remove the capscrews (1), lockwashers (2) and
flat washers (3) holding the bottom wear pad (4) c. Remove the capscrews (13), lockwashers (14) and
and spacer (5) to the intermediate boom. Label flat washers (15) holding the side wear pads (16)
the wear pad and spacer as “Bottom.” Save the and shims (17) to the intermediate boom. Label
capscrews, lockwashers, flat washers, spacer the wear pads and shims as “Left Side Top” and
and wear pad inserts (6). “Right Side Top/Bottom.” Save the capscrews,
inserts (18).
13
1 17
14
2
15
18
16
5
MH1080
4
6 MH1060
3.14 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
d. At the front of the intermediate boom, remove the 3.3.3 Outer Boom Removal
capscrew (19) and lockwasher (20) holding the
WARNING:
extend chain sheave pin (21) to the mounting
ears on the intermediate boom. Remove the pin Wear protective footwear
from the mounting ears and the extend chain with reinforced toe caps and slip-resistant
sheave (22). Remove the extend chain sheave soles. Failure to comply can result in foot or
and inspect the condition of the sheave bushings. other bodily injury from crushing, slipping or
Replace the bushings if showing any signs of falling.
wear.
WARNING:
e. Inspect the pin (21), and replace it pin if there are
any signs of wear. NEVER lift a heavy object
1. Remove both the inner boom and intermediate

boom as described in Section 3.3.1, “Inner Boom
20 Removal,” and Section 3.3.2, “Intermediate Boom
Removal.”
2. Use a suitable overhead lifting device and sling
22 attached to the Lift/Lower cylinder; remove slack
19 from the sling.
3. Securely block the outer boom section.
21 4. At the front of the outer boom, remove the
MH1090 capscrews (23) and lockwashers (24) holding the
wear pads (25) and spacers (26) to the inside of the
outer boom. Label the wear pads and spacers as
“Lower Left” or “Lower Right.” Save the capscrews,
lockwashers, spacers and wear pad inserts (27).
27
25
26
24
23 MH1100
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.15

Boom
5. At the underside of the outer boom, locate the retract 10. Without auxiliary hydraulics: Label and remove
chain locknut (1). Measure the amount of threads the Attachment Tilt retract (outer) hose (3) and the
protruding beyond the elastic locknut and record that extend (inner) hose (4) from the bulkhead fittings on
measurement for reassembly of the chain. Remove the mounting plate (5). Plug the hose ends and cap
the elastic locknut and the flat washer (2). Save the flat the bulkhead fittings. Remove the Attachment Tilt
washer and discard the locknut. tubes (6) from the bulkhead fittings.
MH1120
2 1 MH1110
11. At the rear right side of the outer boom, label and
remove the boom extend hose (14) and retract
6. Remove the retract chain by pulling it out the rear of
hose (15) from the bulkhead fittings on the mounting
the boom. Place the retract chain on a clean surface.
plate (16). Plug the hose ends and cap the bulkhead
7. With auxiliary hydraulics: At the rear left side of the fittings.
outer boom, label and remove the (outer) auxiliary
hose for the female coupler (7) and the (inner) hose
(8) for the male nipple from the bulkhead fittings on the
16
mounting plate (9).
8. Label and remove the Attachment Tilt retract (outer)
hose (9) and the extend (inner) hose (11) from the 15
bulkhead fittings on the mounting plate (9). Plug the
hose ends and cap the bulkhead fittings. 14
9. Remove the auxiliary tube assemblies (12) and the
attachment tube assemblies (13) from the bulkhead
fittings.
MH1140
13 9
10 12. Remove the capscrew (17) and elastic locknut (18)

holding the tube clamps (19) and clamp covers (20)
to the extend (21) and retract (22) tubes under the
11 boom. Discard the elastic locknut and retain the
12 capscrew, covers and clamps.
9
8
MH1130
3.16 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
22
21
17
20
31
19
20 29
30
18 28
MH1180
MH1150
17. Without auxiliary hydraulics: Label the auxiliary

13. At the rear right side of the outer boom, label and tube assemblies (32) located under the Attachment
remove the extend tube (23) and retract tube (24) Tilt tubes (33). Remove the capscrews (34) holding
from the bulkhead fittings (25). Plug the tube ends the tube clamps (35) and clamp covers (36) to the
and cap the bulkhead fittings. Attachment Tilt tube clamp stacking bolt (37) under
14. Remove the extend tube (23) and retract tube (24) the outer boom. Save the capscrews, clamps and
from the 90° elbow fittings (26) on the rear of the clamp covers. Remove the tubes from the boom.
Extend/Retract cylinder (27). Plug the tube ends and
18. Label the Attachment Tilt tube assemblies (33) located
cap the 90° elbows.
under the boom. Remove the stacking bolts (37)
24 23 holding the tube clamps (38), locking plates (39) and
Attachment Tilt tubes (33) to the underside of the
24 outer boom. Save the stacking bolts, clamps and
25 locking plates. Remove the tubes from the boom.
19. Inspect all tubes (32 and 33) for kinks or crushed
areas. If any kinks or crushed areas exist, replace
23 the damaged tube or tubes.
27
26 MH1160
15. Without auxiliary hydraulics: Label the 38

Attachment Tilt tube assemblies located under the
boom. Remove the capscrews (28) holding the tube 33 39
clamps (29), clamp covers (30) and Attachment Tilt
32
tubes (31) to the underside of the outer boom. Save the 37
capscrews, clamps and clamp covers. Remove the
tubes from the boom.
16. Inspect the tubes (31) for kinks or crushed areas. If 35
any kinks or crushed areas exist, replace the
damaged tube or tubes. 36 34
MH1190
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.17

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
6
the hose ends and cap the straight connectors on 10
the Slave cylinders.
7
2 4
1
9
2
3 8 MH1210
27. On the right side boom pivot mounting plate, locate

1 the boom proximity sensor (11). Remove the nut (12) on
the inside of the mounting plate. Remove the boom
proximity sensor from the outside of the plate and
3 allow the sensor to rest on top of the frame, next to the
MH1200
mounting plate. The sensor can remain connected to
the harness.
22. Remove the capscrew (1) and elastic locknut (2)
holding the upper Slave cylinder pivot pin (3) to the
12
outer boom. Use a hoist and a sling to hold the Slave
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 11
pin to remove the pin. Discard the elastic locknut and
retain the capscrew.
holding the lower Slave cylinder pivot pin (9) to the
mounting ear on the frame. Use a brass punch and a
rawhide hammer to remove the lower pivot pin from
the mounting ear. Discard the elastic locknut and MH1220
24. Inspect the pivot pins (9) for nicks or damage. If the 28. Remove the capscrew (13) and elastic locknut (14)
pins are damaged, they must be replaced. holding the upper Lift/Lower cylinder pivot pin (15) to
the outer boom. Securely block the Lift/Lower cylinder in
25. Use the hoist to remove the Slave cylinder (10) from position. Remove the pivot pin from the pin mount by
the vehicle. Place the Slave cylinder on a clean, flat pulling the pin out. It may be necessary to use an
surface. appropriate puller threaded into the pivot pin to remove
26. Repeat Steps 22 thru 25 to remove the other Slave the pin. Discard the elastic locknut and retain the
cylinder. capscrew.
3.18 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
29. Inspect the pivot pin (15) for nicks or damage. If the c. Discard the elastic locknuts and retain the
pin is damaged, it must be replaced. capscrews, flat washers, cover plates, clamp,
30. Repeat Steps 28 and 29 to remove the other Lift/ safety plate and stop plate.
Lower cylinder.
22
20
14
24
13 26
25
25
24 23
15
MH1230
21 MH1250
31. Remove the capscrews (16) and elastic

34. Use a hoist and slings to support the Extend/Retract
locknuts (17) holding the boom pivot pins (18) to the
cylinder. At the base end of the cylinder, remove a
frame. Use a brass punch and a rawhide hammer to
retaining ring (27) from one side of the cylinder base
remove the pivot pins from the frame. While removing
end pin (28). Use a brass punch and a rawhide
the pins, note the location and quantity of shims (19)
hammer to remove the base end pin from the
between the outer boom and frame.
mounting ears on the outer boom.
19 35. Inspect the pin (28) for damage. If the pin is
16
damaged, it should be replaced. Retain the retaining
rings for reassembly.
36. Lower the base end of the Extend/Retract cylinder
and remove the rod end of the cylinder from the
retainer at the front of the boom. Place the Extend/
Retract cylinder on a clean, flat surface.
18
17 MH1240
32. Use the hoist to remove the outer boom from the
frame. Position the outer boom on a hard, flat
surface. Block the boom as required to allow removal
of the Extend/Retract cylinder from the underside of 27
the boom.
33. This step is for Model 10042 S/N 13198 thru 18405 28
Only:
Note: On Model 10042 S/N 18406 & After, the stop
plate is an internal component of the extend/retract MH1260
cylinder.
a. Remove the boom stop plate (20) from the rod of
the Extend/Retract cylinder.
b. Remove the capscrews (21), elastic locknuts (22)
and flat washers (23) holding the stop plate (20),
cover plates (24), clamp (25) and safety plate
(26) to the Extend/Retract cylinder rod.
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.19

Boom
37. At the front of the outer boom, remove the elastic 42. Remove the self-aligning bearings (10) from the Lift/
locknut (1) holding the rubber bumper (2) to the Lower cylinder mounts (8) and the Slave cylinder
Extend/Retract cylinder retainer (3). Discard the mounts (9).
elastic locknut. 43. Inspect the bearings (10). If the bearing rotates
38. Inspect the rubber bumper (2). If it is in good freely inside the outer race, the bearing can be
condition, the rubber bumper can be reused. If the reused.
rubber bumper is showing signs of cracking or
deterioration, it should be replaced.
10
9
7
2 10
7 8 MH1290
1 3 MH1270
44. On the left side of the outer boom, remove the
locknut (11), angle indicator (12) and flat
39. Remove the elastic locknut (4) and shoulder bolt (5) washers (13) from the weld stud. Save the angle
holding the two yoke plates (6) to the mount at the indicator and all the hardware for reassembly.
front of the outer boom. Retain the shoulder bolt and
discard the elastic locknut.
40. Inspect the yoke plates (6) for wear or distortion. If
any wear or distortion is detected, both plates must 13
be replaced. If no wear is detected, the plates can
remain assembled to the extend chain clevis.
5 11
12
MH1300
45. Remove the extend and retract bulkhead fittings (14)

4
from the mounting plate on the right side of the outer
boom assembly.
46. Remove the Attachment Tilt bulkhead fittings (15)
MH1280 from the mounting plate on the left side of the outer
boom assembly.
41. Remove the grease fittings (7) from the Lift/Lower
47. If equipped with optional auxiliary hydraulics, remove
cylinder mounts (8) and the Slave cylinder
the auxiliary hydraulic bulkhead fittings (16).
mounts (9) on the outer boom. Save the grease
fittings for reassembly. 48. Inspect all fittings (14, 15 and 16) for damage. If the
fittings or threads are damaged, the fittings should
be replaced.
3.20 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
1. On the rear of the boom, assemble the extend and

14 retract bulkhead fittings (17) to the mounting plate on
15 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.
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.
2. On the rear of the boom, assemble the Attachment
Tilt bulkhead fittings (19) to the mounting plate on
the left side. Insert the fittings from the bottom up
into the set of holes closest to the boom and secure
in place with the bulkhead fitting nuts (20) on the top
16 MH1310 side. Tighten securely.
3. If equipped with optional auxiliary hydraulics,
49. Inspect the boom and welds. Contact the local Sky assemble the auxiliary hydraulic bulkhead
Trak distributor or the JLG Service Department at fittings (21) to the mounting plate on the left side.
1-877-554-5438 or 1-717-485-6657, if structural Insert the fittings from the bottom up into the outer
damage is detected. set of holes and secure in place with the bulkhead
50. Inspect hoses, hardware, wear pads, mounting fitting nuts (22) on the top side. Tighten securely.
points, chains and other components visible with the
outer boom removed. Replace if damaged. 17
51. Inspect all wear pads for wear. (Refer to Section 19
3.3.4 Outer Boom Installation
WARNING:
18
Wear protective footwear
with reinforced toe caps and slip-resistant 20
soles. Failure to comply can result in foot or
21
other bodily injury from crushing, slipping or
falling.
WARNING: NEVER lift a heavy object 22 MH1310

suitable sling and hoist. Failure to comply can Note: If you are assembling a new outer boom
result in death or serious personal injury. assembly, continue with Step 4. If reassembling the
existing boom assembly, go to Step 5.
IMPORTANT: Light lubrication of the boom wear surfaces
with a rust inhibitor/lubricant such as LPS 3 or equivalent
is recommended to keep the boom wear surfaces
lubricated properly. Light lubrication of the boom wear
surfaces is also recommended in salt air climates and
when the vehicle is stored, to help prevent rusting.
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.21

Boom
4. Assemble a new angle indicator decal (1) to the left 8. Install grease fittings (13) into the Lift/Lower cylinder
side of the boom assembly. Place the hole in the mounts (7) and the Slave cylinder mounts (12) on
decal around the weld stud (2) and line up the upper the outer boom. Tighten all the grease fittings.
edge of the decal parallel with the top edge of the
boom assembly. 12
1
11
6 13
8
13
2 10
MH1320
9
5. Place the two flat washers (3) and the angle
indicator (4) onto the weld stud. Secure in place with MH4380
the locknut (5). After tightening the locknut, the angle
indicator must pivot freely on the weld stud. If the Note: Slings and a hoist are required to perform the
angle indicator binds, loosen the locknut slightly. following step.
Recheck to be sure the angle indicator pivots freely.
9. Position the Extend/Retract cylinder (14) with the
extend and retract port elbows facing down. Place
the rod end of the Extend/Retract cylinder (15)
3 through the Extend/Retract cylinder retainer at the
front of the outer boom. 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 (16)
5
under the outer boom.
10. Coat the base end cylinder pin with anti-seize
compound. Insert the base end cylinder pin (17)
4 through both mounting ears and the base end of the
MH1300
Extend/Retract cylinder. Secure the pin in place with
a retaining ring (18) on each side of the pin. Be sure
6. Install new or saved Lift/Lower cylinder bearings (6) the retaining rings are completely seated in the
into the Lift/Lower cylinder mounts (7) on each side grooves on each side of the pin.
of the boom assembly. Orient the fracture (8) in the
outer race of each bearing so that it is perpendicular
to the force of the load. Press the bearings into
position until the edge of the outer race (9) of each 18
bearing is flush with the edge of the plate (10).
7. Install new or saved Slave cylinder bearings (11) into
the Slave cylinder mounts (12) on each side of the
boom assembly. Orient the fracture (8) in the outer 17
race of each bearing so that it is perpendicular to the
force of the load. Press the bearings into position
until the edge of the outer race (9) of each bearing is 16
15 18
flush with the edge of the plate (10). 14
MH1350
3.22 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
Note: ALWAYS replace elastic locknuts with new elastic

locknuts to help ensure proper fastening. 32
23
11. Lift the rod end of the Extend/Retract cylinder (19) 31
far enough to insert the threaded stud on the rubber 30
bumper (20) into the hole in the Extend/Retract
cylinder retainer (21). Secure the rubber bumper in 29
place with a new elastic locknut (22). Tighten 24
securely. Lower the rod end of the Extend/Retract 27
cylinder, and allow it to rest on the rubber bumper.
26 25
28 MH1250
13. Using a hoist capable and slings, lift the outer boom
assembly and position the boom on the frame. Align
the mounting plates (33) on the frame between the
mounting hubs (34) on each side of the boom
19 assembly. Lower the boom assembly until the holes
in the boom assembly and the mounting plates align.
20 MH1360
22 33
21
34
12. This step is for Model 10042 S/N 13198 thru 18405
Only:
Note: On Model 10042 S/N 18406 & After, the stop
plate is an internal component of the extend/retract
cylinder. 34
Install the boom stop plate: 33
a. Extend the boom far enough to reassemble the
boom stop plate (23) to the extend cylinder
rod (24).
b. Place the flat washers (25), saved, a cover
plate (26), saved, and a clamp (27), saved, onto
MH1370
the capscrews (28), saved.
c. Place the clamp and capscrews onto the bottom
of the extend cylinder rod and place the other
clamp (29), saved, the safety plate (30), saved,
the other cover plate (31), saved, and the stop
plate (23) on top of the cylinder rod. Secure the
capscrews and clamps in place with two new
elastic locknuts (32). Be sure the stop plate is
lined up with the bottom edge of the outer boom
and tighten both elastic locknuts securely.
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.23

Boom
14. On the end of the boom pivot pin (1), closest to the 19. Coat the entire Lift/Lower cylinder pivot pin (8) with
capscrew hole, mark the capscrew mounting hole anti-seize compound. Insert the pin through the rod
location. Coat the entire pin with anti-seize end of the cylinder and the self-aligning bearing. If
compound. necessary, use a rawhide hammer to install the pin.
15. Insert the pivot pin (1) from the outside of the boom Note: ALWAYS replace elastic locknuts with new elastic
assembly, making sure the marks for the capscrew locknuts to help ensure proper fastening.
mounting hole stay in line with the capscrew
mounting holes in the boom mounting hub. If 20. Use a tapered punch to align the capscrew mounting
necessary, use a rawhide hammer to install the pivot hole in the pin with the mounting tabs on the rod end
pin. of the cylinder. Secure the pin in place with the
capscrew (9), saved, and a new elastic locknut (10).
16. Shim the boom as required using the shims (2), Tighten the elastic locknut securely.
saved, to maintain a .10" (2,5 mm) maximum gap (3)
between the boom mounting hub and the self 21. Repeat Steps 18 thru 20 to install the Lift/Lower
aligning bearing (4) in the frame. If an additional cylinder on the other side of the outer boom.
shim is required to maintain the maximum gap, the
extra shim MUST be inserted on the right side of the 10
boom.
9
3
4
5
8
7 MH1230
2 22. Use a hoist and sling to position the Slave

cylinder (11) onto the lower cylinder mount (12)
located on the frame. The cylinder should be
positioned with the extend and retract port
fittings (13) to the outside.
1 Note: ALWAYS replace elastic locknuts with new elastic
6 23. Coat the lower pivot pin (14) with anti-seize
MH1380
compound. Insert the pin through the base end of
the Slave cylinder. Use a tapered punch to align the
capscrew hole in the pin with the mounting tabs on
the cylinder. Secure the lower pivot pin in place with
17. After the pivot pin and shims are in place, use a the capscrew (15), saved, and a new elastic
tapered punch to align the capscrew hole in the pin locknut (16). Tighten the elastic locknut securely.
with the mounting holes in the hub. Insert the 24. Position the rod end of the Slave cylinder around the
capscrew (5), saved, through the hub and the pin. self-aligning bearing on the outer boom.
Secure the capscrew in place with a new
elastic locknut (6). Tighten the elastic locknut
securely.
18. Align the rod end of one of the Lift/Lower
cylinders (7) with the self-aligning bearing on the
outer boom assembly.
3.24 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom

22
25. Coat the upper pivot pin (17) with anti-seize
compound. Insert the pin through the rod end of the 21
Slave cylinder. If necessary, use a rawhide hammer
to install the upper pivot pin. Use a tapered punch to 20
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). Tighten the elastic locknut
securely.
26. Repeat Steps 22 thru 25 to install the other Slave
cylinder to the other side of the outer boom. MH1390
29. Assemble the extend tube (24) to the extend port 90°
19
elbow (25) on the Extend/Retract cylinder (26) and
the inside bulkhead fitting (27) on the right side of
the outer boom. Hand-tighten the tube fitting to the
17
11 90° elbow. Reposition the tube as needed to align
the other end of the tube with the bulkhead fitting.
Tighten the tube end at the bulkhead fitting and then
15 tighten the tube end at the 90° elbow.
18
13 30. Assemble the retract tube (28) to the retract port 90°
12 14 elbow (29) on the Extend/Retract cylinder (26) and
the outside bulkhead fitting (30) on the right side of
the outer boom. Hand-tighten the tube fitting to the
16 MH1210 90° elbow. Reposition the tube as needed to align
the other end of the tube with the bulkhead fitting.
27. Install the boom proximity sensor (20) on the right Tighten the tube end at the bulkhead fitting and then
side mounting plate. With the boom properly tighten the tube end at the 90° elbow.
shimmed, position the boom assembly all the way to
the right side.
28. Insert the boom proximity sensor (20) through the 28 24
hole in the right side mounting plate (21). Install the
28
jam nut (22), saved, onto the boom proximity sensor 30
on the inside of the plate. Adjust the inner and outer
jam nuts on the boom proximity sensor until the 24
gap (23) between the sensor and the boom is .12" 27
(3 mm). Torque the inside jam nut to 36 lb-in
(4,1 Nm), to hold the boom proximity sensor in
position. 26
25
29 MH1160
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.25

Boom
Note: ALWAYS replace elastic locknuts with new elastic 34. Without auxiliary hydraulics: Position the extend
locknuts to help ensure proper fastening. tube assembly (9) onto the inner bulkhead
fitting (10). Loosely assemble the nut on the tube
31. Assemble the tube clamp halves (1) to the extend (2)
assembly to the bulkhead fitting; DO NOT fully
and retract (3) tubes under the outer boom. Place
tighten until both tubes are assembled at both ends.
one clamp half on top of the tubes and one on the
underside of the tubes. Place a clamp cover (4) on 35. Position the retract tube assembly (11) onto the
the top and bottom of the clamps. Secure in place outer bulkhead fitting (12). Assemble the nut on the
with the capscrew (5), saved, and a new elastic tube assembly to the bulkhead fitting; DO NOT fully
locknut (6). Position the clamp halves to securely tighten until both tubes are assembled at both ends.
hold the tubes without putting tension on either tube.
Tighten the elastic locknut securely. 11
9 12
3 10
2 9
5
4
4 11
6
MH1420
MH1150
36. With auxiliary hydraulics: Position the extend tube

32. Assemble the boom extend hose (7) to the inside assembly (13) onto the inner bulkhead fitting (14).
bulkhead fitting (extend tube) on the right side of the Assemble the nut on the tube assembly to the
boom. Remove all twists from the boom extend bulkhead fitting; DO NOT fully tighten until all the
hose, and tighten the hose end securely to the tubes are assembled at both ends.
bulkhead fitting.
37. Position the retract tube assembly (15) onto the
33. Assemble the boom retract hose (8) to the outside second bulkhead fitting (16). Assemble the nut on
bulkhead fitting (retract tube) on the right side of the the tube assembly to the bulkhead fitting; DO NOT
boom. Remove all twists from the boom retract hose, fully tighten until all the tubes are assembled at both
and tighten the hose end securely to the bulkhead ends.
fitting.
38. Position the inner auxiliary tube assembly (17) onto
the third bulkhead fitting (18). Assemble the nut on
the tube assembly to the bulkhead fitting; DO NOT
fully tighten until all the tubes are assembled at both
ends.
8 39. Position the outer auxiliary tube assembly (19) onto

the outer bulkhead fitting (20). Assemble the nut on
the tube assembly to the bulkhead fitting; DO NOT
7 fully tighten until all the tubes are assembled at both
ends.
MH1140
3.26 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
41. With auxiliary hydraulics: Assemble the tube

15 clamp halves, saved, to the underside of the outer
boom. Place a upper clamp half (25) on each side of
13 16 the Attachment Tilt (upper) tubes (26). Secure each
set of clamp halves to the boom with a locking
14 plate (27), saved, and a stacking bolt (28), saved.
17
Tighten the stacking bolt securely to hold the upper
tubes in place.
19
42. Place a lower clamp half (29) on each side of the
auxiliary hydraulic (lower) tubes (30). Secure each
set of clamp halves to the stacking bolt with a clamp
20 cover (31), saved, and a capscrew (32), saved.
Tighten the capscrew securely to hold the lower
tubes in place.
43. Repeat Steps 41 and 42 to assemble the clamps at
18 MH1440 the other two clamp locations under the outer boom.
40. Without auxiliary hydraulics: Assemble the tube

clamp halves (21), saved, to the underside of the
outer boom. Place a clamp half on each side of the
Attachment Tilt tubes (22). Secure each set of clamp
halves to the boom with a clamp cover (23), saved,
and a capscrew (24), saved. Tighten the capscrew
securely to hold the tubes in place. Repeat for the
other two clamp locations under the outer boom.
25
26 27
30
28
22
29
21 31 32
MH1190
23
24 MH1180
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.27

Boom
44. Without auxiliary hydraulics: At the rear left side

of the boom, connect the Attachment Tilt extend 8
(inner) hose (1) to the inner bulkhead fitting (2).
Remove all twists from the hose, and tighten the 7
hose end securely to the bulkhead fitting. 6
45. Connect the Attachment Tilt retract (outer) hose (3)
to the outer bulkhead fitting (4). Remove all twists 5
from the hose, and tighten the hose end securely to
the bulkhead fitting. Proceed to Step 49.
12
11
2 10
4
9
MH1130
49. Inside the rear of the outer boom, slide the threaded
clevis end (13) of the retract chain down the right
3
side of the boom. Guide the threaded part of the
clevis out through the hole in the tab (14) on the
1
bottom of the outer boom. Pull threaded part of
clevis all the way through the tab.
MH1120
46. With auxiliary hydraulics: At the rear left side of locknuts to help ensure proper fastening.
the boom, connect the Attachment Tilt extend (inner)
50. Coat the entire threaded portion of the clevis (13)
hose (5) to the inner bulkhead fitting (6). Remove all
with multi-purpose grease. Install one flat
twists from the hose, and tighten the hose end
washer (15), saved, onto the threaded clevis and
securely to the bulkhead fitting.
assemble a new elastic locknut (16). Thread the nut
47. Connect the Attachment Tilt retract (second) onto the clevis until the threads are flush with the top
hose (7) to the second bulkhead fitting (8). Remove of the nut.
all twists from the hose, and tighten the hose end
securely to the bulkhead fitting. 14
48. Connect the auxiliary hydraulic (third) hose (9) for the
male nipple to the third bulkhead fitting (10). Remove
all twists from the hose, and tighten the hose end
securely to the bulkhead fitting. Assemble the
auxiliary hydraulic (outer) hose (11) for the female
coupler to the outer bulkhead fitting (12). Remove all
twists from the hose, and tighten the hose end
securely to the bulkhead fitting.
13
16 15 MH1460
3.28 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
51. At the front of the outer boom, reassemble the lower 52. Install the intermediate boom, retract chain and
outside wear pads (17) and wear pad spacers (18): attaching hardware. (Refer to Section 3.3.5,
a. Place the wear pad inserts (19) into the cavities “Intermediate Boom Installation.”)
in the wear pad. Be sure the inserts are seated 53. Install the inner boom, extend chain and attaching
completely in the cavities. hardware. (Refer to Section 3.3.6, “Inner Boom
b. Place a wear pad (17) and a spacer (18) into the Installation.”)
outer boom with the hole offset of the wear pad 54. Clean up all debris, hydraulic fluid, etc., in, on, near
toward the middle of the boom. Align the holes in
and around the vehicle.
the spacer and wear pads with the holes in the
bottom of the boom.
c. Apply Loctite® 242 threadlocker to the threads of WARNING: Avoid prolonged engine
the capscrews (20), saved. Insert the capscrews operation in closed areas without adequate
with lockwashers (21), saved, through the bottom ventilation. Failure to properly ventilate
of the boom and into the wear pads. Be careful exhaust fumes can result in death or serious
not to push the wear pad inserts out of the wear personal injury.
pads.
d. Torque all wear pad mounting capscrews to 55. Start the engine and operate all boom functions
31 ±3 lb-ft (42 ±4 Nm). several times. Check the chain tension again and
adjust as necessary. Check for leaks, and check the
e. Fill wear pad cavities with a good grade of
hydraulic fluid level in the tank; add fluid if required.
lithium-based EP grease.
f. Repeat Steps a thru e to install the lower wear 56. Apply grease at all lubrication points (grease fittings).
pad on the other side of the outer boom. (Refer to Model 8042 Legacy Owners/Operators
Manual or Model 10042 Legacy Owners/Operators
Manual.)
19
19
17
17
18
18
21
20 20 21 MH1470
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.29

Boom
3.3.5 Intermediate Boom Installation 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
WARNING:
horizontal direction.
Wear protective footwear 3. Assemble the hose reel assembly, left side and
with reinforced toe caps and slip-resistant bottom wear pads to the rear of the intermediate boom:
soles. Failure to comply can result in foot or a. Apply Loctite® 242 threadlocker to the threads of
other bodily injury from crushing, slipping or the two capscrews (6), saved. Insert a capscrew
falling. with a lockwasher (7), saved, and a flat
washer (8), saved, through each of the mounting
holes in the left side plate of the hose reel
assembly. Place three flat washers (8), saved, onto
without the help of at least one assistant or a each of the capscrews and insert the capscrews
suitable sling and hoist. Failure to comply can through the mounting holes in the left side of the
result in death or serious personal injury. boom.
b. Place the wear pad shims (9), saved, onto the
1. At the rear of the intermediate boom, assemble the capscrews. Place the shims onto the capscrews
retract chain sheave (1) to the mounting ears on the with the holes offset to the top.
right side of the boom. Place the sheave between the
ears and insert the sheave pin (2) from the left side. c. Place the wear pad inserts (10), saved, into the
Align the hole in the pin retainer plate with the threaded cavities in the wear pad (11). Be sure the inserts
hole in the left ear. Secure the pin in place with the are seated completely in the cavities.
capscrew (3), saved, and the lockwasher (4), saved. d. Install the wear pad (11) onto the capscrews. Be
Tighten the capscrew securely. careful not to push the wear pad inserts out of
2. Apply grease to the grease fitting (5) in the pin. Spin the wear pads.
the sheave by hand to ensure the sheave spins freely on e. Apply Loctite® 242 threadlocker to the threads of
the pin and to distribute grease evenly. 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 right side plate of the hose reel
assembly.
f. Place the wear pad inserts (9), saved, into the
1 cavities in the wear pad (10), saved. Be sure the
2 inserts are seated completely into the cavities.
g. Place the wear pad spacer (11), saved, and the
5 wear pad under the intermediate boom. With the
holes offset to the left, align the holes and secure
the hose reel, wear pad spacer and wear pad to
the intermediate boom. Be careful not to push
4 the wear pad inserts out of the wear pads.
3
h. Torque all wear pad mounting capscrews to
MH1480 31 ±3 lb-ft (42 ±4 Nm).
i. Fill all wear pad cavities with a good grade of
3.30 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
Note: Shim ALL upper rear wear pads as needed to

10 11 maintain a total maximum gap of .06" (1,5 mm) at the
rear of the pads and maintain a total minimum gap of .07
8
8 to .13" (1,8 to 3,3 mm) in the vertical direction.
7
5. Assemble the top wear pads to the top of the
6 intermediate boom. Position the wear pads so the
9 outside pads are offset to the outside and the center
pad is offset to the right:
a. Apply Loctite® 242 threadlocker to the threads of
the capscrews (18), saved.
top of the boom. Align the holes in the shims with
the holes in the boom.
c. Place the wear pad inserts (20), saved, into the
wear pad (21) cavities in the wear pad. Be sure
MH1500 the inserts are seated completely in the cavities.
Place the wear pads on top of the shims.
4. Install the intermediate boom side wear pads:
d. Insert a capscrew with a lockwasher (22) and a
a. Apply Loctite® 242 threadlocker to the threads of flat washer (23), saved, through each of the
the capscrews (12), saved. Insert a capscrew mounting holes in the top of the intermediate
with a lockwasher (13), saved, and a flat boom. Be careful not to push the wear pad
washer (14), saved, through each of the wear inserts out of the wear pads.
pad mounting holes in the side plates of the
e. Torque all wear pad mounting capscrews to
intermediate boom.
31 ±3 lb-ft (42 ±4 Nm).
f. Fill all wear pad cavities with a good grade of
capscrews. Place the shims onto the capscrews
with the holes offset to the center.
c. Place the wear pad inserts (16), saved, into the
20
cavities in the wear pad (17). Be sure the inserts
are seated completely in the cavities.
d. Install the wear pad (17) onto the capscrews. Be 21
careful not to push the wear pad inserts out of 19
the wear pads.
31 ±3 lb-ft (42 ±4 Nm). 23
f. Fill all wear pad cavities with a good grade of
lithium-based EP grease. 22
18
12
13 15
14
MH1520
17 16
MH1510
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.31

Boom
6. Spray the wear pad pathways on the inside of the 10. Install the side wear pads to the outer boom:
outer boom, inside of the intermediate boom and the a. Slide the intermediate boom over to one side as
underside of the intermediate boom with LPS3 or far as it will go, to allow wear pad installation.
equivalent.
b. Place the wear pad inserts (4), saved, into the
7. Before installing the intermediate boom into the cavities of the side wear pads (5), saved. Place
outer boom, place a string (heavy enough to pull the the shims (6), saved, onto the wear pad and align
Attachment Tilt and auxiliary hydraulic hoses) down the holes.
the inside of the outer boom. Allow the string to hang c. Fill all wear pad cavities with a good grade of
out the rear of the boom. Pull the other end out the lithium-based EP grease.
opening on the left side of the boom where the d. Apply Loctite® 242 threadlocker to the threads of
hoses will exit the boom. Place one string for each the capscrews (7), saved. Slide the wear pad
hose in the boom. Position the strings all the way to with shims in between the intermediate boom
the left side of the outer boom. and the outer boom with the offset of each wear
8. Use the hoist and slings to slightly lift the front of the pad away from the center. Align the holes and
intermediate boom to allow installation of the center secure in place with the capscrews (7),
lockwashers (8), saved, and flat washers (9),
wear pad:
saved. Be careful not to push the wear pad
a. Fill all wear pad cavities with a good grade of inserts out of the wear pads.
lithium-based EP grease. e. Torque all wear pad mounting capscrews to
b. Slide the center wear pad mount (1) into the 31 ±3 lb-ft (42 ±4 Nm).
outer boom with the wear pad offset toward the f. Repeat Steps a thru e to install the side wear
right side. Line up the threaded holes in the wear pads on the other side of the outer boom.
pad mount with the holes in the bottom of the
outer boom.
c. Apply Loctite® 242 threadlocker to the threads of
the capscrews (2), saved. Secure the wear pad
mount to the outer boom with the capscrews (2)
and lockwashers (3), saved.
d. Torque all wear pad mounting capscrews to
31 ±3 lb-ft (42 ±4 Nm).
8
7
4
9
1
5
6 MH1540
3
2 MH1530
9. Remove the slings and the hoist from the

intermediate boom.
3.32 Model 8042, 10042, 10054 Legacy Rev. 03/04

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 18
the capscrews (12), saved. Slide the wear pad 15
between the intermediate boom and the outer
boom with the offset of each wear pad away from 17
the center. Align the holes and secure in place
with the capscrews (12), lockwashers (13),
saved, and flat washers (14), saved. Be careful 16
not to push the wear pad inserts out of the wear MH1090
pads.
d. Torque all wear pad mounting capscrews to 14. Use a hoist and sling to lift the rod end of the Extend/
31 ±3 lb-ft (42 ±4 Nm). Retract cylinder (19). Align the rod end of the
Extend/Retract cylinder with the mounts (20) at the
12 13 front of the intermediate boom.
15. Coat the Extend/Retract cylinder rod end pin (21),
14 saved, with anti-seize compound. Insert the rod end
pin through the mounts and secure in place with the
retaining rings (22), saved. Be sure the retaining
rings are securely seated in the rod end pin grooves.
11
10
MH1550
12. Place the double extend chain sheave (15), saved,

between the mounts at the front of the intermediate 22
boom. Insert the sheave pin (16), saved, through the
mounts and the double sheave. Align the mounting
20 21
hole in the sheave pin with the threaded hole in the
sheave mount and secure in place with the saved
capscrew (17) and lockwasher (18). Tighten 19 22
securely. 20 MH1560
13. After the sheave is assembled, grease the sheave

with a good grade of multi-purpose grease. Turn the
sheave by hand to distribute the grease evenly.
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.33

Boom
16. Install the intermediate boom front, bottom wear pads: IMPORTANT: Light lubrication of the boom wear
a. Place the wear pad inserts (1), saved, into the surfaces with a rust inhibitor/lubricant such as LPS 3 or
cavities of the front bottom wear pads (2), saved. equivalent is recommended to keep the boom wear
surfaces lubricated properly. Light lubrication of the boom
b. Place the wear pads and spacers (3), saved, into
wear surfaces is also recommended in salt air climates
the intermediate boom with the offset of the wear
pads toward the outside. and when the vehicle is stored, to help prevent rusting.
c. Apply Loctite® 242 threadlocker to the threads of 1. Stretch the Attachment Tilt and auxiliary hoses out
the capscrews (4), saved. Align the holes and straight on a flat surface. Measure from the male
secure in place with the capscrews (4) and end (6) of each hose back 196" (498 cm) and apply
lockwashers (5), saved. Be careful not to push tape (7) around each hose at that point. The tape is
the wear pad inserts out of the wear pads. for proper tensioning of the hoses during reassembly
d. Torque all wear pad mounting capscrews to of the hose clamps.
31 ±3 lb-ft (42 ±4 Nm).
e. Fill all wear pad cavities with a good grade of
6.0 )
19 8 cm
(49
6 MH1400
1
2. Without auxiliary hydraulics: Slide the elbow ends
of the two Attachment Tilt hoses (8 and 9) down the
2 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
3 5 gooseneck, pull both hoses out. Be careful not to
4 cross the hoses as you pull them out. Label the left
MH1570
side hose (8) as “Retract” and the right side hose (9)
as “Extend.” Label the hoses the same on the male
3.3.6 Inner Boom Installation end of each hose.

with reinforced toe caps and slip-resistant soles.
Failure to comply can result in foot or other
bodily injury from crushing, slipping or falling.

without the help of at least one assistant or a 8
MH1600
9
3.34 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
3. With auxiliary hydraulics: Slide the elbow ends of 5. Without auxiliary hydraulics: Keep the two hoses
the two Attachment Tilt hoses (10 and 11) down the on the left and right sides as they come out of the
inner boom and out to the gooseneck. Keep the rear of the inner boom. Place a lockwasher (14),
hoses next to each other as they are being pushed saved, onto each capscrew (15), saved, and insert
down the inner boom. the capscrews through the clamp cover plate (16),
At the opening in the gooseneck, pull both hoses saved.
out. Be careful not to cross the hoses as you pull 6. Place a hose clamp half (17), saved, onto the
them out. Label the left side hose (10 ) as “Retract” capscrews. Place the right Attachment Tilt hose (18)
and the right side hose (11) as “Extend.” Label the and a hose clamp half (17) onto the capscrews.
hoses the same on the male end of each hose. 7. Place another hose clamp half (17), saved, the left
4. Slide the female end of the two auxiliary hydraulics Attachment Tilt hose (19) and a hose clamp half (17)
hoses (12 and 13) down the inner boom and out the onto the capscrews.
gooseneck. Keep the auxiliary hoses to the left and 8. Place two more hose clamp halves (17) onto the
right sides of the Attachment Tilt hoses (10 and 11). capscrews positioned as shown. Assemble the
At the opening in the gooseneck, pull both hoses out capscrews to the left side of the inner boom. Tighten
and down toward the bulkhead plate for the couplers. the capscrews only enough to hold the hoses in
Keep the left side hose (12) on the left side and label place.
that hose as “Female Coupler.” Label both ends of 9. Position the Attachment Tilt hoses (18 and 19) with
the hose. Keep the right side hose (13) on the right the edge of the tape (20) at the hose clamps. Hold
side and label that hose as “Male Nipple.” Label both the Attachment Tilt hoses in this position and tighten
ends of the hose. the two capscrews securely to hold the hoses.
17
17
16
14
19
18 15
10
17
20
11
19
20
18 MH1620
12
13 MH1610
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.35

Boom
10. With auxiliary hydraulics: Keep the four hoses in 15. Assemble the hose clamp support bracket to the top
line (left to right) as they come out of the rear of the of the inner boom:
inner boom. Place a lockwasher (1), saved, and a
Note: Shim ALL upper rear wear pads as needed to
flat washer (2), saved, onto each capscrew (3),
maintain a total maximum gap of .06" (1,5 mm) at the
saved. Insert the capscrews through the hose clamp
rear of the pads and maintain a total minimum gap of
support bracket (4), saved. Insert the capscrews
.07 to .13" (1,8 to 3,3 mm) in the vertical direction.
from the side as shown.
11. Place a 3/4" diameter hose clamp half (5), saved, a. Place the wear pad inserts (12), saved, into the
cavities of the inner boom top left side wear
onto the capscrews. Place the right auxiliary
pad (13), saved.
hydraulic hose (6) and another 3/4" diameter hose
clamp half (5) onto the capscrews. b. Place the wear pad, spacer (14), saved, and
shims (15), saved, onto the inner boom with the
12. Place a 5/8" diameter hose clamp half (7), saved, the offset of the wear pad toward the outside edge.
right Attachment Tilt hose (8) and another 5/8"
diameter hose clamp half (7) onto the capscrews.
the capscrews (16), saved. Align the holes and
13. Place two more 5/8" diameter hose clamp secure the wear pad and hose clamp support
halves (7), the left Attachment Tilt hose (9) and bracket (17) in place with the capscrews (16) and
another 5/8" diameter hose clamp half onto the lockwashers (18), saved. Be careful not to push
capscrews. the wear pad inserts out of the wear pads.
14. Place a 3/4" diameter hose clamp half (5), saved, the d. Torque all wear pad mounting capscrews to
31 ±3 lb-ft (42 ±4 Nm).
left auxiliary hydraulic hose (10) and another 3/4"
diameter hose clamp half (5) onto the capscrews. e. Fill all wear pad cavities with a good grade of
Assemble the capscrews to the left side of the inner lithium-based EP grease.
boom. Tighten the capscrews only enough to hold
the hoses in place. 12
13
5 14
5 7
4 15
7
10
2
1 17
9
8 3 18
7 5 16
6 5
MH1640
11 16. Position the Attachment Tilt and auxiliary hydraulic

hoses with the edge of the tape (11) at the hose
10 clamps. Hold the hoses in this position, and tighten
the two capscrews securely to hold the hoses.
9
8
6 MH1630
3.36 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
17. Assemble the wear pads to the rear of the inner c. Apply Loctite® 242 threadlocker to the threads of
boom. If your vehicle has optional auxiliary the capscrews (23), saved. Align the holes and
hydraulics, the upper left wear pad has been already secure the wear pads in place with the
assembled. capscrews (23) and lockwashers (24), saved. Be
careful not to push the wear pad inserts out of
Note: Shim ALL upper rear wear pads as needed to the wear pads.
maintain a total maximum gap of .06" (1,5 mm) at the d. Torque all wear pad mounting capscrews to
rear of the pads and maintain a total minimum gap of 31 ±3 lb-ft (42 ±4 Nm).
.07 to .13" (1,8 to 3,3 mm) in the vertical direction.
e. Place the wear pad inserts (25), saved, into the
Note: Shim ALL side wear pads as needed to maintain cavities of the inner boom left and right side
a total minimum gap of .07 to .13" (1,8 to 3,3 mm) in the upper and lower wear pads (26), saved.
horizontal direction. f. Place the wear pads and shims (27), saved, onto
the sides of the inner boom with the offset of the
a. Place the wear pad inserts (19), saved, into the wear pads toward the top and bottom edge.
cavities of the inner boom top left and right side
wear pads (20), saved. g. Apply Loctite® 242 threadlocker to the threads of
secure the wear pads in place with the
19 20 capscrews (28), lockwashers (29), saved, and
21 flat washers (30), saved. Be careful not to push
34 the wear pad inserts out of the wear pads.
22
35 h. Torque all wear pad mounting capscrews to
31 ±3 lb-ft (42 ±4 Nm).
24 28 i. Place the wear pad inserts (31), saved, into the
29 cavities of the inner boom bottom wear pad (32),
23 saved.
30 j. Place the wear pad and spacer (33), saved, onto
the bottom of the inner boom with the offset of
27 the wear pads toward the right side.
26 k. Apply Loctite® 242 threadlocker to the threads of
secure the wear pads in place with the
capscrews (16) and lockwashers (35), saved. Be
33
25 the wear pads.
32 31 MH0970 l. Torque all wear pad mounting capscrews to
31 ±3 lb-ft (42 ±4 Nm).
b. Place the wear pads, spacers (21), saved, and m. Fill all wear pad cavities with a good grade of
shims (22), saved, onto the inner boom with the lithium-based EP grease.
offset of the wear pads toward the outside edge.
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.37

Boom
Note: ALWAYS replace elastic locknuts with new elastic 21. Assemble the side wear pads to the intermediate boom:
locknuts to help ensure proper fastening. Note: Shim ALL side wear pads as needed to maintain
18. Lay the two extend chains (1) on the top of the inner a total minimum gap of .07 to .13" (1,8 to 3,3 mm) in the
boom with the threaded clevis ends (2) toward the horizontal direction.
rear of the boom. Coat the threads on each clevis a. Slide the inner boom over to one side as far as it
with multi-purpose grease, and insert the clevis’ will go, to allow wear pad installation.
through the holes in the anchor plate. Install a flat b. Place the wear pad inserts (5), saved, into the
washer (3), saved, onto each clevis. Install a new cavities of the side wear pads (6), saved. Place
elastic locknut (4) onto each clevis. Tighten the the shims (7), saved, onto the wear pad and align
elastic locknut far enough so the threads are even the holes.
with the top of the locknut. c. Apply Loctite® 242 threadlocker to the threads of
the capscrews (8), saved. Slide the wear pad with
3 shims between the inner boom and the
2 intermediate boom with the offset of each wear
4 pad away from the center. Align the holes and
secure in place with the capscrews (8),
2 saved. Be careful not to push the wear pad inserts
out of the wear pads.
1 d. Torque all wear pad mounting capscrews to
31 ±3 lb-ft (42 ±4 Nm).
f. Repeat Steps a thru e to install the side wear
MH1650 pads on the other side of the intermediate boom.
19. At the rear of the inner boom, place the male ends of
the hoses (Attachment Tilt and optional auxiliary
hydraulics) inside the inner boom. Be sure the hoses
are coiled up and inside the boom completely.
20. Spray the wear pad pathways on the underside of
the inner boom with LPS3 or equivalent.
6
5
7 10 8 MH1660
3.38 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
22. Install the top wear pads to the inside of the a. Remove the elastic locknut (16) from the upper
intermediate boom: retaining capscrew (17). While pulling the
capscrew out, catch the spacers (18) from
a. Place the wear pad inserts (11), saved, into the between the plates as the capscrew is removed.
Pull the capscrew out far enough to place the
b. Apply Loctite® 242 threadlocker to the threads of hoses around the hose reel.
the capscrews (13), saved. Slide the wear pads
Place the left side Attachment Tilt hose (19) into the
with the spacers (14), saved, between the inner second position from the left on the hose reel.
boom and the intermediate boom, with the offset
of each wear pad toward the center. Align the Place the right side Attachment Tilt hose (20)
holes and secure in place with the into the second position from the right on the
capscrews (13) and lockwashers (15), saved. Be hose reel.
careful not to push the wear pad inserts out of Note: ALWAYS replace elastic locknuts with new elastic
the wear pads.
c. Torque all wear pad mounting capscrews to
31 ±3 lb-ft (42 ±4 Nm). b. Reinsert the retaining capscrew (17) back
through the plates of the hose reel, inserting the
d. Fill all wear pad cavities with a good grade of spacers (18) back in position between the plates
lithium-base EP grease. as the capscrew is inserted. Secure the retaining
capscrew in place with a new elastic locknut (16).
13 Tighten the elastic locknut securely.
15 c. Remove the elastic locknut (21) and flat
15 bolt (23). While pulling the shoulder bolt out,
as the shoulder bolt is removed. Place the
Attachment Tilt hoses around the hose reel.
d. Insert the shoulder bolt (23) through the plates of
the hose reel, inserting the spacers (24) back in
position between the plates as the shoulder bolt is
inserted. Place the flat washer (22) onto the
shoulder bolt and secure in place with a new
elastic locknut (21). Tighten securely.
14
18 19
12 16
11 MH1670
23. Pull the male ends of the hoses out the rear of the
21 20
inner boom. Stretch the hoses out straight behind
the vehicle.
24. Without auxiliary hydraulics: Assemble the hoses 22
to the hose reel at the back of the boom:
17
IMPORTANT: Keep the hoses in the same order as they
come from the hose clamps. DO NOT allow the hoses to 24
cross. 23
MH1680
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.39

Boom
25. With auxiliary hydraulics: Assemble the hoses to

the hose reel at the back of the boom:
3 4
come from the hose clamps. DO NOT allow the hoses to 1
cross.
a. Remove the elastic locknut (1) from the upper
retaining capscrew (2). While pulling the
capscrew out, catch the spacers (3) from 7
between the plates as the capscrew is removed. 8
Pull the capscrew out far enough to place the
hoses around the hose reel. 9
Place the left side auxiliary hydraulic hose (4) into
the left position on the hose reel. Place the left side 11 2
Attachment Tilt hose (5) into the second position
5
from the left on the hose reel. 10
6 MH1690
Place the right side Attachment Tilt hose (6) into
the second position from the right on the hose
reel. 26. Without auxiliary hydraulics: Tie the strings
(positioned inside the outer boom) to the male end of
Place the right side auxiliary hydraulic hose (7)
each of the Attachment Tilt hoses, coming off the
into the right position on the hose reel.
bottom of the hose reel assembly.
come off the hose reel. DO NOT allow the hoses to
b. Insert the retaining capscrew (2) back through cross.
the plates of the hose reel, inserting the 27. Working from the front of the boom, pull each hose
spacers (3) back in position between the plates
through the boom assembly:
as the capscrew is inserted. Secure the retaining
capscrew in place with a new elastic locknut (1). a. Pull the right side Attachment Tilt hose (12) through
Tighten the elastic locknut securely. the boom assembly. Pull the hose out of the
c. Remove the elastic locknut (8) and flat opening (13) at the bottom of the outer boom.
washer (9) from the lower retaining shoulder b. Pull the left side Attachment Tilt hose (14) through
bolt (10). While pulling the shoulder bolt out, the boom. Keep the left Attachment Tilt hose to
catch the spacers (11) from between the plates the left side of the right side Attachment Tilt
as the shoulder bolt is removed. Place the hose. Pull the hose out of the opening (13) at the
Attachment Tilt hoses and the auxiliary hydraulic bottom of the outer boom.
hoses around the hose reel.
d. Insert the shoulder bolt (10) through the plates of 14
12
the hose reel, inserting the spacers (11) back in
position between the plates as the shoulder bolt
is inserted. Place the flat washer (9) onto the 12
shoulder bolt and secure in place with a new
14
13
MH1700
3.40 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
28. With auxiliary hydraulics: Tie the strings 31. Without auxiliary hydraulics: At the front of the
(positioned inside the outer boom) to the male end of outer boom, assemble the hose assemblies and
each of the Attachment Tilt hoses and the auxiliary tube assemblies to the mounting plate:
hydraulic hoses.
Note: Where the hose assemblies come out of the outer
IMPORTANT: Keep the hoses in the same order as they boom, lubricate the radius in the outer boom with soap
come off the hose reel. DO NOT allow the hoses to and water to allow proper tensioning of hoses.
cross.
Note: ALWAYS use new o-rings when servicing the
29. Working from the front of the boom, pull each hose vehicle.
a. Install new o-rings into the fittings. Lubricate o-rings
a. Pull the right side auxiliary hydraulic hose (15)
with clean hydraulic oil.
through the boom assembly. Pull the hose out of
the opening (16) at the bottom of the outer boom. b. Assemble the right side Attachment Tilt
hose (20) as it comes down the outer boom to
b. Pull the right side Attachment Tilt hose (17)
the upper right side hole (21) on the mounting
through the boom assembly, keeping the hose to plate. Insert the male end of the right side hose
the left of the right side auxiliary hydraulic hose.
through the upper right side hole. Tighten the
Pull the hose out of the opening (16) at the
right side Attachment Tilt tube assembly (22) to
bottom of the outer boom. the hose assembly. Tighten the tube assembly
c. Pull the left side Attachment Tilt hose (18) through nut securely to hold the tube and hose to the
the boom, keeping the hose to the left of the plate. Tighten the other end of the tube assembly
hoses installed. Pull the hose out of the to the bulkhead fitting at the rear of the boom.
opening (16) at the bottom of the outer boom. c. Assemble the left side Attachment Tilt hose (23)
d. Pull the left side auxiliary hydraulic hose (19) as it comes down the outer boom to the upper
through the boom, keeping the hose to the left of left side hole (24) on the mounting plate. Insert
the hoses already installed. Pull the hose out of the male end of the left side hose through the
the opening (16) at the bottom of the outer boom. upper left side hole. Tighten the left side
Attachment Tilt tube assembly (25) to the hose
15 assembly. Tighten the tube assembly nut
17 securely to hold the tube and hose to the plate.
18 Tighten the other end of the tube assembly to the
19 bulkhead fitting at the rear of the boom.
17 20
18 23
15
19
16
MH1410
30. Remove the strings from the hoses. 22

21
20
25
24
23 MH1430
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.41

Boom
32. With auxiliary hydraulics: At the front of the outer 7 1

boom, assemble the hose assemblies and tube 4
assemblies to the mounting plate:
Note: Where the hose assemblies come out of the outer 10
boom, lubricate the radius in the outer boom with soap
and water to allow proper tensioning of hoses.
vehicle.
a. Install new o-rings into the fittings. Lubricate o-rings
b. Assemble the right side Attachment Tilt hose (1) 6
as it comes down the outer boom to the upper 3
5
right side hole (2) on the mounting plate. Insert 2
the male end of the right side hose through the 9
upper right side hole. Tighten the upper right side
Attachment Tilt tube assembly (3) to the hose 1
assembly. Tighten the tube assembly nut
securely to hold the tube and hose to the plate.
Tighten the other end of the tube assembly to the
bulkhead fitting at the rear of the boom. 8 12
7
c. Assemble the left side Attachment Tilt hose (4)
as it comes down the outer boom to the upper
left side hole (5) on the mounting plate. Insert the 10 11 4 MH1450
male end of the left side hose through the upper
left side hole. Tighten the upper left side
Attachment Tilt tube assembly (6) to the hose 33. Place the retract chain (13) up around the retract
assembly. Tighten the tube assembly nut chain sheave on the right side of the boom. Stretch
securely to hold the tube and hose to the plate. the chain forward and place the clevis between the
Tighten the other end of the tube assembly to the two anchor plates (14). Align the hole in the clevis
bulkhead fitting at the rear of the boom. with the second hole from the rear of the anchor
d. Assemble the right side auxiliary hydraulic plates.
hose (7) as it comes down the outer boom to the Note: ALWAYS replace elastic locknuts with new elastic
lower right side hole (8) on the mounting plate.
Insert the male end of the right side hose through
the lower right side hole. Tighten the lower right 34. Insert the shoulder bolt (15), saved, from the top
side auxiliary hydraulic tube assembly (9) to the down and secure in place with a new elastic
hose assembly. Tighten the tube assembly nut locknut (16). Tighten the locknut securely.
securely to hold the tube and hose to the plate.
Tighten the other end of the tube assembly to the
bulkhead fitting at the rear of the boom. 15
e. Assemble the left side auxiliary hydraulic 14
hose (10) as it comes down the outer boom to
the lower left side hole (11) on the mounting 13
plate. Insert the male end of the left side hose
through the lower left side hole. Tighten the lower
left side auxiliary hydraulic tube assembly (12) to
the hose assembly. Tighten the tube assembly
nut securely to hold the tube and hose to the 14
plate. Tighten the other end of the tube assembly
16 MH2340
to the bulkhead fitting at the rear of the boom.
3.42 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
35. Assemble the two extend chains to the outer boom 23 24

mount if the yoke plates were removed from the
extend chains. If the yoke plates were not replaced,
proceed to Step 38.
36. Assemble the yoke plates (17) to the mount on the
front of the outer boom. Coat the shoulder bolt (18), 25
saved, with anti-seize compound and insert the
shoulder bolt through a yoke plate (17), the mount
on the boom and through a second yoke plate (17)
on the bottom. Secure in place with a new elastic
locknut (19). Tighten the locknut securely; but the MH1710
yoke plates must pivot freely.

37. Assemble the clevis’ on the two extend chains (20) 39. Assemble the quick attach to the gooseneck. Align
between the yoke plates. Align the holes in each the quick attach (26) between the mounts on the
clevis with the holes in the yoke plates. Coat the gooseneck. Assemble a washer (27), saved, on
capscrews (21), saved, with anti-seize compound each side of the quick attach. Reassemble the
and insert the capscrews through the yoke plates shims (28), saved, between the quick attach and the
and the clevis. Secure in place with new elastic gooseneck. DO NOT put all the shims on one side.
locknuts (22). Tighten the locknuts securely; but the The quick attach should be centered in the gooseneck.
extend chain clevis’ must pivot freely. Note: ALWAYS replace elastic locknuts with new elastic
21 18
40. Coat the quick attach pivot pin (29) with anti-seize
compound. Insert the quick attach pivot pin through
17 the gooseneck, washers, shims and quick attach.
Use a tapered punch to align the hole in the pivot pin
with the hole in the quick attach. Insert the
20 capscrew (30), saved, through the quick attach and
17 pin. Secure the capscrew in place with a new elastic
locknut (31). Tighten securely.
22 19
SH1870
38. Align the holes in the yoke plates (23) with the hole
in the mount on the outer boom. Coat the shoulder
bolt (24), saved, with anti-seize compound and
insert the shoulder bolt through the yoke plates and 26
the mount on the boom. Secure in place with a new
elastic locknut (25). Tighten the locknut securely; but 27
the yoke plates must pivot freely. 31
~
29
28
30
28 27 MH1720
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.43

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. Assemble the male nipple (4) and dust cap (5) to
the right side swivel connector fitting. Tighten the 11 9
swivel connector and male nipple securely. 12
Assemble the dust cap onto the male nipple.
Assemble the female coupler (6) and dust
plug (7) to the left side swivel connector fitting.
Tighten the swivel connector and female coupler 10
securely. Insert the dust plug into the female
coupler.
MH0840
42. Use a hoist and slings to position the Attachment Tilt

1 cylinder (13) inside the gooseneck (14). Be sure the
Attachment Tilt cylinder is positioned with the tube
for the rod end positioned inside the gooseneck.
43. Coat the base end pivot pin (15), saved, with anti-
2 seize compound. Align the hole in the cylinder base
3 end with the mounting holes in the gooseneck and
insert the pivot pin through the gooseneck. Secure
4 the pivot pin to the gooseneck with the two retaining
2
rings (16), saved. Be sure the retaining rings are
5 3 resting squarely in the grooves on the pivot pin.
6
7 MH1730
d. Assemble the left auxiliary hydraulic hose (9) 16

labeled “Female Coupler” from inside the
gooseneck to the female coupler (10) bulkhead
fitting. Tighten securely. 14
e. Assemble the right auxiliary hydraulic hose (11)
labeled “Male Nipple” from inside the gooseneck 15
to the male nipple (12) bulkhead fitting. Tighten
securely.
16
13
MH0960
3.44 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
44. Coat the rod end pivot pin (17), saved, with anti-
seize compound. Swing the rod end (18) of the
Attachment Tilt cylinder up and line up the rod end 22 24
with the mounting holes in the quick attach (19).
45. Insert the rod end pivot pin (17) through the lined-up
23
holes. Use a tapered punch to line up the capscrew
hole in the pivot pin and the mounting hole in the
quick attach hub. Insert the capscrew (20), saved, 25
through the quick attach hub from the backside and
secure in place with a new elastic locknut (21).
MH1740
Tighten securely.
48. Clean up all debris, hydraulic fluid, etc., in, on, near
and around the vehicle.
49. Connect the battery negative (-) ground cable.
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.
18
WARNING:
20
Hydraulic oil leaking under
21 pressure can penetrate the skin and cause
~
19
severe personal injury. DO NOT use your hand
or any part of your body to check the hydraulic
17 MH0940 leaks. When checking for hydraulic leaks, wear
safety glasses and gloves to help provide
46. Assemble the Attachment Tilt hoses from the protection from spraying hydraulic oil. Use a
backside of the gooseneck to the fittings on the base piece of cardboard or paper to search for leaks.
end of the Attachment Tilt cylinder. Assemble the left
side hose (22) labeled as “Retract” to the retract port 50. Start the engine and operate all boom functions
(upper) fitting (23) on the base end of the several times. Check the chain tension again and
Attachment Tilt cylinder. Index the elbow end of the adjust as necessary. Check for leaks, and check the
hose to remove any undo tension and tighten the hydraulic fluid level in the tank; add fluid if required.
elbow completely to the fitting on the cylinder.
47. Assemble the right side hose (24) labeled as
“Extend” to the extend port (lower) fitting (25) on the
base end of the Attachment Tilt cylinder. Index the
elbow end of the hose to remove any undo tension
and tighten the elbow completely to the fitting on the
cylinder.
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.45

Boom
3.4 BOOM CHAINS - THREE SECTION Environments in which material handling vehicles
BOOM (8042 AND 10042) operate can vary widely, from outdoor moisture to mildly
corrosive or highly corrosive industrial atmospheres, in
This vehicle uses double extend chains to extend the addition to abrasive exposures such as sand and grit.
boom and a single retract chain to retract the boom. The Some effects can be as follows:
extend and retract chains are constructed of 3/4" pitch • Moisture - Corrosive rusting reduces chain strength
links with 6 x 6 leaf lacing. by pitting and cracking.
Note: DO NOT attempt to repair a chain. Replace a • Temperature - Low temperature reduces chain
stretched or damaged chain with a new part. Always strength by embrittlement. Going in and out of cold
replace both the chain and the clevis. It is recommended storage results in moisture from condensation.
that when any chain is replaced, that all the chains and • Chemical Solutions or Vapors - Corrosive attack on
clevis’ be replaced at the same time. the chain components and/or the mechanical
connections between the chain components.
3.4.1 Boom Chain Inspection Cracking can be (and often is) microscopic. Going
from microscopic cracking to complete failure can be
either abrupt or may require an extended period of
time.
250
• Abrasives - Accelerated wearing and scoring of the
articulating members of the chain (pins and plates),
with a corresponding reduction in chain strength.
MS21702 Due to the inaccessibility of the bearing surfaces (pin
surfaces and plate apertures), wear and scoring are
OH23902 not readily noticeable to the naked eye.
Following are some examples of dynamic shock loading
WARNING: Worn pins, stretched or which can impose abnormal loads above the endurance
cracked links or corrosive environments can limit of a leaf chain:
cause chain failure. A chain failure could result • High velocity movement of load, followed by sudden,
in uncontrolled boom movement, loss of load abrupt stops.
or vehicle instability, and could cause death or
• Carrying loads in suspension over irregular surfaces
serious injury and/or property damage.
such as railroad tracks, potholes and rough terrain.
Under normal operating conditions the extend chains will • Attempting to “inch” loads which are beyond the
need to be inspected every 250 hours of operation. The rated capacity of the vehicle.
retract chain will need to be exposed and inspected every
The above load cycles and environmental conditions
1000 hours of operation. Environmental conditions and
make it impossible to predict chain life. It is therefore
dynamic impulse/shock loads can drastically affect
necessary to conduct frequent inspections until
normal operating conditions and require more frequent
replacement life can be predicted.
inspection intervals.
The boom chain’s normal life expectancy can be expressed
as a maximum percent of elongation. This is generally
3% of pitch. As the chain flexes back and forth over the
sheave, the bearing joints (pins and inside link plates)
gradually incur wear due to articulation.
3.46 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
a. Inspection Guidelines Edge Wear

Expose the extend and retract chains (refer to Section Check the chain for wear on the link plate edges caused
3.4.1, b. “Expose Extend Chain for Inspection,” or Section by running back and forth over the sheave. The maximum
3.4.1, c. “Expose Retract Chain for Inspection.”) and reduction of material must not exceed 5%. This can be
inspect the chains for the following conditions: compared to a normal link plate height by measuring a
portion of chain that does not run over the sheave.
Elongation
The new chain link measures .713" (18 mm) (3). If the
When the original length (1) of 12" (305 mm) per foot of
measurement of the worn chain is less than .677"
new chain has elongated from wear to a length (2) of
(17 mm) (4), the chain must be replaced. (Refer to
12.36" (313 mm), the chain must be discarded and
Section 3.4.5, “Boom Extend and Retract Chains
replaced. (Refer to Section 3.4.5, “Boom Extend and
Removal and Replacement.”)
Retract Chains Removal and Replacement.”)
It is important to measure the chain in the section that
moves over the sheaves because it receives the most
frequent articulation. Measuring the chain near its clevis
terminals could give an inaccurate reading. 4 3
Measure across a span of 17 pins at the center of the
extend chain. Measure from pin center to pin center.
The maximum measurement allowed is 12.36" (313 mm).
MM2051
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.”) Distorted or Battered Link Plates
Distorted or battered link plates (5) on a leaf chain can
cause tight joints and prevent flexing.
1
2
MA9340
MM2120
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.47

Boom
Turning or Protruding Pins • Fatigue Cracking - Fatigue cracks (4) are a result of
repeated cyclic loading beyond the chain’s
Highly loaded chain, operating with inadequate
endurance limit. The size of the load and the
lubrication, can generate abnormal frictional forces frequency of its occurrence are factors which
between pin and link plates. When chain is allowed to determine when fatigue failure will occur. The
operate in this condition, a pin or series of pins, can begin loading can be continuous or intermittent
to twist out of a chain, resulting in failure. (impulse load).
Examine the pin head rivets to determine if the “VEE” flats • Stress Corrosion Cracking - The outside link
are still in correct alignment (1). Chain with rotated/ plates are particularly susceptible to stress corrosion
displaced heads (2) or abnormal pin protrusion (3) must cracking (5). Like fatigue cracks, these initiate at the
be replaced immediately. (Refer to Section 3.4.5, “Boom point of highest stress but tend to extend in an
Extend and Retract Chains Removal and Replacement.”) arc-like path between holes in the pin plate. More
than one crack can often appear on a link plate. In
DO NOT attempt to repair the chain by welding or driving
addition to rusting, this condition can be caused by
the pin(s) back into the chain. Once the press fit integrity exposure to an acidic or caustic medium or
between outside plates and pins has been altered, it atmosphere.
cannot be restored.
Stress corrosion is an environmentally assisted failure.
Any wear pattern on the pin heads or the sides of the link Two conditions must be present: corrosive agent and
plates indicates misalignment in the system. This static stress. In the chain, static stress is present at the
condition damages the chain as well as increases aperture due to the press fit pin. No cyclic motion is
frictional loading and must be corrected. required, and the plates can crack during idle periods.
• Corrosion Fatigue Cracking - Corrosion fatigue
2 cracks are very similar to fatigue cracks (4) in
appearance. They generally begin at the aperture
and grow perpendicular to the chain pitch line.
1 3 Corrosion fatigue is not the same as stress
corrosion. Corrosion fatigue is the combined action
of an aggressive environment and cyclic stress, not
MM2060 a static stress alone, as in stress corrosion.
Cracked Plates
4
Inspect the chains very carefully, front and back as well MM2070
as side to side, for any evidence of cracked plates. If any
one crack is discovered, the chain must be replaced in its
entirety. (Refer to Section 3.4.5, “Boom Extend and 5
MM2080
3.48 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
Other Modes of Failure b. Expose Extend Chain for Inspection

• Ultimate Strength Failure - These types of failures 1. Park the vehicle on level ground. Place the travel
are caused by overloads far in excess of the design select lever in (N) NEUTRAL, place the neutral lock
load. Either fractured plates (6) or enlarged holes (7) lever in the (N) NEUTRAL LOCK position, engage
can occur. If either of these failures occurs, the chain the parking brake switch and raise the boom to a
must be replaced immediately. (Refer to Section horizontal (level) position.
3.4.5, “Boom Extend and Retract Chains Removal
and Replacement.”) 2. Fully extend the boom until the extend chain is taut.
Shut the engine OFF.
Note: The tight joints inspection must be done with the
chain disconnected from the boom. (Refer to Section The extend chains will be visible for inspection with the
3.4.5, “Boom Extend and Retract Chains Removal and vehicle in this state.
Replacement.”) While doing the chain inspection, check all chain clevis
• Tight Joints - All joints in the chain must flex freely. ends for distortion or cracking and sheaves for bearing
Tight joints (8) resist flexing and increase internal wear or grooving from the chain.
friction, thus increasing chain tension required to lift If during the inspection, any chain is found to be damaged
a given load. Increased tension accelerates wear or stretched, the chain must be replaced. It is
and fatigue problems. recommended that when any chain is replaced, that all
If the problem is caused by dirt or foreign substance the chains and clevis’ be replaced at the same time.
packed in the joints, clean and lubricate thoroughly Note: DO NOT attempt to repair a chain. Replace a
before re-installing the chain. stretched or damaged chain with a new part. Always
If the problem is caused by corrosion and rust or bent replace both the chain and the clevis. It is recommended
pins, replace the chain. (Refer to Section 3.4.5, “Boom that when any chain is replaced, that all the chains and
Extend and Retract Chains Removal and Replacement.”) clevis’ be replaced at the same time.
3. If the chain needs to be replaced, refer to Section
MM2090 and Replacement.”
6 4. If the chain does not need to be replaced, lubricate
7 the chain. (Refer to Section 3.4.2, “Chain
Lubrication.”)
MM2100
MM2110
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.49

Boom
c. Expose Retract Chain for Inspection 4. At the front underside of the boom, record the amount of
threads extending beyond the elastic locknut (6). This
The retract chain must be removed from the boom in
measurement will be the starting point for adjustment
order to be visually inspected. This must be done every
of the boom retract chain.
1000 hours or whenever the retract chain is removed
from the boom. (If removal of the chain is required refer 5. Loosen the elastic locknut (6) far enough so that it
to Section 3.4.5, “Boom Extend and Retract Chains can be removed by hand.
While doing the chain inspection, check all chain clevis
ends for distortion or cracking and sheaves for bearing
wear or grooving from the chain.
If during the inspection, any chain is found to be damaged
or stretched, the chain must be replaced. It is 8
recommended that when any chain is replaced, that all
the chains and clevis’ be replaced at the same time.
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 6
(N) NEUTRAL, move the neutral lock lever to
7 MH1110
NEUTRAL LOCK position, engage the parking brake
switch and shut the engine OFF.
washer (3), holding the rear cover (4) to the rear of
the outer boom (5). Lift the rear cover straight up
the cover from the outer boom.
5 4
1
MH0850
3.50 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
6. If the chain clevis has a threaded hole on the 7. Remove the elastic locknut (6) and flat washer (7)
end (9), a string or wire can be attached to the holding the retract chain threaded clevis (8) to the
retract chain clevis using a threaded eye (10) or a mounting tab. Save the flat washer and discard the
flat washer tack welded to a capscrew (11). The elastic locknut.
outside diameter of the eye or flat washer must be 8. If a threaded eye or capscrew with flat washer
smaller than the diameter of the threads on the (10 or 11) was installed in step 6, attach a string or
clevis. The string or wire will be used to pull the wire to the end of the retract chain clevis. The string
chain back through the boom during the reassembly. or wire must be long enough to pull the clevis and
If there is no threaded hole on the end of the clevis, a chain through the outer boom.
phillips screwdriver will be needed to catch the 9. Place a pan or tarp, free of dirt, at the rear of the
countersunk hole in the end of the clevis and guide it vehicle, for the chain to rest on as it is being
through the tab during reassembly. removed from the boom. From the rear of the boom,
pull the retract chain out of the rear of the boom.
10 10. With the chain hanging from the rear of the boom,
inspect wear and condition of the chain, clevis’, chain
sheaves, chain pins, clevis anchors and all mounting
hardware. Replace a worn or damaged chain. DO
NOT attempt to make any repairs to the chain.
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
9 11 that when any chain is replaced, that all chains and
clevis’ be replaced at the same time.
MA9430
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.51

Boom
11. Measure the chain elongation. Measure across 17 13. Lubricate the chain, while it is exposed, if it does not
pins (1), somewhere between the chain sheave and need to be replaced. (Refer to Section 3.4.2, “Chain
where the chain is laying in the pan or on the tarp. Lubrication.”)
The maximum measurement allowed is 12.36" 14. Coat the threads of the threaded clevis (2) with
(313 mm). If the measurement is more than 12.36" multi-purpose grease.
(313 mm), the chain must be replaced. (Refer to
Section 3.4.5, “Boom Extend and Retract Chains Note: Have a second person help with the installation of
Removal and Replacement.”) the retract chain between the intermediate and outer
boom assemblies.
If a string or wire was installed to the end of the
clevis:
15. From the rear of the boom, one person should push
the threaded clevis end (2) of the retract chain (3)
under the chain sheave and down between the
intermediate boom and the outer boom. The person
at the front of the boom should pull the clevis using
the string or wire ( 4) attached to the clevis in step 6.
Push and pull the threaded clevis down to the tab (5)
at the front underside of the outer boom.
16. The person at the front of the boom should guide the
threaded end of the clevis (2) through the hole in the
tab (5).
3
2
5
MA9350
4
Note: Chains and clevis’ are wear items and experience
MA9440
the same stress. DO NOT attempt to repair a chain.
Replace a stretched or damaged chain with a new part.
17. Remove the string or wire, and the threaded eye or
Always replace both the chain and the clevis’.
capscrew with flat washer, from the end of the clevis.
and Replacement.”
3.52 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
If no string or wire was installed to the end of the

clevis:
12
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. The person at the front of the boom should guide the 10
threaded end of the clevis (6) through the hole in the 11
tab (8) using a Phillips screwdriver (9). 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 MA9510
boom pushes the retract chain forward.
23. After adjustment is complete, assemble the rear cover
7 to the rear of the outer boom. At the rear of the outer
6 boom (13), position the rear cover (14) in place.
Secure the cover in place with the saved, 5/16" flat
washer (15), lockwasher (16) and thumbscrew (17).
8
Insert the thumbscrew through the bottom of the
outer boom and into the rear cover. Tighten the
thumbscrew securely to hold the cover in place.
9 13 14
MA9520
Once the threaded clevis is through the tab on the

outer boom:
20. Reassemble the flat washer (10), saved, and a new
3/4-16 elastic locknut (11) onto the threaded
clevis (12). Tighten the locknut until the threaded
end of the clevis is flush with the top of the locknut.
15
21. Tighten the elastic locknut (11) on the retract chain
clevis (12) until the amount of threads protruding 16
beyond the elastic locknut is the same as the
17
measurement recorded during removal of the retract
MH0850
chain.
22. Adjust retract chain tension. (Refer to Section 3.4.3,
“Boom Chain Tension Check.”)
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.53

Boom
3.4.2 Chain Lubrication 3. Slowly, fully extend the boom and retract it about
halfway. Fully extend the boom, then retract it
After inspection and before being returned to service,
2" (51 mm) (one inch per section). Turn the
chains must be lubricated with a quality chain lubricant
engine OFF.
(“LUBRIPLATE” Chain & Cable Fluid, “LPS3” or
equivalent). 4. Measure the sag in the top boom extend chains (1)
between the bottom of the extend chains and the top
The lubricant must penetrate the chain joint to prevent
of the intermediate boom at their closest point (2).
wear. Applying lubricant to the external surfaces will
Acceptable boom chain sag (3) is between 1.5" (38
prevent rust, but the chains should be articulated to make
mm) and 2.5" (64 mm).
sure the lubricant penetrates to the working surfaces
between the pins and links.
3
To prepare the chain for lubrication, the chain plates
should be brushed with a stiff brush or wire brush to clear
the space between the plates so that the lubricant can
penetrate to the working surfaces.
Lubricant may be applied with a narrow paint brush or
1
directly poured on, but the chain should be well flooded
with lubricant, and the boom should be extended and 2
retracted to be sure that the lubricant penetrates to the
working surfaces. All surplus lubricant should be wiped
away from the external surfaces. DO NOT use a solvent
for this wiping operation.
Regular application of lubricant is necessary to make
sure that all working surfaces are adequately lubricated.
In extremely dusty conditions, it may be necessary to
lubricate the chains more often.
Lubrication of chains on vehicles working consistently in
extreme hot or cold conditions requires special OA0492
consideration. It is important that a reputable lubrication

specialist, consult the local Sky Trak distributor or the JLG If the measurement is either less than, or greater
Service Department at 1-877-554-5438 or than the range given, the boom chains need to
1-717-485-6657, for guidance. be adjusted. Continue with Section 3.4.4, “Boom
Chain Tension Adjustment,” to adjust the chain
3.4.3 Boom Chain Tension Check system.
5. Start the engine, retract the boom completely and
1. Make sure the carriage is attached to the gooseneck
turn the engine OFF.
before doing the tension check.
2. Start the engine. If necessary, attach carriage to
gooseneck. Park the vehicle on level ground. Place
the travel select lever in (N) NEUTRAL, place the
position, engage the parking brake switch and raise
the boom to a horizontal (level) position.
3.54 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
3.4.4 Boom Chain Tension Adjustment 3. Tighten or loosen the two extend chain adjustment
locknuts (11) located at the rear of the boom. Be
Note: Always perform Section 3.4.3, “Boom Chain Ten-
sure each of the locknuts are adjusted equally so
sion Check” before adjusting the boom chain tension.
that each extend chain maintains the same tension.
1. Remove the thumbscrew (4), lockwasher (5) and flat Equal chain tension can be checked by the position
washer (6), holding the rear cover (7) to the rear of of the yoke (10) on the outer boom. The front of the
the outer boom (8). Lift the rear cover straight up yoke should be parallel with the front edge of the
until the capscrew in the top of the cover clears the outer boom.
11
8 7
MH1751
4. If there is no adjustment left on the extend chains,

tighten the retract chain locknut (12) at the front on
6 the underside of the outer boom.
4
MH0850
12
2. Adjust the two boom extend chains (9).

If the chain sag measurement (3) is less than
1.5" (38 mm), tighten the two extend chain
adjustment locknuts (11).
If the chain sag measurement (3) is more than
2.5" (64 mm), loosen the two extend chain
adjustment locknuts (11). OA0512
10
OH0240
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.55

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 7
moving the rear retract chain clevis (3) from the
original mounting hole (4) in the anchor plate to the 3
next hole (5).
MA9450
MH1751
OA0512
OA0492
This is only acceptable when boom chain sag (9)
cannot be acquired and the chain elongation
8. Assemble the rear cover to the rear of the outer boom.
measurement is still less than 12.36" (313 mm).
On the rear of the outer boom (10), position the rear
Make sure to use a new 3/8-16 elastic locknut (6) to
cover (11) in place. Secure the cover in place with
re-secure the chain clevis to the anchor plate. Follow
the saved 5/16" flat washer (12), lockwasher (13), and
the instructions in Section 3.4.4, a. “Component/
thumbscrew (14). Insert the thumbscrew through the
Assembly Verification.”
bottom of the outer boom and into the rear cover.
7. Recheck chain tension. (Refer to Section 3.4.3, Tighten the thumbscrew securely to hold the cover in
“Boom Chain Tension Check.”) place.
3.56 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
11 17
10
16
15
12
13 OH1090
14 MH0850 If the distance is less than 8.5" (216 mm) or greater than
11" (279 mm):
a. Component/Assembly Verification 1. Verify that the retract chain clevis (3) is not mounted
in the last hole (7) in the anchor plate (8).
The inner (15) to intermediate (16) boom separation
2. Make sure that the chain system is properly
should be checked when assembling new boom sections
tensioned. Refer to Section 3.4.3, “Boom Chain
or chains, or when the rear retract chain clevis has been
Tension Check,” and Section 3.4.4, “Boom Chain
moved forward on the anchor plate.
Tension Adjustment.”
Measure the separation between the inner and
intermediate boom top plates (17). The distance 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. A distance of less than
8.5" (216 mm) could result in interference and cause
damage to boom components.
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.57

Boom
3. To increase the separation distance: Loosen the Note: If the inner to intermediate boom separation
retract chain locknut (1) on the bottom of the outer distance cannot be achieved, contact the local Sky Trak
boom one or two turns and tighten the two extend distributor or the JLG Service Department at
chain locknuts (2) equally the same number of turns. 1-877-554-5438 or 1-717-485-6657.
A minimum of one full thread on the clevis must
protrude beyond the elastic collar of the locknut. 3.4.5 Boom Extend and Retract Chains
4. To decrease the separation distance: Loosen the Removal and Replacement
extend chain locknuts (2) at the rear of boom equally
one or two turns and tighten the retract chain locknut a. Extend Chains Removal and Replacement
(1) the same number of turns. A minimum of one full 1. Park the vehicle on a hard, level surface.
thread on the clevis must protrude beyond the elastic
collar of the locknut.
horizontal position. Place the travel select lever in
5. Assemble the rear cover (3) to the rear of the outer (N) NEUTRAL, move the neutral lock lever to
boom. On the rear of the outer boom (4), position the NEUTRAL LOCK position, engage the parking brake
rear cover (3) in place. Secure the cover in place switch and shut the engine OFF.
with the saved 5/16" flat washer (5), lockwasher (6),
and thumbscrew (7). Insert the thumbscrew through
the bottom of the outer boom and into the rear cover.
Tighten the thumbscrew securely to hold the cover in
place.
3
4
1
OA0512 5
6
7
MH0850
2
MH1751
3.58 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
4. At the rear of the boom, locate the extend chain 7. At the rear of the boom, attach one end of a wire (17)
elastic locknuts (8). Record the amount of threads to the threaded clevis (18) on the right side extend
extending beyond both the elastic locknuts. These chain. Loop the wire around and twist together to
measurements will be the starting point for form a loop. Route the wire around the right side of
adjustment of the extend chains after installation. the clevis anchor plate (19).
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 18
clevis (10) to the anchor plate (11) on the inner 19
boom (12). Save the flat washer and discard the
elastic locknut.
9 17
8
10
11
17 SH1830
12
8. Have a second person assist with the removal of the
MH0911
extend chain. One person should pull the chain from
6. At the front of the outer boom, remove the hex the front of the boom while the second person
socket head capscrew (13) and elastic locknut (14), guides the wire into the boom from the rear. Remove
holding the right side extend chain clevis (15) to the the wire from the clevis, but not from inside the
yoke plates (16). Discard the elastic locknut. Inspect boom.
the hex socket head capscrew for signs of wear or 9. Inspect wear and condition of the booms, chains,
damage. Replace with a new hex-socket head clevis’, chain sheaves, extend/retract cylinder, chain
capscrew if damaged or worn. rods, clevis anchors and all mounting hardware.
Replace any worn or damaged parts. DO NOT
13 attempt to make any repairs to the chain.
16 IMPORTANT: Chains and clevis’ are wear items and
15 experience the same stress. 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’.
10. Coat the threads of the threaded clevis (18) with
multi-purpose grease.
14 SH1810
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.59

Boom
11. Lay the new extend chain (1) on top of the outer 16. Pull the anchor clevis (13) up around the double
boom (2) with the threaded clevis (3) toward the front chain sheave and position the clevis between the
of the boom. yoke plates (14).
12. Attach the wire (4) to the threaded clevis (3) of the 17. Coat the hex-socket head capscrew (15), saved, with
new extend chain. Loop the wire through the clevis anti-seize compound. Insert the capscrew through the
and twist together to form a loop. yoke plates and clevis and secure in place with a
13. Pull the extend chain forward and place over the new 3/8-16 elastic locknut (16). Tighten securely; but
right side of the chain sheave (5). Guide the wire and the chain clevis must pivot freely.
the threaded clevis into the boom by placing the
threaded clevis under the chain sheave, and 15
between the top of the inner boom (6) and the
14
intermediate boom (7).
13
1
3
16 SH1810
4
~
5 18. Cut the loop in the wire and remove the wire from the
clevis.
6 2
19. Repeat Section 3.4.5, a. “Extend Chains Removal
and Replacement,” starting with Step 5, to remove
and replace the left side extend chain.
~
20. At the rear of the boom, tighten the two elastic

locknuts (12) on the extend chain clevis’ until the
7 SH1851
amount of threads protruding beyond each elastic
locknut is the same as the measurement recorded
14. While one person guides the extend chain into the
during removal of the extend chains.
front of the boom, a second person should pull the
wire (8) and threaded clevis toward the rear of the 21. Adjust extend chain tension. (Refer to Section 3.4.4,
boom. Guide the threaded clevis (9) into the hole in “Boom Chain Tension Adjustment.”)
the anchor plate (10). 22. After adjustment is complete, assemble the rear cover
15. Place the 3/4" flat washer (11), saved, onto the to the rear of the outer boom. At the rear of the outer
threaded end of the threaded clevis and assemble a boom (17), position the rear cover (18) in place.
new 3/4-16 elastic locknut (12). Thread the elastic Secure the cover in place with the saved 5/16" flat
locknut onto the threaded clevis until the threads are washer (19), lockwasher (20), and thumbscrew (21).
flush with the top of the nut. Insert the thumbscrew through the bottom of the
9
12
11
10
8
SH1861
3.60 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
6. If the chain clevis has a threaded hole on the

17 18 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.
If there is not threaded hole on the end of the clevis,
19 you will need to use a phillips screwdriver to catch the
end of the clevis and guide it through the tab during
20 reassembly.
21 MH0850
b. Retract Chain Removal and Replacement 26

switch and shut the engine OFF. 25 27
3. Remove the thumbscrew (21), lockwasher (20) and
flat washer (19), holding the rear cover (18) to the
rear of the outer boom (17). 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.
4. At the front underside of the boom, record the amount of
threads extending beyond the elastic locknut (22).
MA9430
This measurement will be the starting point for
adjustment of the boom retract chain.
7. Remove the elastic locknut (22) and flat washer (23)
5. At the front underside of the outer boom, loosen the holding the retract chain threaded clevis (24) to the
elastic locknut (22) far enough so that it can be mounting tab. Save the flat washer and discard the
removed by hand. elastic locknut.
8. If a threaded eye or capscrew with flat washer
(26 or 27) was installed in step 6, attach a string or
wire to the eye or flat washer on the end of the
retract chain clevis. The string or wire must be long
enough to pull the clevis and chain through the outer
24 boom.
MH1110
23 22
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.61

Boom
Note: Record the location of the shoulder bolt (1) to 13. Coat the threads of the threaded clevis (6) with multi-
ensure correct installation. purpose grease.
9. At the rear of the boom, locate the two retract chain 14. From the rear of the boom, one person should push
anchor plates (2) holding the retract chain to the the threaded clevis end (6) of the retract chain (7)
inner boom just in front of the retract chain sheave under the chain sheave and down between the
(3). Remove the elastic locknut (4) and shoulder bolt intermediate boom and the outer boom. The person
(1) holding the retract chain clevis to the anchor at the front of the boom should pull the front clevis
plates. Discard the elastic locknut and save the using the string or wire (8) attached to the clevis in
shoulder bolt. The two anchor plates can remain in step 6. Keep the retract chain (7) to the right side of
place on the inner boom. the boom, push the threaded clevis down to the
tab (9) at the front underside of the outer boom.
1 15. The person at the front of the boom should guide the
tab (9).
5
7
6
2
4
3
MH2550
9
10. From the rear of the boom, pull the retract chain out
of the rear of the boom.
8
11. Inspect wear and condition of the booms, chains, MA9440
clevis’, chain sheaves, extend/retract cylinder, chain
rods, clevis anchors and all mounting hardware. 16. Remove the string or wire from the end of the clevis.
Replace a worn or damaged chain. DO NOT attempt
to make any repairs to the chain.
clevis:
Note: Chains and clevis’ are wear items and experience 17. Coat the threads of the threaded clevis (10) with
the same stress. DO NOT attempt to repair a chain. multi-purpose grease.
Always replace both the chain and the clevis’. 18. From the rear of the boom, one person should push
Note: Have a second person help with the installation of under the chain sheave and down between the
the new retract chain between the intermediate and intermediate boom and the outer boom. Keep the
outer boom assemblies. retract chain (11) to the right side of the boom, push
If a string or wire was installed to the end of the the threaded clevis down to the tab (12) at the front
clevis: underside of the outer boom.
12. If the new chain has a clevis with a threaded hole,
remove the string from the old chain and attach it to
the new clevis. If the new chain does not have the
threaded hole, you will need to pull the string out of
the boom and follow the instructions under the "If no
sting or wire was installed to the end of the
clevis:" heading.
3.62 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
19. The person at the front of the boom should guide the 22. If re-installing a used chain insert the saved shoulder
threaded end of the clevis (10) through the hole in bolt (1), in the same position in the plates and clevis
the tab (12) using a Phillips screwdriver (13). Insert recorded during removal.
the screwdriver through the hole in the tab and catch 23. If installing a new chain, line up the hole in the clevis
the countersunk hole in the end of the clevis. Guide with the second hole from the rear of the anchor
the threaded clevis out as the person at the rear of plates. Insert the shoulder bolt (1), saved during
the boom pushes the retract chain. removal of the old chain.
24. Secure the shoulder bolt in place with a new 3/8-16
elastic locknut (4). Tighten the locknut securely.
11 25. Tighten the elastic locknut (15) on the retract chain
10
clevis (16) until the amount of threads protruding
12 measurement recorded during removal of the retract
chain.
a. “Component/Assembly Verification.”)
boom (17), position the rear cover (18) in place.
MA9520 Secure the cover in place with the saved 5/16" flat
20. Reassemble the flat washer (14), saved, and a new
3/4-16 elastic locknut (15) onto the threaded
clevis (16). Tighten the locknut until the threaded
18
end of the clevis is flush with the top of the locknut. 17
16
19
14 20
15
21
MH0850
MA9510
21. At the rear of the boom, place the retract chain (5)
up and over the chain sheave (3). Place the clevis
between the two anchor plates (2).
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.63

Boom
3.5 BOOM SYSTEM - FOUR SECTION 3.6 BOOM ASSEMBLY MAINTENANCE

BOOM (10054) (10054)
The boom assembly consists of the inner, secondary and
3.5.1 Boom System Description primary intermediate, and outer booms and supporting
The boom operates via an interchange among the hardware.
electrical, hydraulic and mechanical systems. Components IMPORTANT: Boom replacement must be completed in
involved include the joystick, Attachment Tilt cylinder, sequence, one boom section at a time, as described in
Extend/Retract cylinder, Lift/Lower cylinder, Slave these instructions. Replacement of two or more boom
cylinders, electronic sensors, extend and retract chains, sections as a unit requires special considerations that
various pivots, supporting hardware and other components. are not covered in these instructions.
3.5.2 Boom System Operation IMPORTANT: Before removing the inner boom, the
The four section boom consists of the inner, secondary carriage or any other attachment must be removed from
intermediate, primary intermediate and outer boom the quick attach.
assemblies with double intermediate boom extend The inner, secondary and primary intermediate, and
chains, a single inner boom extend chain, a single inner outer boom removal instructions must be completed in
boom retract chain and a single intermediate boom sequence. The inner boom must be removed before
retract chain. removing the secondary and primary intermediate
As the Extend/Retract hydraulic cylinder, which is booms. The inner boom, and secondary and primary
anchored at the front of the primary intermediate boom, intermediate booms must be removed one at a time
and the rear of the outer boom begins to extend, it forces before removing the outer boom.
the primary intermediate boom out of the outer boom. Before beginning, conduct a visual inspection of the
The inner, secondary intermediate, primary intermediate vehicle and work area, and review the task about to be
and outer booms are connected by extend and retract undertaken. Read, understand and follow these
chains. These chains are routed around sheaves on the instructions.
secondary and primary intermediate booms. As the After servicing the boom, perform the following:
primary and secondary intermediate booms are forced 1. Check wear pads. (Refer to Model 10054 Legacy
out, the extend chain pulls the inner boom out of the Owners/Operators Manual.)
secondary intermediate boom.
2. Check chain wear and tension adjustment. (Refer to
As hydraulic pressure is applied to the retract port on the Section 3.7.1, “Boom Chain Inspection,” and Section
Extend/Retract cylinder, the secondary intermediate 3.7.3, “Boom Chain Tension Check.”)
boom is pulled back into the outer boom, and the retract
chain pulls the secondary intermediate and inner booms 3. Apply grease at all lubrication points (grease fittings).
back into the primary intermediate boom. (Refer to Model 10054 Legacy Owners/Operators
Manual.)
This mechanical linkage formed by the chains and
supporting hardware, extends and retracts the primary 4. Check for proper operation by operating all boom
and secondary intermediate booms and inner boom at functions through their full ranges of motion several
the same rate. times.
The outer boom does not extend or retract, but lifts and
lowers via action of the Lift/Lower cylinders.
3.64 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
3.6.1 Inner Boom Removal 4. Move the Attachment Tilt joystick in both directions
system. Move the auxiliary hydraulic joystick in both
directions to relieve any trapped pressure in the
auxiliary hydraulic system.
Note: If you are replacing the inner boom with a new 5. Locate the two hoses (1) attached to the base of the
inner boom, remove the quick attach from the inner Attachment Tilt cylinder (2) inside the gooseneck (3).
boom. (Refer to Section 3.10.3, “Quick Attach Removal.”)
6. Label and remove the hoses (1) from the elbow
fittings (5) on the Attachment Tilt cylinder. Plug the
hose ends and cap the elbow fittings on the
with reinforced toe caps and slip-resistant
Attachment Tilt cylinder to prevent dirt and debris
from entering the hydraulic system and/or cylinder.
falling. 7. Label and remove the two auxiliary hydraulic
hoses (6) from the bulkhead fittings (7) inside the
WARNING:
gooseneck (8). Plug the hose ends and cap the
NEVER lift a heavy object bulkhead fittings to prevent dirt and debris from
without the help of at least one assistant or a entering the hydraulic system.
8. If you are replacing the inner boom with a new inner
boom, remove the female coupler (9) male
2. Park the vehicle on a hard, level surface. Be sure nipple (10) and bulkhead fittings (7) from the
there is enough room in front of the vehicle to allow bulkhead plate inside the gooseneck. Save all the
the inner boom section to be removed from the front hardware for reassembly.
of the boom assembly.
(N) NEUTRAL, move the neutral lock lever to the
switch and shut the engine OFF. Allow the hydraulic
oil to cool before proceeding.
3 6
7
10 9
MH0840
1
4
MH1760
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.65

Boom
9. Remove the thumbscrew (1), lockwasher (2) and flat 12. Label and remove the four hoses from the hose reel.
washer (3) holding the rear cover (4) to the rear of The center bolt (13) can remain in place to hold the
the outer boom (5). Lift the rear cover straight up hose reel and side plates together:
until the capscrew (6) in the top of the cover clears a. Remove the elastic locknut (14) and flat
the retaining hole in the top of the outer boom. washer (15) from the lower retaining shoulder
Remove the cover from the outer boom. bolt (16). While pulling the shoulder bolt out,
5 6 as the bolt is removed. Pull the bolt out far
4 enough to remove the hoses from the hose reel.
b. Pull the four hoses from the lower part of the
hose reel out from between the outer boom and
the primary intermediate boom sections.
Carefully lay the hoses out behind the back of the
~
boom.
c. After the hoses are removed from between the
outer and primary intermediate boom sections,
reinsert the shoulder bolt (16) through the plates,
inserting the spacers (17) between the plates as
3 the bolt is inserted. Reassemble the flat
washer (15) and elastic locknut (14) to hold the
2
shoulder bolt in place. DO NOT fully tighten at
1 this time.
MH5690 d. Remove the elastic locknut (18) from the upper
retaining capscrew (19). While pulling the
10. At the front of the outer boom, label and remove the capscrew out, catch the spacers (20) from
auxiliary hoses (7 and 8) from the bottom tube between the plates as the capscrew is removed.
assemblies (9) at the mounting plate. Cap the hose Pull the capscrew out far enough to remove the
ends. hoses from the hose reel.
11. Label and remove the Attachment Tilt hoses e. After the hoses are removed, reinsert the
(10 and 11) from the top tube assemblies (12) at the capscrew (19) through the plates, inserting the
spacers (20) between the plates as the capscrew
mounting plate. Cap the hose ends.
is inserted. Reassemble the elastic locknut (18)
to hold the capscrew in place. DO NOT fully
7 10 tighten.
11
12
9
10
MH1450
8 11
3.66 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
22
20
18 21
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 17. Return to the operator’s cab, start the engine and
threads protruding beyond the elastic locknut and extend the boom approximately 2" (51 mm). Retract
record that measurement for reassembly. the boom slightly until there is slack in the inner
boom extend chain. Shut the engine OFF, and exit
14. Using a 1-7/16" socket and a 12" extension, loosen the cab using the hand holds.
the elastic locknut (21) until the nut is held on by a
couple of threads. DO NOT remove the elastic 18. At the front of the boom, disconnect the inner boom
locknut at this time. extend chain clevis (23) from the anchor plates on
the primary intermediate boom. Remove the elastic
15. At the rear of the boom, locate the two secondary locknut (24) holding the shoulder bolt (25) to the
intermediate boom extend chain locknuts (22). anchor plates. Pull the extend chain clevis from
Measure the amount of threads protruding beyond between the plates and lay over the front of the inner
each elastic locknut and record these boom (26). Save the shoulder bolt and discard the
measurements for reassembly. elastic locknut.
16. Using a 1-1/16" socket and a 12" extension, loosen
both elastic locknuts (22) until each nut is held on by
25
at least two full threads. DO NOT remove these
elastic locknuts at this time.
23
24
26
MH1790
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.67

Boom

holding the inner boom extend chain sheave (3) to 7 8
the front of the secondary intermediate boom (4).
Use a brass punch and a rawhide hammer to 8
remove the sheave pin (5).
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
4 10
3
9
11 MH1810
5 22. At the front of the secondary intermediate boom (12),

remove the capscrews (13), lockwashers (14) and flat
1
shims (17) to the inside of the secondary
intermediate boom. Label the wear pads and shims
MH1800
as “Secondary Intermediate Boom Left Upper/Lower”
and “Secondary Intermediate Boom Right Upper/
21. At the front of the secondary intermediate boom (6), Lower.” Save the shims, capscrews, flat washers,
remove the capscrews (7) and lockwashers (8) lockwashers and wear pad inserts (18).
holding the top wear pads (9) and spacers (10) to
the inside of the secondary intermediate boom.
Label the wear pads and spacers as “Secondary
Intermediate Boom Top Left” and “Secondary
Intermediate Boom Top Right” sides. Save the
spacers, capscrews, lockwashers and wear pad
inserts (11).
3.68 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
25. Remove the hose reel (33) as an assembly, from the

rear of the boom.
31 30
12 28
32
29 27
26
16
18
25
13
17 15 14 MH1820
33 MH1040
23. At the rear of the boom, remove the capscrews (19), 26. Inside the secondary intermediate boom, loosen, but
lockwashers (20) and flat washers (21) holding the DO NOT remove the two capscrews (34) securing
hose reel assembly (22), lower wear pad (23) and the upper left side wear pad and hose clamp support
spacer (24) to the lower plate on the primary bracket (35) to the top of the secondary intermediate
intermediate boom. Reassemble the capscrews, boom.
lockwashers and flat washers to hold the lower wear
27. Remove the two capscrews (36) and
pad in place for primary intermediate boom removal.
lockwashers (37) holding the stack clamps (38) and
hose clamp support bracket (35) to the left side of
22 19 the secondary intermediate boom. Remove the
clamps and the clamp support bracket from the
20 secondary intermediate boom.
21
35
37
36
23
24 MH1030 35
24. Remove the capscrews (25), lockwashers (26) and flat

washers (27) holding the hose reel side plate (28), 38
lower left side wear pad (29) and shims (30) to the side 34
of the primary intermediate boom. Save the capscrews,
inserts (31). Watch for the six washers (32) to fall out
from between the side plate of the hose reel MH2840
assembly and the side plate of the primary intermediate

boom.
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.69

Boom
28. Return to the operator’s cab, start the engine and 30. Remove the two capscrews (6) and lockwashers (7)
fully retract the boom slowly. Shut the engine OFF, holding the hose carrier support (8) and the lower
and exit the cab using the hand holds. wear pad to the secondary intermediate boom.
Note: Record the location of the shoulder bolt (1) to 31. Pull the hose carrier support with hose carrier
ensure correct installation. attached toward the rear of the boom. Reinstall the
capscrews (6) and lockwashers (7) back through the
29. At the rear of the boom, locate the inner boom holes in the bottom of the secondary intermediate
retract chain (2) on the left side of the boom, just in boom to hold the wear pad in place. DO NOT fully
front of where the hose reel was located. In front of tighten the capscrews.
the inner boom retract chain sheave (3), locate the
shoulder bolt (1) which holds the retract chain (2) to
the anchor plates (4). Remove the elastic locknut (5) 6
from the shoulder bolt and remove the shoulder bolt. 7
Save the shoulder bolt and discard the elastic
locknut. Let the inner boom retract chain hang out
the rear of the boom.
2
8 MH1850
3 5 32. Remove the four capscrews (9) and locknuts (10)

holding the hose carrier support (11) to the hose
carrier (12). To access the capscrews, it is
necessary to move the hoses to the side. Save the
capscrews and hose carrier support, and discard the
locknuts.
MH4070
9
12
11
10 MH1860
3.70 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
Note: If replacing the inner boom assembly with a new 36. Remove the elastic locknut (18) and capscrew (19)
inner boom, the quick attach assembly and the holding the quick attach pivot pin (20) to the quick
Attachment Tilt cylinder should be removed at this time. attach assembly (21). Save the capscrew and
discard the elastic locknut. Place a support under
If the inner boom is not to be replaced, the quick attach
the quick attach assembly to prevent it from dropping
assembly and Attachment Tilt cylinder can remain in
when the pivot pin is removed.
place. Proceed to Step 42.
37. Use a brass punch and rawhide hammer to remove
33. Remove the elastic locknut (13) and capscrew (14) the quick attach pivot pin (20) from the quick attach
holding the Attachment Tilt cylinder rod end pin (15) assembly and the bushings in the gooseneck.
to the quick attach assembly (16). Save the Record the location and quantity of the shim
capscrew and discard the elastic locknut. washers (22 and 23) as the pin is being removed.
34. Support the rod end of the Attachment Tilt Save the washers (22 and 23) from each side of the
cylinder (17). Use a brass punch and rawhide quick attach.
hammer to remove the rod end pin (15) from the 38. Inspect the pivot pin (20) for nicks or surface
quick attach assembly. corrosion. Use fine emery cloth to repair minor nicks
35. Inspect the pin (15) for nicks or surface corrosion. or corrosion. If damaged and if it cannot be repaired,
Use fine emery cloth to repair minor nicks or the pin must be replaced.
corrosion. If damaged or if it cannot be repaired, the
pin must be replaced.
21
18
14 23 ~
17 22
13 16 19 20
~
22
15 23 MH0950
MH0940
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.71

Boom
Note: The Attachment Tilt cylinder is heavy. Use a hoist 43. At the rear of the inner boom, remove the elastic
and sling to support the Attachment Tilt cylinder when locknut (5) and flat washer (6) holding the threaded
the base end pin is removed. clevis on the inner boom extend chain (7) to the clevis
39. Remove the retaining ring (1) from one side of the base anchor. Pull the threaded clevis from the anchor, and
end pivot pin (2). Save the retaining ring. Use a brass remove the extend chain from the inner boom. Save the
punch and rawhide hammer to remove the base end flat washer and discard the elastic locknut.
pivot pin from the inner boom gooseneck (3).
40. Inspect the pivot pin (2) for nicks or surface corrosion. 7 5
Use fine emery cloth to repair minor nicks or corrosion.
If damaged and if it cannot be repaired, the pin must 6
be replaced.
41. Lower the Attachment Tilt cylinder (4) down with the
hoist and remove from the rear of the gooseneck.
Place the Attachment Tilt cylinder on a clean, level
surface until installation.
MH1870
1 44. At the rear of the inner boom (8), remove the

capscrews (9) and lockwashers (10) holding the top
wear pads (11), spacer (12) and shims (13) to the top of
3 the inner boom. Label the wear pads, spacers and
shims as “Inner Boom Top Left” and “Inner Boom Top
Right” sides. Save the spacers, capscrews,
2 lockwashers and wear pad inserts (14).
14
11
4 12 13
MH0960
42. Pull the inner boom straight out of the secondary 10

intermediate boom. Guide the four hose ends into the
rear of the boom as the inner boom is being 9
removed. Reposition the slings as needed so that the
inner boom balances when removed from the
secondary intermediate boom. Set the inner boom
down on a level hard surface. Support the boom as
needed to prevent it from tipping over.
8
MH1880
3.72 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
45. At the rear of the inner boom (15), remove the 47. On each side of the inner boom, remove the rear
capscrews (16), lockwashers (17) and flat elastic locknuts (25), capscrews (26) and flat
washers (18) holding the lower wear pad (19) to the washers (27) holding the rear of the hose carrier
bottom of the inner boom. Label the wear pad as guide (28) in place. Save the capscrews and flat
“Inner Boom Bottom.” Save the capscrews, washers. Discard the locknuts.
lockwashers, flat washers and wear pad inserts (20). 48. Loosen, but DO NOT remove the capscrews (29)
holding the front of the hose carrier guide and the
16 top wear pad (30) to each side of the inner boom.
17
28 25
18
27
15
29
26
19
30 MH1910
20 MH1890
46. Inside the rear of the inner boom (21), remove the
four elastic locknuts (22) and capscrews (23) holding
the hose carrier assembly (24) to the bottom of the
inner boom. Save the capscrews and discard the
locknuts.
21
22
24
23
MH1900
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.73

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
6
side outer hose (4) as “Auxiliary Male Nipple” and
the left side inner hose (5) as “Attachment Tilt
Retract.” While holding the back of the hose carrier
guide up, pull the hoses from the channels inside the
inner boom. Lay the hoses out behind the inner 7
boom. MH1930
50. After the hoses are removed from the boom, remove
52. Remove the upper side wear pads from the inner
the hose carrier guide (1) by pulling the guide out the
boom. On the upper wear pads (8), remove the
rear of the boom.
capscrews (9), lockwashers (10) and flat washers
(11) holding the wear pads (8) and shims (12) to the
5 3 side of the boom. The front capscrews will not have
a flat washer under the lockwasher. Label the wear
pads and shims as “Inner Boom Upper Side.” Save
the shims, capscrews, lockwashers, flat washers and
wear pad inserts (13).
4 Note: The front capscrews also hold the mount clips
2 (14) for the hose channel assembly to the side of the
1 inner boom.
10 12
11
MH1920
51. Remove the hose carrier assembly (6) from the inner 14 13
boom by carefully pulling the hose carrier straight 8 MH1940
out the rear of the inner boom (7). Pull both the
upper and lower portion of the hose carrier assembly
out at the same time. Once the hose carrier is out of
the boom, carefully lay the hose carrier on a flat
surface, being careful not to bend the hose carrier
too sharply, which will cause damage to the carrier.
3.74 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
53. Remove the capscrews (15) and lockwashers (16)

holding the lower side wear pads (17) and 21
23
shims (18) to the side of the inner boom. The front 22
capscrews will also hold the mounting clips (19) for 25
the hose channel assembly to the side of the inner 24
boom. Label the wear pads and shims as “Inner
Boom Lower Side.” Save the shims, capscrews,
lockwashers and wear pad inserts (20).
24
16
15 26
19 27
28 MH1960
17
56. Carefully lower the inner boom onto suitable
supports, or to the ground.
18 20
MH1950
54. Carefully slide the hose channel assembly out the
rear of the inner boom. Place the hose channel
assembly on a level surface. Unless the hose
channel assembly has been damaged, there is no 57. Inspect the boom and welds. Consult the local Sky
need to disassemble the hose channel assembly. Trak distributor or the JLG Service Department at
55. If the hose channel has been damaged, disassemble 1-877-554-5438 or 1-717-485-6657, if structural
the hose channel assembly to replace any parts that damage is detected.
are bent or twisted: 58. Inspect hoses, hardware, wear pads, mounting
a. Remove the capscrews (21) and points, chains and other components visible with the
lockwashers (22) holding the mounting clips (23) inner boom removed. Replace if damaged.
to the channels (24). Remove the retainer 59. Inspect all wear pads for wear. (Refer to Section
nuts (25) from the mounting clips.
b. At the front of the hose channel assembly,
remove the capscrews (26) and elastic
locknuts (27) holding the channels to the front
guide (28). Save all hardware and discard the
elastic locknuts.
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.75

Boom
3.6.2 Secondary Intermediate Boom Removal 3. At the front of the primary intermediate boom (7)
WARNING: NEVER lift a heavy object washers (10) holding the side wear pads (11) and
shims (12) to the inside of the primary intermediate
suitable sling and hoist. Failure to comply can boom. Label the wear pads and shims as “Primary
result in death or serious personal injury. Intermediate Boom Left Upper/Lower” and “Primary
Intermediate Boom Right Upper/Lower”. Save the
1. Remove the inner boom as described in Section shims, capscrews, flat washers, lockwashers and
3.3.1, “Inner Boom Removal.” wear pad inserts (13).
2. At the front of the primary intermediate boom (1)
remove the capscrews (2) and lockwashers (3)
holding the upper wear pads (4) and spacers (5) to
the inside of the primary intermediate boom. Label
the wear pads and spacers as “Primary Intermediate
Boom Top Left” and “Primary Intermediate Boom Top
Right” sides. Save the capscrews, lockwashers,
spacers and wear pad inserts (6).
8
13
2
3
10
9
11 7
12 MH1980
4. At the front of the boom, remove the elastic

locknut (14) and shoulder bolt (15) holding the two
yoke plates (16) to the mount at the front of the outer
boom. Retain the shoulder bolt and discard the
1 elastic locknut.
4
15
16
5 6 MH1970
14
MH1990
3.76 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
5. Remove the socket head capscrews (17) and elastic

locknuts (18) holding the extend chain clevis’ (19) to 24
the yoke plates (20).
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 22
MH2000
20 8. At the rear of the boom, remove the two elastic

18 MH2330
locknuts (25) holding the threaded clevis’ (26) of the
extend chains to the anchor bracket on the
7. At the front of the primary intermediate boom, secondary intermediate boom. Save the flat
remove the capscrew (21) and lockwasher (22) washers (27) and discard the elastic locknuts.
holding the extend chain sheave pin (23) to the
sheave mount bracket on the primary intermediate
boom. Remove the pin from the mount bracket and 25
the extend chain sheave (24). Remove the extend
chain sheave and inspect the condition of the
bushings. Replace the bushings if there are any
signs of wear. Inspect the pin, and replace it if there
are any signs of wear.
27
26
MH2011
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.77

Boom
9. From the front of the boom, pull both extend chains

out from between the secondary intermediate boom 6
and the primary intermediate boom.
9
10. At the rear of the secondary intermediate boom (1),
remove the capscrew (2) and lockwasher (3) holding 7
the retract chain sheave pin (4) to the mounting plate
on the left side of the secondary intermediate boom.
11. Remove the retract chain sheave pin (4) from the
mount and the retract chain sheave (5). Remove the 10
retract chain sheave from the secondary 8
intermediate boom.
12. Inspect the bushings inside the sheave (5). Replace 7
the bushings if there are any signs of wear. MH4080
13. Inspect the pin (4) for wear or damage. Replace the
pin if there are any signs of wear. 15. Pull the secondary intermediate boom straight out of
the primary intermediate boom. Reposition the
3 slings as needed so the secondary intermediate
2 4
1 boom balances when removed from the primary
intermediate boom. Set the secondary intermediate
boom down on blocks on a hard, level surface.

5 in death or severe personal injury.
16. Inspect the boom and welds. Consult the local Sky
1-877-554-5438 or 1-717-485-6657, if structural
MH2020 damage is detected.
17. Inspect hoses, hardware, wear pads, mounting
Note: Record the location of the shoulder bolt (6) to points, chains and other components visible with the
ensure correct installation. intermediate boom removed. Replace if damaged.
14. At the rear of the boom, locate the secondary 18. Inspect all wear pads for wear. (Refer to Section
intermediate boom retract chain (7) on the right side 3.9.1, “Wear Pad Inspection.”)
of the boom. In front of the retract chain sheave (8),
locate the shoulder bolt (6) which holds the two
anchor plates (9) to the mount on the secondary
intermediate boom. Remove the elastic locknut (10)
from the shoulder bolt and remove the shoulder bolt.
Save the shoulder bolt and discard the elastic
locknut. Let the retract chain hang out the rear of the
boom.
3.78 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
19. If you are replacing the secondary intermediate boom 22

with a new boom section, the following items need to
be removed from the secondary intermediate boom: 19
21
a. Remove the capscrews (11) and lockwashers
20
(12) holding the bottom wear pad (13) and
spacer (14) to the secondary intermediate boom. 18
Label the wear pad and spacer as Secondary
Intermediate Boom Bottom.” Save the capscrews, 16
lockwashers, spacer and wear pad inserts (15). 18
17
11
12
MH2050
c. Remove the capscrews (23), lockwashers (24) and

14 flat washers (25) holding the side wear pads (26)
and shims (27) to the secondary intermediate
boom. Label the wear pads and shims as
13 “Secondary Intermediate Boom Left Side Upper”
and “Secondary Intermediate Boom Right Side
15 MH2040 Upper/Lower.” Save the capscrews, lockwashers,
flat washers, shims and wear pad inserts (28).
b. Remove the capscrews (16) for the right side wear
pad, the capscrews (17) for the left side wear 23
pad and lockwashers (18) holding the upper
wear pad (19), shims (20) and spacer (21) to the 27
secondary intermediate boom. Label the wear
pads, shims and spacers as “Secondary 24 26
Intermediate Boom Top Right” and “Secondary
25
Intermediate Boom Top Left.” Save the
capscrews, lockwashers, spacers, shims and
28
MH2060
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.79

Boom
d. Remove the capscrews (1), flat washers (2) and 3.6.3 Primary Intermediate Boom Removal
lockwashers (3) holding the lower wear pads (4)
WARNING:
to the inside of the secondary intermediate
boom. Label the wear pads as “Secondary Wear protective footwear
Intermediate Boom Left” or “Secondary with reinforced toe caps and slip-resistant
Intermediate Boom Right” sides. Save the soles. Failure to comply can result in foot or
capscrews, flat washers, lockwashers and wear other bodily injury from crushing, slipping or
pad inserts (5). falling.

5 without the help of at least one assistant or a
1. At the front of the outer boom (6), remove the

4 capscrews (7), lockwashers (8) and flat washers (9)
holding the top wear pads (10) to the inside of the
outer boom. Label the wear pads as “Primary
2
3 Intermediate Boom Top Left” and “Primary
1 MH2070
Intermediate Boom Top Right” sides. Save the
capscrews, lockwashers, flat washers and wear pad
inserts (11).
7
6
8
9
10
11
MH2080
3.80 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
2. At the front of the outer boom (12), remove the 4. If replacing the primary intermediate boom with a
capscrews (13), lockwashers (14) and flat washers new boom section, remove the lower wear pads at
(15) holding the side wear pads (16) and shims (17) the front of the boom:
to the inside of the outer boom. Label the wear pads a. Remove the capscrews (22) and
as “Primary Intermediate Boom Left Side Upper/ lockwashers (23) holding the lower wear
Lower” and “Primary Intermediate Boom Right Side pads (24) and spacers (25) to the inside of the
Upper/Lower.” Save the capscrews, lockwashers, flat boom. Label the wear pads and spacers as
washers, shims and wear pad inserts (18). “Outer Boom Left” or “Outer Boom Right” sides.
Save the capscrews, lockwashers, spacers and
12 wear pad inserts (26).
26
15
14
24
18 13 25
23 22
MH2110
16
17 MH2090

holding the center wear pad spacer mount (21) to
the front of the outer boom. Save the capscrews and
lockwashers.
20 21
19 MH2100
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.81

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). 6
Replace the bushings if there are any signs of
wear.
e. Inspect the sheave pin (3) for wear or damage. 7
Replace the pin if there are any signs of wear. 8
5
8 MH2130
8. On the left side of the outer boom assembly, locate

4 the boom extend sensor (9). Remove the two
capscrews (10) and lockwashers (11) holding the
3 boom extend interlock proximity sensor mounting
bracket (12) to the side of the outer boom. The boom
proximity sensor can remain assembled to the
mounting bracket.
9. Remove the tie wraps holding the boom extend
2
interlock proximity sensor wires to the hydraulic
1 tubes. Secure the boom extend interlock proximity
MH2120 sensor and wires out of the way, at the rear of the
frame. Remove the retainer nuts (13) from the holes
5. Support the front of the Extend/Retract cylinder (5). in the outer boom. Save all hardware.
6. Remove the retaining ring (6) from one side of the
Extend/Retract cylinder rod end mounting pin (7).
12
Use a brass punch and a rawhide hammer to
remove the rod end pin from the mounting ears (8) 13
on the primary intermediate boom.
7. Inspect the pin (7) for wear or damage. Use fine
emery cloth to repair minor nicks or corrosion. If pin 11
10
is damaged, replace it. Save the retaining ring.
9 MH2170
10. Pull the primary intermediate boom straight out of

the outer boom. Reposition the slings as needed so
the primary intermediate boom balances when
removed from the outer boom. Set the primary
intermediate boom down on blocks on a hard, level
surface.
3.82 Model 8042, 10042, 10054 Legacy Rev. 03/04

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 14
suitable supports or to the ground.
15

boom. The structural integrity of the boom will 16
18
13. Inspect the boom and welds. Consult the local Sky
1-877-554-5438 or 1-717-485-6657, if structural
17 19 MH1060
damage is detected.
14. Inspect hoses, hardware, wear pads, mounting points,
b. Remove the capscrews (20), lockwashers (21)
chains and other components visible with the primary and flat washers (22) holding the upper wear
intermediate boom removed. Replace if damaged. pads (23) and shims (24) to the primary
15. Inspect all wear pads for wear. (Refer to Section intermediate boom. Label the wear pads and
3.9.1, “Wear Pad Inspection.”) shims as “Primary Intermediate Boom Top Left,”
“Primary Intermediate Boom Top Center” or
16. If you are replacing the primary intermediate boom “Primary Intermediate Boom Top Right.” Save the
with a new boom section, the following items need to capscrews, lockwashers, flat washers, shims and
be removed from the primary intermediate boom: wear pad inserts (25).
a. Remove the capscrews (14), lockwashers (15)
and flat washers (16) holding the bottom wear 25
pad (17) and spacer (18) to the primary 23
intermediate boom. Label the wear pad and
spacer as “Primary Intermediate Boom Bottom.”
Save the capscrews, lockwashers, flat washers, 24
spacer and wear pad inserts (19).
22
21
20
MH1070
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.83

Boom
17. Remove the capscrews (1), lockwashers (2) and flat 3.6.4 Outer Boom Removal
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
falling.
1
5 suitable sling and hoist. Failure to comply can
2 result in death or serious personal injury.
3
1. Remove the inner boom, secondary intermediate
boom and primary intermediate boom as described
in Section 3.6.1, “Inner Boom Removal,” Section
3.6.2, “Secondary Intermediate Boom Removal,” and
6 Section 3.6.3, “Primary Intermediate Boom
4 Removal.”
MH1080 2. Attach a suitable overhead lifting device and sling to
the Lift/Lower cylinder, and remove slack from the
18. At the underside of the primary intermediate boom, sling.
locate the retract chain locknut (7). Measure the
3. Securely support the outer boom section.
amount of threads protruding beyond the elastic
locknut, and record that measurement for 4. At the front of the outer boom, remove the
reassembly of the chain. Remove the elastic locknut capscrews (9) and lockwashers (10) holding the
and the flat washer (8). Save the flat washer and wear pads (11) and spacers (12) to the inside of the
discard the locknut. outer boom. Label the wear pads and spacers as
“Outer Boom Lower Left” or “Outer Boom Lower
Right.” Save the capscrews, lockwashers, spacers
and wear pad inserts (13).
13
11
12
8
7 MH2140
10
19. Remove the retract chain by pulling it out the rear of 9 MH2150
the primary intermediate boom. Place the retract
chain on a clean surface.
3.84 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
5. At the underside of the outer boom, locate the retract 22 18

chain locknut (14). Measure the amount of threads
protruding beyond the elastic locknut, and record that 19
measurement for reassembly of the chain. Remove the
elastic locknut and the flat washer (15). Save the flat
washer and discard the locknut. 20
21
18
16
17
MH1130
remove the boom extend hose (23) and retract
hose (24) from the bulkhead fittings on the mounting
plate (25). Plug the hose ends and cap the bulkhead
15 14 MH1110
fittings.
6. Remove the retract chain by pulling it out the rear of

the outer boom. Place the retract chain on a clean 25
surface.
7. Label and remove the (outer) auxiliary hose for the
female coupler (16) and the (inner) hose (17) for the
male nipple from the bulkhead fittings on the
mounting plate (18). 23
8. Label and remove the Attachment Tilt retract (outer) 24
hose (19) and the extend (inner) hose (20) from the
bulkhead fittings on the mounting plate (18). Plug the
hose ends and cap the bulkhead fittings.
9. Remove the auxiliary tube assemblies (21) and the MH1140
attachment tube assemblies (22) from the bulkhead

fittings.
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.85

Boom
11. Remove the capscrew (1) and elastic locknut (2) 14. Label the auxiliary tube assemblies (12) located
holding the tube clamp (3) and clamp covers (4) to under the Attachment Tilt tubes (13). Remove the
the extend (5) and retract (6) tubes under the boom. capscrews (14) holding the tube clamps (15) and
Discard the elastic locknut and retain the capscrew, clamp covers (16) to the Attachment Tilt tube clamp
covers and clamps. stacking bolt (17) under the outer boom. Save the
capscrews, clamps and clamp covers. Remove the
tubes from the boom.
6
5 15. Label the Attachment Tilt tube assemblies (13)
located under the boom. Remove the stacking
1
4 bolts (17) holding the tube clamps (18), locking
plates (19) and Attachment Tilt tubes (13) to the
underside of the outer boom. Save the stacking
3 bolts, clamps and locking plates. Remove the tubes
from the boom.
4 16. Inspect the tubes (12 and 13) for kinks or crushed
areas. If any kinks or crushed areas exist, replace
the damaged tube or tubes.
2
MH1150
remove the extend tube (7) and retract tube (8) from
the bulkhead fittings (9). Plug the tube ends and cap
the bulkhead fittings.
13. Remove the extend tube (7) and retract tube (8) from
the 90° elbow fittings (10) on the rear of the Extend/
Retract cylinder (11). Plug the tube ends and cap the 18
90° elbows.
13 19
8 7 12
17
8
9
15
7
16 14
MH1190
11
10 MH1160
3.86 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
17. Label and remove the retract hoses (20) from the 24
straight connectors on both Slave cylinders (21).
Label and remove the extend hoses (22) from the
straight connectors on both Slave cylinders (21). 25
Plug the hose ends and cap the straight connectors
on the Slave cylinders.
26
21 23
20
28
21
22 27 MH1210
23. On the right side boom pivot mounting plate, locate

20 the boom proximity sensor (29). Remove the nut (30)
on the inside of the mounting plate. Remove the
boom proximity sensor from the outside of the plate,
22
MH1200 and let the sensor rest on top of the frame, next to
the mounting plate. The sensor can remain
18. Remove the capscrew (23) and elastic locknut (24) connected to the harness.
holding the upper Slave cylinder pivot pin (25) to the
outer boom. Use a hoist and a sling to hold the Slave 30
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 29
holding the lower Slave cylinder pivot pin (28) to the
mounting ear on the frame. Use a brass punch and a
rawhide hammer to remove the lower pivot pin from
the mounting ear. Discard the elastic locknut and
retain the capscrew. MH1220
20. Inspect the pivot pins (25 and 28) for nicks or 24. The slings should be placed far enough apart on the
damage. If the pins are damaged, they must be outer boom so the boom will balance when the boom
replaced. Lift/Lower cylinder mounting pins and pivot pins are
21. Use the hoist to remove the Slave cylinder from the removed in the following steps.
vehicle. Place the Slave cylinder on a clean, flat
surface.
22. Repeat Steps 18 thru 21 and remove the other Slave
cylinder.
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.87

Boom
25. Remove the capscrew (1) and elastic locknut (2) 28. Use the hoist to remove the outer boom from the
holding the upper Lift/Lower cylinder pivot pin (3) to frame. Position the outer boom on a flat, hard
the outer boom. Securely block the Lift/Lower surface. Block up the boom as required to allow
cylinder in position. Remove the pivot pin from the removal of the Extend/Retract cylinder from the
pin mount by pulling the pin out. It may be necessary underside of the boom.
to use an appropriate puller threaded into the pivot 29. Carefully lower the outer boom onto suitable
pin to remove the pin. Discard the elastic locknut and supports or to the ground.
retain the capscrew. Repeat for the other Lift/Lower
WARNING:
cylinder.
NEVER weld or drill the
26. Inspect the pivot pins (3) for nicks or damage. If the boom. The structural integrity of the boom will
pins are damaged, they must be replaced. be impaired if subjected to any repair involving
2 in death or serious personal injury.
1 30. Inspect the boom and welds. Consult the local Sky
1-877-554-5438 or 1-717-485-6657, if structural
damage is detected.
31. Inspect hoses, hardware, wear pads, mounting
points, chains and other components visible with the
outer boom removed. Replace if damaged.
3 32. Inspect all wear pads for wear. (Refer to Section
MH1230 3.9.1, “Wear Pad Inspection.”)
27. Remove the capscrews (4) and elastic locknuts (5)

holding the boom pivot pins (6) to the frame. Use a
brass punch and a rawhide hammer to remove the
pivot pins from the frame. While removing the pins,
note the location and quantity of shims (7) between
the outer boom and the frame.
4 7
5
MH1240
3.88 Model 8042, 10042, 10054 Legacy Rev. 03/04

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. Place the 13
Extend/Retract cylinder on a clean, flat surface.
14
35. Inspect the pin (9) for damage. If the pin is damaged,
it should be replaced. Retain the retaining rings for 12 MH2160
reassembly.
38. Remove the grease fittings (15) from the Lift/Lower
mounts (17) on the outer boom. Save the grease
fittings for reassembly.
39. Remove the self-aligning bearings (18) from the Lift/
Lower cylinder mounts (16) and the Slave cylinder
mounts (17).
8 40. Inspect the bearings (18). If the bearing rotates
freely inside the outer race, the bearing can be
reused.
11 10 MH1260
36. At the front of the outer boom, remove the elastic 18

locknut (12) holding the rubber bumper (13) to the
Extend/Retract cylinder retainer (14). Discard the
17
elastic locknut.
37. Inspect the rubber bumper (13). If it is in good 15
18
condition, the rubber bumper can be reused. If the
15 16
rubber bumper is showing signs of cracking or MH1290
deterioration, it should be replaced.
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.89

Boom
41. On the left side of the outer boom, remove the 3.6.5 Outer Boom Installation
locknut (1), angle indicator (2) and flat washers (3)
from the weld stud. Save the angle indicator and all
the hardware for reassembly. 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:
3
NEVER lift a heavy object
1 result in death or serious personal injury.
1. On the rear of the boom, assemble the extend and

retract bulkhead fittings (7) to the mounting plate on
the right side. Insert the fittings from the bottom up
2 and secure in place with the bulkhead fitting nuts (8)
on the top side. Tighten securely. Keep the caps on
MH1300
the threaded ends of the fittings to protect the
threads from damage and to keep dirt and debris out
42. Remove the extend and retract bulkhead fittings (4)
of the fittings.
from the mounting plate on the right side of the outer
boom assembly.
7
43. Remove the Attachment Tilt bulkhead fittings (5) 9
from the mounting plate on the left side of the outer
boom assembly.
44. Remove the auxiliary hydraulic bulkhead fittings (6).
45. Inspect all fittings (4, 5 and 6) for damage. If the
8
fittings or threads are damaged, the fittings should
be replaced.
10
4 11
5
12 MH1310
2. On the rear of the boom, assemble the Attachment

Tilt bulkhead fittings (9) to the mounting plate on the
left side. Insert the fittings from the bottom, into the
set of holes closest to the boom and secure in place
with the bulkhead fitting nuts (10) on the top side.
Tighten securely. Keep the fittings capped to protect
the threads from damage and to keep dirt and debris
6 MH1310
out of the fittings.
3. Assemble the auxiliary hydraulics bulkhead
fittings (11) to the mounting plate on the left side.
Insert the fittings from the bottom, into the outer set
of holes and secure in place with the bulkhead fitting
nuts (12) on the top side. Tighten securely. Keep the
fittings capped to protect the threads from damage
and to keep dirt and debris out of the fittings.
3.90 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
Note: If you are assembling a new outer boom 6. Assemble new or saved Lift/Lower cylinder
assembly, continue with Step 4. If reassembling the bearings (18) into the Lift/Lower cylinder mounts
existing boom assembly proceed to Step 5. (19) on each side of the boom assembly. Orient the
fracture (20) in the outer race of each bearing at the
4. Assemble a new angle indicator decal (13) to the left
3 o’clock position. Press the bearings into position
side of the boom assembly. Place the hole in the
until the edge of the outer race (21) of each bearing
decal around the weld stud (14) and align the upper
is flush with the edge of the plate (22).
edge of the decal parallel with the top edge of the
boom assembly. 7. Assemble new or saved Slave cylinder bearings (23)
into the Slave cylinder mounts (24) on each side of
the boom assembly. Orient the fracture (20) in the
outer race of each bearing so that it is perpendicular
to the force of the load. Press the bearings into
position until the edge of the outer race (21) of each
bearing is flush with the edge of the plate (22).
13 8. Assemble the grease fittings (25) into the Lift/Lower
mounts (24) on the outer boom. Tighten all grease
fittings.
14
MH1320
5. Place the two flat washers (15) and the angle

indicator (16) onto the weld stud. Secure in place
with the locknut (17). After tightening the locknut, the
angle indicator must pivot freely on the weld stud. If
the angle indicator binds, loosen the locknut slightly. 23
Recheck to be sure the angle indicator pivots freely. 24
25
18 20
19 25
22
15
21
17
MH4380
16
MH1300
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.91

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. Insert the base end cylinder pin (4)
through both mounting ears and the base end of the
Extend/Retract cylinder. Secure the pin in place with 6
7 MH1360
a retaining ring (5) on each side of the pin. Be sure
the retaining rings are securely seated in the
grooves on each side of the pin. 14. Lift the outer boom assembly and position the boom
on the frame. Align the mounting plates (8) on the
frame between the mounting hubs (9) on each side
of the boom assembly. Lower the boom assembly
until the holes in the boom assembly and the
5 mounting plates align.
8
4 9
2
3
1 5
9
MH1350
8
12. Lift the rod end of the Extend/Retract cylinder up far
enough to insert the threaded stud on the rubber
bumper (6) into the hole in the Extend/Retract
cylinder retainer.
Note: ALWAYS replace elastic locknuts with new elastic MH1370
13. Secure the rubber bumper (6) in place with a new
elastic locknut (7). Tighten securely. Lower the rod
end of the Extend/Retract cylinder, and allow it to
rest on the rubber bumper.
3.92 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
15. On the end of the boom pivot pin (10) closest to the 19. Line up the rod end of one of the Lift/Lower
capscrew hole, mark the capscrew mounting hole cylinders (17) with the self-aligning bearing on the
location. Coat the entire pin with anti-seize outer boom assembly.
compound. 20. Coat the entire Lift/Lower cylinder pivot pin (18) with
16. Insert the pin (10) from the outside of the boom anti-seize compound. Insert the pin through the rod
assembly, making sure the marks (11) for the end of the cylinder and the self-aligning bearing. If
capscrew mounting hole stay in line with the capscrew necessary, use a rawhide hammer to install the pin.
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 .10" (2,5 mm) maximum gap 21. Use a tapered punch to line up the capscrew
(13) between the boom mounting hub and the self- mounting hole in the pin with the mounting tabs on
aligning bearing (14) in the frame. If an additional the rod end of the cylinder. Secure the pin in place
shim is required to maintain the maximum gap, the with the capscrew (19), saved, and a new elastic
extra shim MUST be inserted on the right side of the locknut (20). Tighten the elastic locknut securely.
boom.
Note: ALWAYS replace elastic locknuts with new elastic 20
19
18. After the pivot pin and shims are in place, use a
tapered punch to line up the capscrew hole in the pin
with the mounting holes in the hub. Insert the
capscrew (15), saved, through the hub and the pin.
Secure the capscrew in place with a new elastic
locknut (16). Tighten the elastic locknut securely.
13 18
17 MH1230
22. Repeat Steps 19 thru 21 to assemble the Lift/Lower

cylinder to the other side of the outer boom.
14
15
12
11
10
16
MH1380
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.93

Boom
23. Use a hoist and sling to position the Slave 29. Reassemble the boom proximity sensor (10) to the
cylinder (1) onto the lower cylinder mount (2) located right side mounting plate. With the boom properly
on the frame. The cylinder should be positioned with shimmed, position the boom assembly all the way to
the extend and retract port fittings (3) to the outside. the right side.
Note: ALWAYS replace elastic locknuts with new elastic 30. Insert the boom proximity sensor (10) through the
locknuts to help ensure proper fastening. hole in the right side mounting plate (11). Assemble
the jam nut (12), saved, onto the boom proximity
24. Coat the lower pivot pin (4) with anti-seize sensor on the inside of the plate.
compound. Insert the pin through the base end of
the Slave cylinder. Use a tapered punch to line up 31. Adjust the inner and outer jam nuts on the boom
the capscrew hole in the pin with the mounting tabs proximity sensor until the gap (13) between the
on the cylinder. Secure the lower pivot pin in place sensor and the boom is .12" (3 mm). Tighten the
with the capscrew (5), saved, and a new elastic inside jam nut to hold the boom proximity sensor in
locknut (6). Tighten the elastic locknut securely. position. Torque the jam nut to 36 lb-in (4,1 Nm).
25. Position the rod end of the Slave cylinder around the
13
self-aligning bearing on the outer boom. 12
26. Coat the upper pivot pin (7) with anti-seize
compound. Insert the pin through the rod end of the 11
Slave cylinder. If necessary, use a rawhide hammer
to install the upper pivot pin. Use a tapered punch to 10
line up the capscrew hole in the pin with the
mounting tabs on the cylinder.
1 7 MH1390
32. Assemble the extend tube (14) to the extend port 90°
5 elbow (15) on the Extend/Retract cylinder (16) and
8 the inside bulkhead fitting (17) on the right side of
3 the outer boom. Hand-tighten the tube fitting to the
2 90° elbow. Reposition the tube as needed to align
4 the other end of the tube with the bulkhead fitting.
6 MH1210 tighten the tube end at the 90° elbow.
33. Assemble the retract tube (18) to the retract port 90°
Note: ALWAYS replace elastic locknuts with new elastic elbow (19) on the Extend/Retract cylinder (16) and
locknuts to help ensure proper fastening. the outside bulkhead fitting (20) on the right side of
27. Secure the upper pivot pin (7) with the capscrew (8), the outer boom. Hand-tighten the tube fitting to the
saved, and a new elastic locknut (9). Tighten the 90° elbow. Reposition the tube as needed to align
elastic locknut securely. the other end of the tube with the bulkhead fitting.
28. Repeat Steps 23 thru 26 to assemble the other
tighten the tube end at the 90° elbow.
Slave cylinder to the other side of the outer boom.
3.94 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
36. Assemble the boom retract hose (28) to the outside

18 14 bulkhead fitting (retract tube) on the right side of the
20 boom. Remove all twists from the boom retract hose,
18
and tighten the hose end securely to the bulkhead
17 fitting.
14
16 28
27
19 15
MH1160 MH1140
Note: ALWAYS replace elastic locknuts with new elastic IMPORTANT: DO NOT fully tighten the tube connections,
locknuts to help ensure proper fastening. until all tubes are assembled at both ends.
34. Assemble the tube clamp halves (21) to the 37. Position the extend tube assembly (29) onto the
extend (22) and retract (23) tubes under the outer inner bulkhead fitting (30). Assemble the nut on the
boom. Place one clamp half on top of the tubes and tube assembly to the bulkhead fitting.
one on the underside of the tubes. Place a clamp 38. Position the retract tube assembly (31) onto the
cover (24) on the top and bottom of the clamps. second bulkhead fitting (32). Assemble the nut on
Secure in place with the capscrew (25), saved, and a the tube assembly to the bulkhead fitting.
new elastic locknut (26). Position the clamp halves to
securely hold the tubes without putting tension on 39. Position the inner (to male nipple) auxiliary tube
either tube. Tighten the elastic locknut securely. assembly (33) onto the third bulkhead fitting (34).
Assemble the nut on the tube assembly to the
bulkhead fitting.
23 40. Position the outer (to female coupler) tube
22 assembly (35) onto the outer bulkhead fitting (36).
25 Assemble the nut on the tube assembly to the
24 bulkhead fitting.
21 31
29 32
24
30 33
26 35
MH1150
35. Assemble the boom extend hose (27) to the inside 36

bulkhead fitting (extend tube) on the right side of the
boom. Remove all twists from the boom extend
hose, and tighten the hose end securely to the
bulkhead fitting.
34 MH1440
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.95

Boom
41. Assemble the tube clamp halves, saved, to the

underside of the outer boom. Place an upper clamp 12
half (1) on each side of the Attachment Tilt (upper)
tubes (2). Secure each set of clamp halves to the 11
10
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. 9
42. Place a lower clamp half (5) on each side of the
auxiliary hydraulic (lower) tubes (6). Secure each set
of clamp halves to the stacking bolt with a clamp 16
cover (7), saved, and a capscrew (8), saved. Tighten
the capscrew securely to hold the lower tubes in 15
14
place.
43. Repeat Steps 41 and 42 to assemble the clamps at
the other two clamp locations under the outer boom. 13
MH1130
48. Inside the rear of the outer boom, slide the threaded
clevis end (17) of the retract chain down the right
side of the boom. Guide the threaded part of the
clevis out through the hole in the tab (18) on the
bottom of the outer boom. Pull the threaded part of
the clevis all the way through the tab.
1 locknuts to help ensure proper fastening.
2 3 49. Coat the entire threaded portion of the clevis (17)
6 with multi-purpose grease. Install the flat
4 washer (19), saved, onto the threaded clevis and
assemble a new elastic locknut (20). Thread the nut
5 onto the clevis until the threads are flush with the top
of the nut.
7 8
MH1190
18
44. At the rear left side of the boom, assemble the
Attachment Tilt extend (inner) hose (9) to the inner
bulkhead fitting (10). Remove all twists from the
hose, and tighten the hose end securely to the
bulkhead fitting.
45. Assemble the Attachment Tilt retract (second)
hose (11) to the second bulkhead fitting (12).
Remove all twists from the hose, and tighten the
hose end securely to the bulkhead fitting.
46. Assemble the auxiliary hydraulic (third) hose (13) for
17
the male nipple to the third bulkhead fitting (14).
Remove all twists from the hose, and tighten the
hose end securely to the bulkhead fitting.
47. Assemble the auxiliary hydraulic (outer) hose (15)
for the female coupler to the outer bulkhead
fitting (16). Remove all twists from the hose, and 20 19 MH1460
tighten the hose end securely to the bulkhead fitting.
3.96 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
50. At the front of the outer boom, reassemble the lower 3.6.6 Primary Intermediate Boom
outside wear pads (21) and wear pad spacers (22): Installation
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 other bodily injury from crushing, slipping or
outer boom with the hole offset of the wear pad falling.
toward the middle of the boom. Line up the holes
in the spacer and wear pads with the holes in the
bottom of the boom. WARNING: NEVER lift a heavy object
c. Apply Loctite® 242 threadlocker to the threads of without the help of at least one assistant or a
the capscrews (24), saved. Insert the capscrews suitable sling and hoist. Failure to comply can
with lockwashers (25), saved, through the bottom result in death or serious personal injury.
of the boom and into the wear pads. Be careful
not to push the wear pad inserts out of the wear 1. At the rear of the primary intermediate boom,
pads. assemble the retract chain sheave (26) to the
d. Torque all wear pad mounting capscrews to mounting ears on the right side of the boom. Place
31 ±3 lb-ft (42 ±4 Nm). the sheave between the ears and insert the sheave
e. Repeat Steps a thru d to assemble the lower pin (27) from the left side. Line up the hole in the pin
wear pad on the other side of the outer boom. retainer plate with the threaded hole in the left ear.
2. Secure the pin (27) with the capscrew (28), saved,
and the lockwasher (29), saved. Tighten the
capscrew securely.
3. Grease the sheave using the grease fitting (30) in
23 the pin. Spin the sheave by hand to ensure the
23 sheave spins freely on the pin and to distribute
grease evenly.
21
21
22
25 22
26
27
24 25 30
24 MH1470
29 28
MH2260
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.97

Boom
4. Remove the left side mounting plate from the hose a. Apply Loctite® 242 threadlocker to the threads of
reel assembly. Remove the elastic locknut (1) from the two capscrews (6), saved. Insert a capscrew
the upper retaining capscrew (2). with a lockwasher (7), saved, and a flat washer
(8), saved, through each of the mounting holes in
5. Rotate the left side mounting plate (3) out of the way the left side mounting plate (9). Place three flat
and reassemble the elastic locknut loosely onto the washers (8), saved, onto each of the capscrews
retaining capscrew. and insert the capscrews through the mounting
6. Remove the elastic locknut (4) from the center holes in the left side of the boom.
shoulder bolt (5). Remove the left side plate and b. Place the wear pad shims (10), saved, onto the
reassemble the elastic locknut loosely onto the capscrews. Place the shims onto the capscrews
shoulder bolt. with the holes offset to the top. Place the wear
pad inserts (11), saved, into the cavities in the
3 wear pad (12). Be sure the inserts are seated
1 completely in the cavities. Be careful not to push
the wear pad inserts out of the wear pads.
4 31 ±3 lb-ft (42 ±4 Nm).
2 d. Fill each cavity with a good grade of lithium-
based EP grease.
11 10
5 MH2180 8
9
7. Assemble the left side mounting plate and lower left 12
side wear pad to the side of the primary intermediate 8
boom:
Note: Shim ALL side wear pads as needed to maintain
7 6
MH2190
3.98 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
8. Assemble the lower wear pad (13), saved, and wear 9. Assemble the side wear pads:
pad spacer (14), saved, to the bottom of the primary a. Apply Loctite® 242 threadlocker to the threads of
intermediate boom: the capscrews (19), saved. Insert a capscrew
a. Place the wear pad inserts (15), saved, into the with a lockwasher (20), saved, and a flat washer
cavities in the wear pad. Be sure the inserts are (21), saved, through each of the wear pad
seated completely into the cavities. mounting holes in the side plates of the primary
intermediate boom.
Note: DO NOT apply Loctite to the capscrews (16),
saved. The capscrews will be removed later to finish
capscrews with the holes offset to the center.
assembling the hose reel assembly. Place the wear pad inserts (23), saved, into the
b. With the holes offset to the left, line up the holes cavities in the wear pad (24). Be sure the inserts
in the wear pad spacer (14) and wear pad (13) are seated completely in the cavities. Be careful
with the holes in the primary intermediate boom. not to push the wear pad inserts out of the wear
Insert a capscrew with a lockwasher (17), saved, pads
and a flat washer (18), saved, through the holes. c. Torque all wear pad mounting capscrews to
Be careful not to push the inserts out of the wear 31 ±3 lb-ft (42 ±4 Nm).
pads and snug up the capscrews.
d. Fill all wear pad cavities with a good grade of
c. Check to be sure the capscrews (17) DO NOT lithium-based EP grease.
protrude past the wear pads. If the capscrews
protrude past the wear pads, add additional flat
washers (18) under the capscrew.
19
d. Fill all wear pad cavities with a good grade of
lithium-based EP grease. 20 22
21
16
17
23
24
18
MH1510
14
13
15
MH2200
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.99

Boom
Note: Shim ALL upper rear wear pads as needed to 12. Before installing the primary intermediate boom into
maintain a total maximum gap of .06" (1,5 mm) at the the outer boom, place a string (heavy enough to pull
rear of the pads and maintain a total minimum gap of .07 the Attachment Tilt and auxiliary hydraulic hoses)
to .13" (1,8 to 3,3 mm) in the vertical direction. down the inside of the outer boom. Let the string
hang out the rear of the boom. Pull the other end out
10. Assemble the top wear pads to the top of the
the opening on the left side of the boom where the
intermediate boom. Position the wear pads so the
hoses will exit the boom. Place a string for each
outside pads are offset to the outside and the center
hose in the boom. Position the strings all the way to
pad is offset to the right as seen in the following
the left side of the outer boom.
illustration.
13. Lift the primary intermediate boom. Carefully slide
the capscrews (1), saved. the primary intermediate boom into the front of the
outer boom. Push the boom in until the rod end of
b. Place the wear pad shims (2), saved, onto the the Extend/Retract cylinder aligns with the mounts
top of the boom. Line up the holes in the shims
on the primary intermediate boom.
with the holes in the boom. Place the wear pad
inserts (3), saved, into the cavities in the wear 14. Use the hoist and slings to slightly lift the front of the
pad (4). Be sure the inserts are seated primary intermediate boom to allow installation of
completely in the cavities. the center wear pad:
c. Insert a capscrew with a lockwasher (5), saved, a. Fill the cavities of the wear pad with a good
and a flat washer (6), saved, through each of the grade of lithium-based EP grease.
mounting holes in the top of the intermediate
b. Slide the center wear pad mount (7) into the
boom. Be careful not to push the wear pad
outer boom with the wear pad offset toward the
inserts out of the wear pads.
right side. Line up the threaded holes in the wear
d. Torque all wear pad mounting capscrews to pad mount with the holes in the bottom of the
31 ±3 lb-ft (42 ±4 Nm). outer boom.
e. Fill all wear pad cavities with a good grade of c. Apply Loctite® 242 threadlocker to the threads of
lithium-based EP grease. the capscrews (8), saved. Secure the wear pad
mount to the outer boom with the capscrews (8)
3 and lockwashers (9), saved. Torque the capscrews
to 31 ±3 lb-ft (42 ±4 Nm).
4
2
5
1
9 7
8 MH2210
MH1520
15. Remove the slings and the hoist from the primary
11. On the inside of the outer boom and the inside of the
intermediate boom.
primary intermediate boom, spray the wear pad
pathways with LPS3 or equivalent. Spray the wear
pad pathways on the underside of the primary
intermediate boom with LPS3 or equivalent.
3.100 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
16. Assemble the side wear pads to the outer boom: lockwashers (19), saved, and flat washers (20),
a. Slide the primary intermediate boom over to one
side as far as it will go, to allow wear pad inserts out of the wear pads.
installation. c. Torque all wear pad mounting capscrews to
31 ±3 lb-ft (42 ±4 Nm).
cavities of the side wear pads (11), saved. Fill the
cavities of the wear pad with a good grade of 18
lithium-based EP grease. Place the shims (12), 19
saved, onto the wear pad and line up the holes.
20
the capscrews (13), saved. Slide the wear pad
with shims in between the primary intermediate
boom and the outer boom with the offset of each
wear pad away from the center. Line up the holes
and secure in place with the capscrews (13), 17
d. Torque all wear pad mounting capscrews to 16
31 ±3 lb-ft (42 ±4 Nm).
MH2230
e. Repeat Steps a-d to install the side wear pads on
the other side of the outer boom.
18. Use a hoist and sling to lift the rod end of the Extend/
Retract cylinder (21) up. Align the rod end of the
extend cylinder with the mounts (22) at the front of
the primary intermediate boom.
19. Coat the extend cylinder rod end pin (23), saved,
with anti-seize compound. Insert the rod end pin
through the mounts and secure in place with the
retaining rings (24), saved. Be sure the retaining
rings are securely seated in the grooves on the pin.
15
14
10 13
11
12 MH2220
24
outer boom:
a. Place the wear pad inserts (16), saved, into the 22 23
cavities of the top wear pads (17), saved. Fill the
cavities of the wear pad with a good grade of 21 22 24 MH2240
b. Apply Loctite® 242 threadlocker to the threads of
the capscrews (18), saved. Slide the wear pad in
between the primary intermediate boom and the
outer boom with the offset of each wear pad
away from the center. Line up the holes and
secure in place with the capscrews (18),
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.101

Boom
20. Install the primary intermediate boom front lower

wear pads:
7
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
9
the capscrews (4), saved. Line up the holes and
secure in place with the capscrews (4) and
lockwashers (5), saved. Be careful not to push
the wear pad inserts out of the wear pads.
d. Torque all wear pad mounting capscrews to 6
31 ±3 lb-ft (42 ±4 Nm). MH2170

lithium-based EP grease. 22. Secure the boom extend interlock sensor wire to the
Attachment Tilt tubes under the boom with new tie
wraps.
3.6.7 Secondary Intermediate Boom

Installation

1 with reinforced toe caps and slip-resistant
2 falling.
3
4 5 WARNING: NEVER lift a heavy object
MH2250 without the help of at least one assistant or a
21. On the left side of the outer boom, reassemble the result in death or serious personal injury.
boom extend interlock sensor (6) with mounting
bracket (7). Place the two retainer nuts (8), saved, IMPORTANT: Light lubrication of the boom wear
into the holes in the side of the outer boom. Align the surfaces with a rust inhibitor/lubricant such as LPS 3 or
holes in the mounting bracket with the retainer nuts. equivalent is recommended to keep the boom wear
Secure in place with the capscrews (9), saved, and surfaces lubricated properly. Light lubrication of the
lockwashers (10), saved. Tighten securely. boom wear surfaces is also recommended in salt air
climates and when the vehicle is stored, to help prevent
rusting.
3.102 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
1. Install the secondary intermediate boom lower wear Note: Shim ALL side wear pads as needed to maintain
pad: a total minimum gap of .07"-.13" (1,8 to 3,3 mm) in the
Note: DO NOT apply threadlocker to the threads of the
two wear pad capscrews (11). The capscrews will be 2. Install the secondary intermediate boom side wear
removed to assemble the hose carrier support in place pads:
after the inner boom has been installed. a. Apply Loctite® 242 threadlocker to the threads of
a. Insert a capscrew with a lockwasher (12), saved, the capscrews (16), saved. Insert a capscrew with
through each of the mounting holes in the bottom a lockwasher (17), saved, and a flat washer (18),
of the secondary intermediate boom. saved, through each of the wear pad mounting
holes in the side plates of the secondary
b. Place the wear pad inserts (13), saved, into the intermediate boom.
cavities in the wear pad (14), saved. Be sure the
inserts are seated completely into the cavities. b. Place the wear pad shims (19), saved, onto the
Place the wear pad spacer (15), saved, and the capscrews with the holes offset to the center.
wear pad under the secondary intermediate Place the wear pad inserts (20), saved, into the
boom. With the holes offset to the left, line up the cavities in the wear pad (21). Be sure the inserts
holes and secure the wear pad spacer and wear are seated completely in the cavities. Be careful
pad to the secondary intermediate boom. Be not to push the wear pad inserts out of the wear
careful not to push the wear pad inserts out of pads.
the wear pads. c. Torque all wear pad mounting capscrews to
c. Tighten the capscrews only enough to hold the 31 ±3 lb-ft (42 ±4 Nm).
wear pad in place. d. Fill all wear pad cavities with a good grade of
d. Fill all wear pad cavities with a good grade of lithium-based EP grease.
16
19
21
17
18
11
20
12
MH2060
15
14 13 MH2270
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.103

Boom
Note: Shim ALL upper rear wear pads as needed to 4. Install the secondary intermediate boom upper left
maintain a total maximum gap of .06" (1,5 mm) at the rear side wear pad:
rear of the pads and maintain a total minimum gap of .07 Note: DO NOT apply Loctite® 242 threadlocker to the
to .13" (1,8 to 3,3 mm) in the vertical direction. threads of the capscrews (7), saved, for the left side wear
3. Install the secondary intermediate boom upper rear pad (8). The capscrews will need to be removed to assemble
wear pads: the hose clamp support bracket later.
a. Apply Loctite® 242 threadlocker to the threads of a. Place the wear pad shims (9), saved, and wear
the capscrews (1), saved, for the right side wear pad spacer (10) onto the top of the boom with the
pad (2). offset toward the outside of the boom. Line up
the holes in the shims, spacer and wear pad with
b. Place the wear pad shims (3), saved, and wear
the holes in the boom.
pad spacer (4) onto the top of the boom with the
offset toward the outside of the boom. Line up b. Place the wear pad inserts (11), saved, into the
the holes in the shims, spacer and wear pad with cavities in the wear pad. Be sure the inserts are
the holes in the boom. Place the wear pad seated completely in the cavities.
inserts (5), saved, into the cavities in the wear c. Insert a capscrew with a lockwasher (12), saved,
pad. Be sure the inserts are seated completely in through each of the mounting holes in the top of
the cavities. the secondary intermediate boom. Be careful not
c. Insert a capscrew with a lockwasher (6), saved, to push the wear pad inserts out of the wear
through each of the mounting holes in the top of pads.
the secondary intermediate boom. Be careful not d. Tighten the capscrews only enough to hold the
to push the wear pad inserts out of the wear wear pads in place.
pads.
d. Torque all wear pad mounting capscrews to lithium-base EP grease.
31 ±3 lb-ft (42 ±4 Nm).
e. Fill all wear pad cavities with a good grade of 11
5 10
2 4 9
12
3
6 7
1
MH2290
MH2280
3.104 Model 8042, 10042, 10054 Legacy Rev. 03/04

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 17
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
18
capscrew securely.
6. Grease the sheave using the grease fitting in the pin.
21
Spin the sheave by hand to ensure the sheave spins 20
freely on the pin and to distribute grease evenly. 19 MH2070
8. Lay the two extend chains (22) on the top of the

15 16 secondary intermediate boom with the threaded
14
clevis ends (23) toward the rear of the boom.
9. Coat the threads on each clevis (23) with multi-
purpose grease and insert the clevis’ through the
holes in the anchor plate.
10. Install a flat washer (24), saved, and a new elastic
locknut (25) onto each clevis. Tighten the elastic
locknut far enough so the threads are even with the
13 top of the locknut.
23 25
22
MH2020
24
7. Install the lower front wear pads:
a. Place the wear pad inserts (17), saved, into the 23
cavities of the lower front secondary intermediate
boom wear pads (18), saved.
b. Place the wear pads (18), saved, into the
secondary intermediate boom with the offset of 22
the wear pads toward the outside.
c. Apply Loctite® 242 threadlocker to the threads of MH2300
the capscrews (19), saved. Line up the holes and

secure in place with the capscrews (19), 11. On the inside of the secondary intermediate boom,
lockwashers (20), saved, and flat washers (21), spray the wear pad pathways with LPS3 or
saved. Be careful not to push the wear pad equivalent. Spray the wear pad pathways on the
inserts out of the wear pads. underside of the secondary intermediate boom with
d. Torque all wear pad mounting capscrews to LPS3 or equivalent.
31 ±3 lb-ft (42 ±4 Nm). 12. Lift the secondary intermediate boom up. Carefully
e. Fill all wear pad cavities with a good grade of slide the secondary intermediate boom into the front
lithium-based EP grease. of the primary intermediate boom. Push the boom all
the way in.
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.105

Boom
Note: Shim ALL side wear pads as needed to maintain 14. Assemble the top wear pads to the inside of the
a total minimum gap of .07 to .13" (1,8 to 3,3 mm) in the primary intermediate boom:
horizontal direction. a. Place the wear pad inserts (7), saved, into the
13. Assemble the side wear pads to the primary cavities of the top wear pads (8), saved.
intermediate boom: b. Fill all wear pad cavities with a good grade of
a. Slide the secondary intermediate boom over to
one side as far as it will go, to allow wear pad c. Apply Loctite® 242 threadlocker to the threads of
installation. the capscrews (9), saved. Slide the wear pad and
spacer (10), saved, between the secondary
intermediate boom and the primary intermediate
cavities of the side wear pads (2), saved. Fill the
cavities of the wear pad with a good grade of boom with the offset of each wear pad toward the
center. Line up the holes and secure in place
with the capscrews (9) and lockwashers (11),
c. Place the shims (3), saved, onto the wear pad saved. Be careful not to push the wear pad
and line up the holes. inserts out of the wear pads.
d. Apply Loctite® 242 threadlocker to the threads of d. Torque all wear pad mounting capscrews to
the capscrews (4), saved. Slide the wear pad 31 ±3 lb-ft (42 ±4 Nm).
with shims in between the secondary
intermediate boom and the primary intermediate 9
boom with the offset of each wear pad toward the
center. Line up the holes and secure in place 11
with the capscrews (4), lockwashers (5), saved,
and flat washers (6), saved. Be careful not to
push the wear pad inserts out of the wear pads.
31 ±3 lb-ft (42 ±4 Nm).
f. Repeat Steps a-e to install the wear pads on the
other side of the primary intermediate boom.
10 7 MH2320
15. Place the two extend chains (12) up through the

6 double sheave mounting bracket (13) on the front of
the primary intermediate boom.
16. Assemble the two yoke plates (14) to the extend
1 chains. Line up the holes in each clevis with the
3 5 4 holes in the yoke plates.
17. Coat the socket head capscrews (15), saved, with
2 MH2310
anti-seize compound and insert the capscrews
through the yoke plates and the clevis. Secure in
place with new elastic locknuts (16). Tighten the
locknuts securely, but the extend chain clevis’ must
pivot freely.
3.106 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom

12 20. Align the holes in the yoke plates (22) with the hole
14 in the mount on the outer boom. Coat the new
shoulder bolt (23), with anti-seize compound, and
13 12
insert the shoulder bolt through the yoke plates and
the mount on the boom. Secure in place with a new
14 elastic locknut (24). Tighten the locknut securely, but
the yoke plates must pivot freely.
16 23
22
MH2350

between the mounts and under the extend chains at
the front of the primary intermediate boom. Insert
the sheave pin (18), saved, through the mounts and
the double sheave. Align the mounting hole in the
sheave pin with the threaded hole in the sheave 24
mount, and secure in place with the capscrew (19), MH1990
saved, and the lockwasher (20), saved. Tighten
securely. 21. Place the retract chain (25) around the retract chain
19. After the sheave is assembled, apply a good grade sheave on the right side of the boom. Stretch the
of multi-purpose grease to the grease fitting at the chain forward and place the clevis between the two
end of the pin (21). Turn the sheave by hand to anchor plates (26). Align the hole in the clevis with
distribute the grease evenly. the hole location recorded in the removal procedure.
21
22. Insert the shoulder bolt (27), saved, from the top
17
down and secure in place with a new elastic
locknut (28). Tighten the locknut securely.
27
26
25
19
18 20 MH2360
26
28 MH2340
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.107

Boom
3.6.8 Inner Boom Installation Note: Shim ALL side wear pads as needed to maintain
with reinforced toe caps and slip-resistant 3. Assemble the lower side wear pads and hose
soles. Failure to comply can result in foot or channel assembly to the inner boom:
falling. the capscrews (7), saved. Insert a capscrew with
a lockwasher (8), saved, through the lower hole
in the mounting clip (5) and the front mounting
hole of the lower wear pad (9) in the side plates
without the help of at least one assistant or a of the inner boom. Insert the other capscrew and
suitable sling and hoist. Failure to comply can lockwasher through the rear hole.
IMPORTANT: Light lubrication of the boom wear capscrews with the holes offset to the center.
Place the wear pad inserts (11), saved, into the
surfaces with a rust inhibitor/lubricant such as LPS 3 or
cavities in the wear pad. Be sure the inserts are
equivalent is recommended to keep the boom wear surfaces seated completely in the cavities. Be careful not
lubricated properly. Light lubrication of the boom wear to push the wear pad inserts out of the wear
surfaces is also recommended in salt air climates and pads
when the vehicle is stored, to help prevent rusting.
1. Lay the hose carrier assembly (1) out flat on a level 31 ±3 lb-ft (42 ±4 Nm).
surface. Stretch the four “male” ends of the hoses d. Fill each cavity with a good grade of lithium-based
out straight from the hose carrier assembly. Measure EP grease.
from the male end (2) of each hose back toward the e. Repeat Steps a thru d to install the lower wear
hose carrier assembly 196" (498 cm) and apply tape pad on the other side of the inner boom.
(3) around each hose at that point. The tape is for
proper tensioning of the hoses during reassembly of
the hose clamps. 8
7
5
2
10
9
4 6 11
MH2390
3
MH2380
2. Insert the hose channel assembly (4) into the rear of

the inner boom. Slide the hose channel assembly
into the boom and line up the holes in the mounting
clips (5) with the front mounting holes (6) for the side
wear pads.
3.108 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
4. Assemble the upper side wear pads and hose 5. Install the inner boom lower wear pad:
channel assembly to the inner boom: a. Apply Loctite® 242 threadlocker to the threads of
® the two capscrews (20), saved. Insert a
a. Apply Loctite 242 threadlocker to the threads of
the capscrews (12), saved. Insert a capscrew capscrew with a lockwasher (21), saved, and a
with a lockwasher (13), saved, through the upper flat washer (22), saved, through each of the
hole in the mounting clip (14) and the front mounting holes in the bottom of the inner boom.
mounting hole of the upper wear pad (15) in the b. Place the wear pad inserts (23), saved, into the
side plates of the inner boom. cavities in the wear pad (24), saved. Be sure the
b. Insert the capscrew (16), saved (without inserts are seated completely in the cavities.
threadlocker applied to the threads), Place the wear pad (24) under the inner boom.
lockwasher (13), saved, and a flat washer (17), With the holes offset to the right, line up the
saved, through the rear hole. holes and secure the wear pad to the inner
boom. Be careful not to push the wear pad
c. Place the wear pad shims (18), saved, onto the
capscrews with the holes offset to the center.
Place the wear pad inserts (19), saved, into the c. Torque all wear pad mounting capscrews to
cavities in the wear pad. Be sure the inserts are 31 ±3 lb-ft (42 ±4 Nm).
seated completely in the cavities. Be careful not d. Fill all wear pad cavities with a good grade of
to push the wear pad inserts out of the wear lithium-based EP grease.
pads.
d. Torque the front wear pad mounting capscrews 20
to 31 ±3 lb-ft (42 ±4 Nm). 21
22
f. Turn the rear capscrew in far only enough to hold
the wear pad insert in place.
g. Repeat Steps a thru f to install the upper wear
pad to the other side of the inner boom.
13 17
16 24
12
23
18 MH2420
13
15
14 19
MH2400
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.109

Boom
Note: Shim ALL upper rear wear pads as needed to 7. Lay the inner boom extend chain (7) on the top of the
maintain a total maximum gap of .06" (1,5 mm) at the inner boom with the threaded clevis end (8) toward
rear of the pads and maintain a total minimum gap of the rear of the boom.
.07 to.13" (1,8 to 3,3 mm) in the vertical direction. 8. Coat the threads on the clevis (8) with multi-purpose
6. Install the inner boom upper wear pads: grease and insert the clevis through the hole in the
anchor plate.
the capscrews (1), saved, for the upper wear 9. Install a flat washer (9), saved, and a new elastic
pads (2). locknut (10) onto the clevis. Tighten the elastic
b. Place the wear pad shims (3), saved, and wear locknut far enough so the threads are even with the
pad spacer (4) onto the top of the boom with the top of the locknut.
offset toward the outside of the boom. Line up
the holes in the shims, spacer and wear pad with 8
the holes in the boom. Place the wear pad 10
inserts (5), saved, into the cavities in the wear 7
pad. Be sure the inserts are seated completely in
the cavities. 9
c. Insert a capscrew with a lockwasher (6), saved,
through each of the mounting holes in the top of
the inner boom. Be careful not to push the wear
pad inserts out of the wear pads.
31 ±3 lb-ft (42 ±4 Nm).
MH2440
e. Fill each cavity with a good grade of lithium-
based EP grease.
10. Fold the hose carrier assembly (11) in half and slide
into the inner boom. Be careful while folding the
5
hose carrier in half.
2 IMPORTANT: The hose carrier only folds one way;
3 DO NOT force it. DO NOT twist the hose carrier while
folding.
4
11. Ensure the “female” ends (12) of the hoses are on
6 the bottom, and carefully slide the folded hose
carrier into the inner boom (13). Guide the hose
1 carrier assembly between the channels of the hose
channel assembly.
11
13
MH2430
12
MH2410
3.110 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
Note: ALWAYS replace elastic locknuts with new elastic 15. With the hose guide (20) tilted up in the back, insert
locknuts to help ensure proper fastening. the female ends of the two left side hoses (21) (from
the hose carrier) one at a time over the top of the
12. Line up the lower mounting holes in the hose carrier
angled guide (22) on the front side of the hose guide.
assembly (14) with the holes in the bottom of the
Push the hoses into the hose channel (23) on the left
inner boom. Insert the four capscrews (15), saved,
side of the inner boom and down to the front of the
through the bottom boom plate and up through the
inner boom. Repeat this procedure to insert the two
hose carrier mounts. Secure the capscrews in place
right side hoses (24) into the hose channel on the
with new elastic locknuts (16). Tighten all four
right side of the inner boom.
locknuts securely.
21 24
16
22 20
14
21
15
MH2450
13. Lift the upper part of the hose carrier assembly and
place the hose carrier guide (17) under the hose 23
carrier with the angled guides toward the front. Slide
the hose guide into the inner boom, and place the
front notches onto the rear wear pad mounting
capscrew (18). Be sure the notch in the side of the
hose guide is under the flat washer (19) on each MH2470
side of the boom.

14. Rotate the back of the hose guide up toward the top
of the inner boom as far as it will go. Tighten the rear
wear pad mounting capscrews (18) enough to hold
the hose guide.
17
18
19 17
MH2460
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.111

Boom
16. Loosen the wear pad mounting bolts (1) holding the IMPORTANT: DO NOT allow the Attachment Tilt and
hose guide (2) and wear pads (3) to the side of the auxiliary hydraulic hoses to cross inside the inner boom.
inner boom. Remove the wear pad mounting bolts 21. At the front of the inner boom, pull the two hoses that
(one at a time) with washers. were labeled “Attachment Tilt - Retract” (7) left side
17. Apply Loctite® 242 threadlocker to the threads of the and “Attachment Tilt - Extend” (8) right side out the
hose guide and wear pad mounting bolt (1). Reinsert opening in the back of the gooseneck. Let the hoses
the bolts with washers, but DO NOT fully tighten. hang out the back of the gooseneck.
Swing the back of the hose guide down to line up the 22. At the front of the inner boom, pull the two hoses that
rear notches with the holes in each side of the inner were labeled “Auxiliary - Female Coupler” (9) left
boom. side and “Auxiliary - Male Nipple” (10) right side out
Note: ALWAYS replace elastic locknuts with new elastic the opening in the gooseneck and down to the
locknuts to help ensure proper fastening. bulkhead plate, where the auxiliary hydraulic
couplers are to be mounted. Let the hoses hang
18. Insert a capscrew (4), saved, through the hole in the inside the gooseneck.
inner boom. Secure the hose guide in place with a
flat washer (5), saved, and a new elastic locknut (6).
19. Torque all wear pad/hose guide mounting capscrews
to 31 ±3 lb-ft (42 ±4 Nm).
6 5
4 7
2
3
MH2480
20. Run the hose carrier out and in by hand to check for
interference.
9
10
MH2490
3.112 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom

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 16
inner boom into the front of the secondary
intermediate boom.
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. Reassemble the hose carrier support (11), saved, to
the hose carrier (12). Inside the inner boom, pull the
hose carrier out enough to gain access to the
mounting pivot on the end of the carrier.
17 MH1850
27. With the lower mounting plate on the hose carrier
support (11) on the right side, line up the four holes 32. Place the retract chain (18) up around the retract
in the top plate with the holes in the pivot mount of chain sheave on the left side of the boom. Stretch
the hose carrier (12). the chain forward and place the clevis between the
28. Insert the capscrews (13), saved, through the hose two anchor plates (19). Line up the hole in the clevis
carrier pivot mount and the support bracket. Secure with the anchor plate hole location recorded during
in place with new elastic locknuts (14). Tighten removal.
securely.
33. Insert the shoulder bolt (20), saved, from the top
down and secure in place with a new elastic
12 locknut (21). Tighten the locknut securely.
11 20
19
14 MH1860
18
holding the lower wear pad to the bottom of the
30. Apply Loctite® 242 threadlocker to the threads of the 19
capscrews. Line up the holes in the lower mounting 21 MH2340
plate on the hose carrier support (17) and reinsert
the capscrews and lockwashers. Be careful not to
push the wear pad inserts out of the wear pads.
31. Torque all wear pad mounting capscrews to
31 ±3 lb-ft (42 ±4 Nm).
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.113

Boom
Note: Shim ALL side wear pads as needed to maintain holes and secure in place with the capscrews (9)
a total minimum gap of .07 to .13" (1,8 to 3,3 mm) in the and lockwashers (11), saved. Be careful not to
horizontal direction. push the wear pad inserts out of the wear pads.
34. Assemble the side wear pads to the secondary d. Torque all wear pad mounting capscrews to
31 ±3 lb-ft (42 ±4 Nm).
intermediate boom:
a. Slide the inner boom over to one side as far as it 11
will go, to allow wear pad installation. 9
b. Place the wear pad inserts (1), saved, into the 11
cavities of the side wear pads (2), saved.
c. Fill the cavities of the wear pad with a good
grade of lithium-based EP grease. Place the
shims (3), saved, onto the wear pad and line up
the holes.
d. Apply Loctite® 242 threadlocker to the threads of
with shims between the inner boom and the
secondary intermediate boom with the offset of 10
each wear pad toward the top of the boom. Line
up the holes and secure in place with the
capscrews (4), lockwashers (5), saved, and flat 8
washers (6), saved. Be careful not to push the 7 MH1810
wear pad inserts out of the wear pads.

e. Torque all wear pad mounting capscrews to Note: ALWAYS replace elastic locknuts with new elastic
31 ±3 lb-ft (42 ±4 Nm). locknuts to help ensure proper fastening.
f. Repeat Steps a thru e to install the side wear 36. Place the inner boom extend chain sheave (12),
pads on the other side of the secondary saved, between the mounts at the front of the
intermediate boom. secondary intermediate boom. Insert the sheave
pin (13), saved, through the mounts and the sheave.
Use a tapered punch to line up the mounting hole in
the pin with the mounting hole in the hub. Secure in
place with the capscrew (14), saved, and a new
37. After the sheave is assembled, apply a good grade
2 of multi-purpose grease to the grease fitting at the
1 end of the pin (16). Turn the sheave by hand to
distribute the grease evenly.
14
4 MH1820 16
3 6 5
12
secondary intermediate boom:
13
b. Fill the cavities of the wear pad with a good
grade of lithium-based EP grease. 15
the capscrews (9), saved. Slide the wear pad and MH2510
spacer (10), saved, between the inner boom and
the secondary intermediate boom with the offset
of each wear pad toward the center. Line up the
3.114 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
38. Place the inner boom extend chain (17) up and 44. Place another hose clamp half (25), saved, the left
around the sheave (18) at the front of the secondary auxiliary hydraulic hose (29) and another hose
intermediate boom. clamp half (25) onto the capscrews. Assemble the
capscrews to the left side of the inner boom. Tighten
the capscrews only enough to hold the hoses in
place.
39. Place the extend chain clevis (19) between the 45. Remove the capscrews (30) and lockwashers (31)
mounting plates at the front of the secondary holding the upper left side wear pad to the
intermediate boom. Coat the shoulder bolt (20), secondary intermediate boom.
saved, with anti-seize compound and insert through
the plates and clevis. Secure the shoulder bolt in 46. Apply Loctite® 242 threadlocker to the threads of the
place with a new elastic locknut (21). Tighten capscrews (30), and insert the capscrews with
securely, but the chain clevis should pivot freely. lockwashers through the notches in the hose clamp
support bracket (24) and into the wear pad inserts.
20 Be careful not to push the wear pad inserts out of the
wear pads.
47. Torque all wear pad mounting capscrews to 31 ±3 lb-ft
(42 ±4 Nm).
19
48. Position each of the four hoses with the edge of the
tape (32) at the hose clamps. Hold the hoses in this
18
position, and tighten the two capscrews securely to
hold the hoses.
25
21
25
17 25
24
29
MH2520 22
28 23
IMPORTANT: Keep the four hoses in line (left to right)
as they come out of the hose carrier assembly at the rear 27
25
of the secondary intermediate boom. DO NOT allow the 25
26
hoses to cross. 31
40. Place a lockwasher (22), saved, onto each 30
capscrew (23), saved. Insert the capscrews through
the hose clamp support bracket (24), saved. Insert
the capscrews from the side as shown. 32
41. Place a hose clamp half (25), saved, onto the

capscrews. Place the right auxiliary hydraulic
29
hose (26) and another hose clamp half (25) onto the
capscrews. 28
42. Place another hose clamp half (25), saved, the right 27
26 MH2530
Attachment Tilt hose (27) and another hose clamp
half (25) onto the capscrews.
43. Place two more hose clamp halves (25), the left
half onto the capscrews.
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.115

Boom

6
49. Assemble the hose reel assembly to the left side
mounting plate inside the primary intermediate boom: 7
a. Remove the elastic locknut (1) from the upper
retaining capscrew (2). Discard the locknut. 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). Secure the
center shoulder bolt in place with a new elastic
locknut (3). Tighten securely. DO NOT MH1030
reassemble the locknut to the upper retaining

capscrew at this time. IMPORTANT: Keep the hoses in the same order as they
come from the hose clamps. DO NOT allow the hoses to
1 cross.
g. While pulling the upper retaining capscrew (10)
out, catch the spacers (11) from between the
2
plates as the capscrew is removed. Pull the
3 capscrew out far enough to place the hoses
around the hose reel.
Place the left side auxiliary hydraulic hose (12)
into the left position on the hose reel.
Place the left side Attachment Tilt hose (13) into
5 the second position from the left on the hose
reel.
4 MH2540 Place the right side Attachment Tilt hose (14)
into the second position from the right on the
d. Remove the capscrews (6), lockwashers (7) and hose reel.
flat washers (8) holding the lower wear pad to the Place the right side auxiliary hydraulic hose (15)
bottom of the primary intermediate boom. into the right position on the hose reel.
e. Apply Loctite® 242 threadlocker to the threads of
the capscrews (6), and insert the capscrews with
lockwashers and flat washers through the holes locknuts to help ensure proper fastening.
in the right side hose reel mounting bracket (9) h. Insert the retaining capscrew (10) through the
and into the wear pad inserts. Be careful not to plates of the hose reel, inserting the spacers (11)
push the wear pad inserts out of the wear pads. back in position between the plates as the
f. Torque all wear pad mounting capscrews to capscrew is inserted. Secure the retaining
31 ±3 lb-ft (42 ±4 Nm). capscrew in place with a new elastic locknut (16).
Tighten the elastic locknut securely.
i. Remove the elastic locknut (17) and flat
bolt (19). While pulling the shoulder bolt out,
as the shoulder bolt is removed. Place the
Attachment Tilt hoses and the auxiliary hydraulic
hoses around the hose reel.
3.116 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
j. Insert the shoulder bolt (19) back through the c. Pull the left side Attachment Tilt hose (24) through
plates of the hose reel, inserting the spacers (20) the boom assembly, using the hoses already
back in position between the plates as the down the boom as a guide. Keep the left side
shoulder bolt is inserted. Place the flat Attachment Tilt hose to the left of the hoses
washer (18) onto the shoulder bolt and secure in already installed. Pull the hose out the
place with a new elastic locknut (17). Tighten opening (22) at the bottom of the outer boom.
securely. d. Pull the left side auxiliary hydraulic hose (25)
50. Tie the strings (positioned inside the outer boom through the boom assembly, using the hoses
during the outer boom installation) to the male end of already down the boom as a guide. Keep the left
each of the Attachment Tilt and auxiliary hydraulic side auxiliary hydraulic hose to the left of the
hoses coming off the bottom hose reel assembly. hoses already installed. Pull the hose out the
opening (22) at the bottom of the outer boom.
21 23
11 12 24
25
16
23
24
21
17 15
25
18
20 10 22
MH1410
13
14 19
MH1690

come off the hose reel. DO NOT allow the hoses to
cross.
51. Working from the front of the boom, pull each hose
through the boom assembly. Pull the hose out
the opening (22) at the bottom of the outer boom.
b. Pull the right side Attachment Tilt hose (23)
through the boom assembly. Keep the right side
Attachment Tilt hose to the left of the right side
auxiliary hydraulic hose. Pull the hose out the
opening (22) at the bottom of the outer boom.
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.117

Boom
52. Remove the strings from the hoses.

7 1
53. At the front of the outer boom, assemble the hose
assemblies and tube assemblies to the mounting 4
plate:
Note: Lubricate the radius at the opening in the bottom 10
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. Tighten the
upper right side Attachment Tilt tube
6
assembly (3) to the hose assembly. Tighten the
tube assembly nut securely to hold the tube and 5 3
hose to the plate. Tighten the other end of the 2
tube assembly securely to the bulkhead fitting at 9
the rear of the boom.
1
b. Assemble the left side Attachment Tilt hose (4) to
the upper left side hole (5) on the mounting plate.
Insert the male end of the left side hose through
the upper left side hole. Tighten the upper left 8 12
side Attachment Tilt tube assembly (6) to the 7
hose assembly. Tighten the tube assembly nut
securely to hold the tube and hose to the plate. 10 4
Tighten the other end of the tube assembly 11 MH1450
securely to the bulkhead fitting at the rear of the
boom. 54. Assemble the quick attach to the gooseneck. Line up
c. Assemble the right side auxiliary hydraulic the quick attach (13) between the mounts on the
hose (7) to the lower right side hole (8) on the gooseneck. Assemble a washer (14), saved, on
mounting plate. Insert the male end of the right each side of the quick attach. Reassemble the shims
side hose through the lower right side hole. (15), saved, between the quick attach and the
Tighten the lower right side auxiliary hydraulic gooseneck. DO NOT put all the shims on one side.
tube assembly (9) to the hose assembly. Tighten
The quick attach should be centered in the gooseneck.
the tube assembly nut securely to hold the tube
and hose to the plate. Tighten the other end of 55. Coat the quick attach pivot pin (16) with an anti-seize
the tube assembly securely to the bulkhead compound. Insert the quick attach pivot pin through
fitting at the rear of the boom. the gooseneck, washers, shims and quick attach.
d. Assemble the left side auxiliary hydraulic Use a tapered punch to line up the hole in the pivot
hose (10) to the lower left side hole (11) on the pin with the hole in the quick attach.
mounting plate. Insert the male end of the left
side hose through the lower left side hole.
Tighten the lower left side auxiliary hydraulic
tube assembly (12) to the hose assembly.
Tighten the tube assembly nut securely to hold
the tube and hose to the plate. Tighten the other
end of the tube assembly securely to the
bulkhead fitting at the rear of the boom.
3.118 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom

56. Insert the capscrew (17), saved, through the quick
attach and pin. Secure the capscrew in place with a 19
new elastic locknut (18). Tighten securely.
20
21
22
20
13
21
23
25
14 18 24 MH1730
58. Assemble the left auxiliary hydraulic hose (26)

~
16 labeled “Female Coupler” from inside the gooseneck

to the female coupler (27) bulkhead fitting. Tighten
15 securely.
59. Assemble the right auxiliary hydraulic hose (28)
17
labeled “Male Nipple” from inside the gooseneck to
15 the male nipple (29) bulkhead fitting. Tighten
MH1720
14 securely.
57. 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 (19) 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 (20) on the bottom side. Tighten securely.
b. Assemble the two straight swivel connectors (21)
to the two bulkhead fittings.
c. Assemble the male nipple (22) and dust cap (23)
to the right side swivel connector fitting. Tighten
the swivel connector and male nipple securely. 28 26
Assemble the dust cap onto the male nipple.
29
d. Assemble the female coupler (24) and dust
plug (25) to the left side swivel connector fitting.
Tighten the swivel connector and female coupler 27
securely. Insert the dust plug into the female
coupler.
MH0840
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.119

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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 anti-
seize 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. Be sure the retaining rings
6
are securely seated in the pivot pin grooves. 8
~
7
4
5
MH0940
2
64. Connect the Attachment Tilt hoses from the rear of the
gooseneck to the fittings on the base end of the
3 Attachment Tilt cylinder:
a. Connect the left side hose (10) labeled as
4 “Retract” to the retract port (upper) elbow (11) on
the base end of the Attachment Tilt cylinder.
Index the hose to remove any undo tension and
tighten the hose end completely.
1 b. Connect the right side hose (12) labeled as
MH0960 “Extend” to the extend port (lower) elbow (13) on
the base end of the Attachment Tilt cylinder.
62. Coat the rod end pivot pin (5), saved, with an anti- Index the hose to remove any undo tension and
seize compound. Swing the rod end (6) of the tighten the hose end completely.
Attachment Tilt cylinder up and line up the rod end
63. Insert the rod end pivot pin (5) 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. Insert the capscrew (8), saved,
through the quick attach hub from the backside and
secure in place with a new elastic locknut (9).
Tighten securely.
10
13
11
12
MH1760
3.120 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
65. Clean up all debris, hydraulic fluid, etc., in, on, near 3.7 BOOM CHAINS - FOUR SECTION
and around the vehicle. BOOM (10054)
WARNING: Avoid prolonged engine This vehicle uses double extend chains to extend the
operation in closed areas without adequate intermediate boom, a single extend chain to extend the
ventilation. Failure to properly ventilate inner boom and two single retract chains to retract the
exhaust fumes can result in death or serious intermediate booms and the inner boom. The two
personal injury. intermediate extend chains and both retract chains are
constructed of 3/4" pitch links with 6 x 6 leaf lacing. The
inner boom extend chain is constructed of 1" pitch links
WARNING: Hydraulic oil leaking under with 6 x 6 leaf lacing.
pressure can penetrate the skin and cause
or any part of your body to check for hydraulic
leaks. When checking for hydraulic leaks, wear
that when any chain is replaced, that all the chains and
protection from spraying hydraulic oil. Use a
piece of cardboard or paper to search for leaks.
3.7.1 Boom Chain Inspection
66. Start the engine and operate all boom functions
several times. Check the chain tension again and
adjust as necessary. Check for leaks, and check the
250
hydraulic fluid level in the tank; add fluid if required.
MS21702
OH23902
WARNING: Worn pins, stretched or

cracked links or corrosive environments can
cause chain failure. A chain failure could result
in uncontrolled boom movement, loss of load
or vehicle instability, and could cause death or
serious injury and/or property damage.
Under normal operating conditions the extend chains will

need to be inspected every 250 hours of operation. The
retract chain will need to be exposed and inspected every
1000 hours of operation. Environmental conditions and
dynamic impulse/shock loads can drastically affect
normal operating conditions and require more frequent
inspection intervals.
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.121

Boom
Environments in which material handling vehicles a. Inspection Guidelines

operate can vary widely, from outdoor moisture to mildly
Expose the extend and retract chains (refer to Section
corrosive or highly corrosive industrial atmospheres, in
3.7.1, b. “Expose Extend Chains for Inspection,” Section
addition to abrasive exposures such as sand and grit.
3.7.1, c. “Expose Intermediate Boom Retract Chain for
Some effects can be as follows:
Inspection,” or Section 3.7.1, d. “Expose Inner Boom
• Moisture - Corrosive rusting reduces chain strength Retract Chain for Inspection.”) and inspect the chains for
by pitting and cracking. the following conditions:
• Temperature - Low temperature reduces chain Elongation
strength by embrittlement. Going in and out of cold
When the original length (1) of 12" (305 mm) per foot of
storage results in moisture from condensation.
new chain has elongated from wear to a length (2) of
• Chemical Solutions or Vapors - Corrosive attack on 12.36" (313 mm), the chain must be discarded and
the chain components and/or the mechanical replaced. (Refer to Section 3.7.6, “Boom Extend and
connections between the chain components. Retract Chains Removal and Replacement.”)
Cracking can be (and often is) microscopic. Going
from microscopic cracking to complete failure can be It is important to measure the chain in the section that
either abrupt or may require an extended period of moves over the sheaves because it receives the most
time. frequent articulation. Measuring the chain near its clevis
terminals could give an inaccurate reading.
• Abrasives - Accelerated wearing and scoring of the
articulating members of the chain (pins and plates), Intermediate Extend Chains and Retract Chains
with a corresponding reduction in chain strength.
Due to the inaccessibility of the bearing surfaces (pin Measure across a span of 17 pins at the center of the
surfaces and plate apertures), wear and scoring are chain. Measure from pin center to pin center.
not readily noticeable to the naked eye.
Inner Extend Chain
Following are some examples of dynamic shock loading
Measure across a span of 13 pins at the center of the
which can impose abnormal loads above the endurance
extend chain. Measure from pin center to pin center.
limit of a leaf chain:
All Chains
• High velocity movement of load, followed by sudden,
abrupt stops. The maximum measurement allowed is 12.36" (313 mm).
• Carrying loads in suspension over irregular surfaces If the measurement is more than 12.36" (313 mm), the
such as railroad tracks, potholes and rough terrain. chain must be replaced. (Refer to Section 3.7.6, “Boom
Extend and Retract Chains Removal and Replacement.”)
• Attempting to “inch” loads which are beyond the
rated capacity of the vehicle.
The above load cycles and environmental conditions 1
make it impossible to predict chain life. It is therefore 2
necessary to conduct frequent inspections until
replacement life can be predicted.
The boom chain’s normal life expectancy can be expressed
as a maximum percent of elongation. This is generally
3% of pitch. As the chain flexes back and forth over the
sheave, the bearing joints (pins and inside link plates)
gradually incur wear due to articulation.
MM2120
3.122 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
Edge Wear Turning or Protruding Pins

Check the chain for wear on the link plate edges caused Highly loaded chain, operating with inadequate
by running back and forth over the sheave. The maximum lubrication, can generate abnormal frictional forces
reduction of material must not exceed 5%. This can be between pin and link plates. When chain is allowed to
compared to a normal link plate height by measuring a operate in this condition, a pin or series of pins, can begin
portion of chain that does not run over the sheave. to twist out of a chain, resulting in failure.
Intermediate Extend Chains and Retract Chains Examine the pin head rivets to determine if the “VEE” flats
are still in correct alignment (6). Chain with rotated/
The new chain link measures .713" (18 mm) (3). If the displaced heads (7) or abnormal pin protrusion (8) must
measurement of the worn chain is less than .677" be replaced immediately. (Refer to Section 3.7.6, “Boom
(17 mm) (4), the chain must be replaced. Extend and Retract Chains Removal and Replacement.”)
Inner Extend Chain DO NOT attempt to repair the chain by welding or driving
The new chain link measures .950" (24 mm) (3). If the the pin(s) back into the chain. Once the press fit integrity
measurement of the worn chain is less than .903" between outside plates and pins has been altered, it
(23 mm) (4), the chain must be replaced. cannot be restored.
Any wear pattern on the pin heads or the sides of the link
All Chains
plates indicates misalignment in the system. This
For replacement instructions refer to Section 3.7.6, condition damages the chain as well as increases
“Boom Extend and Retract Chains Removal and frictional loading and must be corrected.
Replacement.”
7
6 8
4 3
MM2060
MM2051
Cracked Plates
Distorted or Battered Link Plates Inspect the chains very carefully, front and back as well
as side to side, for any evidence of cracked plates. If any
Distorted or battered link plates (5) on a leaf chain can
one crack is discovered, the chain must be replaced in its
cause tight joints and prevent flexing.
entirety. (Refer to Section 3.7.6, “Boom Extend and
MA9340
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.123

Boom
• Fatigue Cracking - Fatigue cracks (1) are a result of Other Modes of Failure
repeated cyclic loading beyond the chain’s
endurance limit. The size of the load and the • Ultimate Strength Failure - These types of failures
frequency of its occurrence are factors which are caused by overloads far in excess of the design
determine when fatigue failure will occur. The load. Either fractured plates (3) or enlarged holes (4)
loading can be continuous or intermittent can occur. If either of these failures occurs, the chain
(impulse load). must be replaced immediately. (Refer to Section
• Stress Corrosion Cracking - The outside link and Replacement.”)
plates are particularly susceptible to stress corrosion
cracking (2). Like fatigue cracks, these initiate at the Note: The tight joints inspection must be done with the
point of highest stress but tend to extend in an chain disconnected from the boom. (Refer to Section
arc-like path between holes in the pin plate. More 3.7.6, “Boom Extend and Retract Chains Removal and
than one crack can often appear on a link plate. In Replacement.”)
addition to rusting, this condition can be caused by
• Tight Joints - All joints in the chain must flex freely.
exposure to an acidic or caustic medium or
Tight joints (5) resist flexing and increase internal
atmosphere.
friction, thus increasing chain tension required to lift
Stress corrosion is an environmentally assisted failure. a given load. Increased tension accelerates wear
Two conditions must be present: corrosive agent and and fatigue problems.
static stress. In the chain, static stress is present at the If the problem is caused by dirt or foreign substance
aperture due to the press fit pin. No cyclic motion is packed in the joints, clean and lubricate thoroughly
required, and the plates can crack during idle periods. before re-installing the chain.
• Corrosion Fatigue Cracking - Corrosion fatigue If the problem is caused by corrosion and rust or bent
cracks are very similar to fatigue cracks (1) in pins, replace the chain. (Refer to Section 3.7.6, “Boom
appearance. They generally begin at the aperture Extend and Retract Chains Removal and Replacement.”)
and grow perpendicular to the chain pitch line.
Corrosion fatigue is not the same as stress
corrosion. Corrosion fatigue is the combined action
of an aggressive environment and cyclic stress, not MM2090
a static stress alone, as in stress corrosion.
3
4
1
MM2070
MM2100
2
5
MM2080
MM2110
3.124 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
b. Expose Extend Chains for Inspection c. Expose Intermediate Boom Retract Chain for
Inspection
1. Park the vehicle on level ground. Place the travel
select lever in (N) NEUTRAL, place the neutral lock The retract chain must be removed from the boom in
lever in the (N) NEUTRAL LOCK position, engage order to be visually inspected. This must be done every
the parking brake switch and raise the boom to a 1000 hours or whenever the retract chain is removed
horizontal (level) position. from the boom. (If removal of the chain is required refer
2. Lower both outriggers completely to Section 3.7.6, “Boom Extend and Retract Chains
3. Fully extend the boom until both extend chains are
taut. Shut the engine OFF. While doing the chain inspection, check all chain clevis
The extend chains will be visible for inspection with the wear or grooving from the chain.
vehicle in this state.
While doing the chain inspection, check all chain clevis or stretched, the chain must be replaced. It is
ends for distortion or cracking and sheaves for bearing recommended that when any chain is replaced, that all
wear or grooving from the chain. the chains and clevis’ be replaced at the same time.
If during the inspection, any chain is found to be damaged 1. Park the vehicle on a hard, level surface.
or stretched, the chain must be replaced. It is
recommended that when any chain is replaced, that all 2. Fully retract the boom and raise the boom to a
the chains and clevis’ be replaced at the same time. horizontal position. Place the travel select lever in
Note: DO NOT attempt to repair a chain. Replace a NEUTRAL LOCK position, engage the parking brake
stretched or damaged chain with a new part. Always switch and shut the engine OFF.
that when any chain is replaced, that all the chains and
washer (8), holding the rear cover (9) to the rear of
4. If the chain needs to be replaced, refer to Section until the capscrew in the top of the cover clears the
3.7.6, “Boom Extend and Retract Chains Removal retaining hole in the top of the outer boom. Remove
and Replacement.” the cover from the outer boom.
5. If the chain does not need to be replaced, lubricate
the chain. (Refer to Section 3.7.2, “Chain
Lubrication.”) 10 9
6
MH5690
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.125

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 5
of the boom retract chain.
5. Loosen the elastic locknut (1) far enough so that it
can be removed by hand.
4 6
1 MA9430
2 MH1110
6. If the chain clevis has a threaded hole on the holding the retract chain threaded clevis (3) to the
end (4), a string or wire can be attached to the mounting tab. Save the flat washer and discard the
retract chain clevis using a threaded eye (5) or a flat elastic locknut.
washer tack welded to a capscrew (6). The outside 8. If a threaded eye or capscrew with flat washer
diameter of the eye or flat washer must be smaller (5 or 6) was installed in step 6, attach a string or wire
than the diameter of the threads on the clevis. The to the end of the retract chain clevis. The string or
string or wire will be used to pull the chain back wire must be long enough to pull the clevis and chain
through the boom during the reassembly. through the outer boom.
If there is no threaded hole on the end of the clevis, a 9. Place a pan or tarp, free of dirt, at the rear of the
phillips screwdriver will be needed to catch the vehicle, for the chain to rest on as it is being
countersunk hole in the end of the clevis and guide it removed from the boom. From the rear of the boom,
through the tab during reassembly. pull the retract chain out of the rear of the boom.
10. With the chain hanging from the rear of the boom,
inspect wear and condition of the chain, clevis’, chain
sheaves, chain pins, clevis anchors and all mounting
hardware. Replace a worn or damaged chain. DO
NOT attempt to make any repairs to the chain.
that when any chain is replaced, that all chains and
3.126 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
11. Measure the chain elongation. Measure across 17 13. Lubricate the chain, while it is exposed, if it does not
pins (7), somewhere between the chain sheave and need to be replaced. (Refer to Section 3.7.2, “Chain
where the chain is laying in the pan or on the tarp. Lubrication.”)
The maximum measurement allowed is 12.36" 14. Coat the threads of the threaded clevis (8) with
(313 mm). If the measurement is more than 12.36" multi-purpose grease.
(313 mm), the chain must be replaced. (Refer to
Section 3.7.6, “Boom Extend and Retract Chains Note: Have a second person help with the installation of
Removal and Replacement.”) the retract chain between the intermediate and outer
boom assemblies.
If a string or wire was installed to the end of the
clevis:
intermediate boom and the outer boom. The person
at the front of the boom should pull the clevis using
the string or wire (10) attached to the clevis in step 6.
Push and pull the threaded clevis down to the
tab (11) at the front underside of the outer boom.
16. The person at the front of the boom should guide the
tab (11).
9
8
11
MA9350
10
Note: Chains and clevis’ are wear items and experience
MA9440
the same stress. DO NOT attempt to repair a chain.
17. Remove the string or wire, and the threaded eye or
Always replace both the chain and the clevis’.
capscrew with flat washer, from the end of the clevis.
and Replacement.”
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.127

Boom

clevis:
7
intermediate boom and the outer boom. Keep the
the threaded clevis down to the tab (3) at the front
underside of the outer boom.
19. The person at the front of the boom should guide the 5
threaded end of the clevis (1) through the hole in the 6
tab (3) using a Phillips screwdriver (4). 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 MA9510
boom pushes the retract chain forward.
1 boom (8), position the rear cover (9) in place. Secure
the cover in place with the saved, 5/16" flat
3
9
4 8
MA9520
Once the threaded clevis is through the tab on the

outer boom:
20. Reassemble the saved flat washer (5), and a new
3/4-16 elastic locknut (6) onto the threaded clevis (7).
10
Tighten the locknut until the threaded end of the
clevis is flush with the top of the locknut. 11
21. Tighten the elastic locknut (6) on the retract chain
12
clevis (7) until the amount of threads protruding MH5690

measurement recorded during removal of the retract
chain.
3.128 Model 8042, 10042, 10054 Legacy Rev. 03/04

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 13
to Section 3.7.6, “Boom Extend and Retract Chains
While doing the chain inspection, check all chain clevis
wear or grooving from the chain.
or stretched, the chain must be replaced. It is
recommended that when any chain is replaced, that all
the chains and clevis’ be replaced at the same time.
OH0660
horizontal position. Place the travel select lever in 7. If the chain clevis has a threaded hole on the
(N) NEUTRAL, move the neutral lock lever to end (14), 17 gauge wire can be attached to the
NEUTRAL LOCK position, engage the parking brake retract chain clevis using a threaded eye (15) or a
switch and shut the engine OFF. flat washer tack welded to a capscrew (16). The
3. Remove the thumbscrew (12), lockwasher (11) and outside diameter of the eye or flat washer must be
flat washer (10), holding the rear cover (9) to the rear smaller than the diameter of the threads on the
of the outer boom (8). Lift the rear cover straight up clevis.
the cover from the outer boom. 15
4. Start the engine, slowly extend the boom until the
clevis end (13) of the inner boom retract chain is
exposed on the under side of the primary
intermediate boom. Turn the engine OFF.
5. At the front underside of the primary intermediate
boom, record the amount of threads extending beyond
the elastic locknut (13). This measurement will be the 14
starting point for adjustment of the boom retract
chain.
6. Loosen the elastic locknut (13) far enough so that it
can be removed by hand.
16
MH5950
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.129

Boom

holding the retract chain threaded clevis (3) to the 7
mounting tab on the primary intermediate boom (4). 5
Save the flat washer and discard the elastic locknut.
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
MH2660
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
9. If a threaded eye or capscrew with flat washer was clevis. Push the clevis (6) and guide wire (5) into the
installed in step 7, attach a 17 gauge wire to the end primary intermediate boom (8), so that only the guide
of the retract chain clevis. The wire must be long wire is hanging out of the tab.
boom. The wire must be heavy enough, 17 gauge or
heavier, to pull the weight of the entire chain back 10
through the boom during the reassembly.
12
If there is no threaded hole on the end of the clevis, a
tow wire and guide wire will need to be attached to
the clevis before pulling the chain out of the boom.
~
Both wires must be long enough to pull the clevis and
chain through the outer boom. The tow wire must be
heavy enough, 17 gauge or heavier, to pull the weight
of the entire chain back through the boom during the
reassembly. The guide wire is used only to guide the
threaded end of the clevis into the tab on the primary
9
intermediate boom (4) during reassembly.
11
MH5970
Loop the tow wire (9), 17 gauge or heavier, over the

top of the tab (10) and back through the hole (11) and
twist the end securely onto the guide wire. This will
allow the tow wire to be pulled back through the
primary intermediate boom (12) along with the guide
wire attached to the chain clevis.
3.130 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
10. Place a pan or tarp, free of dirt, at the rear of the 15. With the chain hanging from the rear of the boom,
vehicle, for the chain to rest on as it is being inspect wear and condition of the chain, clevis’, chain
removed from the boom. From the rear of the boom, sheaves, chain pins, clevis anchors and all mounting
pull the retract chain out the rear of the boom. Pull hardware. Replace a worn or damaged chain. DO
the chain through the middle of the two center hoses NOT attempt to make any repairs to the chain.
on the chain reel and over the top of the chain reel.
11. The part of the chain that is still inside the boom stretched or damaged chain with a new part. Always
must be exposed for inspection. Have another replace both the chain and the clevis. It is recommended
person assist with this step. that when any chain is replaced, that all chains and
12. At the front of the boom, disconnect the inner boom clevis’ be replaced at the same time.
extend chain clevis (13) from the anchor plates on 16. Measure the chain elongation. Measure across 17
the primary intermediate boom. Remove the elastic pins (17), somewhere between the chain sheave and
locknut (14) holding the shoulder bolt (15) to the where the chain is laying in the pan or on the tarp.
anchor plates. Pull the extend chain clevis from The maximum measurement allowed is 12.36"
between the plates and lay over the front of the inner (313 mm). If the measurement is more than 12.36"
boom (16). Save the shoulder bolt and discard the (313 mm), the chain must be replaced. (Refer to
elastic locknut. Section 3.7.6, “Boom Extend and Retract Chains
15
13
14
16
MH1790
17
13. Return to the operator’s compartment and start the
engine and slowly retract the boom. To avoid having
the inner boom retract chain becoming entangled,
keep tension on the chain coming out the back of the
boom. Retract the boom as far as possible with the
extend/retract cylinder. Turn the engine OFF. MH5700
14. The inner boom will not retract completely and must
be manually pushed in. To avoid having the inner Note: Chains and clevis’ are wear items and experience
boom retract chain becoming entangled, keep the same stress. DO NOT attempt to repair a chain.
tension on the chain coming out the back of the Replace a stretched or damaged chain with a new part.
boom while the inner boom is pushed in. Always replace both the chain and the clevis’.
IMPORTANT: Care should be taken not to push the 17. If the chain needs to be replaced, refer to Section
inner boom in too far. If the inner boom is pushed in too 3.7.6, “Boom Extend and Retract Chains Removal
far it could damage the hose reel at the back of the and Replacement.”
boom.
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.131

Boom
18. Lubricate the chain, while it is exposed, if it does not If a threaded eye or capscrew with flat washer was
need to be replaced. (Refer to Section 3.7.2, “Chain installed to the end of the clevis:
Lubrication.”) 22. Coat the threads of the threaded clevis (8) with
19. Pull the inner boom extend chain (1) up and around multi-purpose grease.
the sheave (2) at the front of the secondary 23. From the rear of the boom, one person should push
intermediate boom. the threaded clevis end (8) of the retract chain (9)
Note: ALWAYS replace elastic locknuts with new elastic under the chain sheave and down between the
locknuts to help ensure proper fastening. primary intermediate boom and the secondary
intermediate boom. The person at the front of the
20. Place the extend chain clevis (3) between the boom should pull the clevis using the 17 gauge
mounting plates at the front of the secondary wire (10) attached to the clevis in step 7. Push and
intermediate boom. Coat the saved shoulder bolt (4) pull the threaded clevis down to the tab (11) at the
with anti-seize compound and insert through the front underside of the primary intermediate boom.
plates and clevis. Secure the shoulder bolt in place
with a new elastic locknut (5). Tighten securely, but 24. The person at the front of the boom should guide the
the chain clevis should pivot freely. threaded end of the clevis (8) through the hole in the
tab (11) on the primary intermediate boom.
4
3
8 9
2
5
1
MH2520 10 11
MH5990
Note: Have a second person help with the installation of

the retract chain between the primary and secondary 25. Remove the wire, and the threaded eye or capscrew
intermediate boom assemblies. with flat washer, from the end of the clevis.
If no threaded eye or capscrew with flat washer was
21. One person should start the engine, and slowly
installed to the end of the clevis:
extend the boom until the rectangular slot (6) on the
under side of the primary intermediate boom (7) is 26. The tow wire and clevis guide wire will be hanging
exposed. A second person should be at the rear of out the rear of the boom along with the chain.
the boom making sure that the inner boom retract 27. Loop the end of the tow wire (12) through the right
chain does not catch on anything while the boom is side of the threaded clevis (13) as seen from the
being extended. Turn the engine OFF. assembled position. This will allow the tow wire to
guide the threaded clevis down the left side of the
6 primary intermediate boom and close to the hole in
the mounting tab. Leave a long enough loop so that
after the clevis is re-assembled into the tab on the
primary intermediate boom, one side of the loop can
be cut and the remainder of the wire can be pulled
~
out of the boom.
7
MH6030
3.132 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
Front of Boom
15
22
14
19
13
12
20
MH6010
21
28. Coat the threads of the threaded clevis (14) with MH6000
29. Have a second person assist with the next steps. 32. Clip the guide (21) and tow (22) wires and remove the
From the front of the boom, one person should pull wires from the boom clevis and the boom.
on the tow wire (12) while the person at the rear of Once the threaded clevis is through the tab on the
the boom guides the chain clevis between the two primary intermediate boom:
center hoses of the hose reel and under the chain
sheave (16), on the left side of the boom (in front of Note: ALWAYS replace elastic locknuts with new elastic
the hose reel assembly not shown for clarity) and locknuts to help ensure proper fastening.
down the boom between the secondary intermediate 33. Reassemble the saved flat washer (23), and a new
boom (17) and the primary intermediate boom (18). 3/4-16 elastic locknut (24) onto the threaded
The person at the front of the boom will need to pull clevis (25). Tighten the locknut until the threaded
on both the tow wire (12) and the guide wire (15) at end of the clevis is flush with the top of the locknut.
the same time. Use the tow wire to take the weight of 34. Tighten the elastic locknut (24) on the retract chain
the chain and the guide wire to guide the end of the clevis (25) until the amount of threads protruding
clevis through the boom. beyond the elastic locknut is the same as the
30. The person at the back of the boom should keep the measurement recorded during removal of the retract
retract chain lined up squarely with the chain sheave chain.
and help feed the retract chain in while the second 35. Adjust retract chain tension. (Refer to Section 3.7.3,
person pulls on the wires from the front of the boom. “Boom Chain Tension Check.”)
16
17
18 MH6020 25
31. Once the clevis is near the tab on the underside of the
primary intermediate boom, using a phillips MH6040
24 23
screwdriver (19) in the countersunk hole in the end of
the clevis (20), may help to center the clevis in the
hole, while pulling on the guide wire (21).
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.133

Boom
3.7.2 Chain Lubrication 4. Slowly, fully extend the boom and retract it about
halfway. Fully extend the boom again, then retract it
After inspection and before being returned to service,
2" (51 mm) (one inch per section). Turn the
chains must be lubricated with a quality chain lubricant
engine OFF.
(“LUBRIPLATE” Chain & Cable Fluid, “LPS3” or
equivalent). 5. Measure the sag in each of the three boom extend
chains (1) between the bottom of the extend chains
The lubricant must penetrate the chain joint to prevent
and the top of the boom at their closest point (2).
wear. Applying lubricant to the external surfaces will
Acceptable boom chain sag (3) is between 1.5" (38
prevent rust, but the chains should be articulated to make
mm) and 2.5" (64 mm).
sure the lubricant penetrates to the working surfaces
between the pins and links. If the measurement is either less than, or greater
than the range given, the boom chains need to
To prepare the chain for lubrication, the chain plates
be adjusted. Continue with Section 3.7.4, “Inter-
should be brushed with a stiff brush or wire brush to clear
mediate Boom Chains Tension Adjustment,” or
the space between the plates so that the lubricant can
to adjust the chain system.
penetrate to the working surfaces.
Lubricant may be applied with a narrow paint brush or
3
directly poured on, but the chain should be well flooded
with lubricant, and the boom should be extended and
retracted to be sure that the lubricant penetrates to the
working surfaces. All surplus lubricant should be wiped
away from the external surfaces. DO NOT use a solvent
for this wiping operation. 1
Regular application of lubricant is necessary to make 2
sure that all working surfaces are adequately lubricated.
In extremely dusty conditions, it may be necessary to
lubricate the chains more often.
Lubrication of chains on vehicles working consistently in
extreme hot or cold conditions requires special
consideration. It is important that a reputable lubrication
specialist, consult the local Sky Trak distributor or the JLG
Service Department at 1-877-554-5438 or
1-717-485-6657, for guidance.
OA0492
3.7.3 Boom Chain Tension Check
6. Start the engine, retract the boom completely and
1. Make sure the carriage is attached to the gooseneck
turn the engine OFF.
before doing the tension check.
2. Start the engine. If necessary, attach carriage to 3.7.4 Intermediate Boom Chains Tension
gooseneck. Park the vehicle on level ground. Place Adjustment
the travel select lever in (N) NEUTRAL, place the
neutral lock lever in the (N) NEUTRAL LOCK Note: Always perform Section 3.7.3, “Boom Chain
position, engage the parking brake switch and raise Tension Check,” before adjusting the boom extend chain
the boom to a horizontal (level) position. tension.
3. Lower both outriggers completely 1. Adjust the two intermediate boom extend chains (4).
1.5" (38 mm), tighten the two extend chain
2.5" (64 mm), loosen the two extend chain
3.134 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
7
4
OA0512

OH0551 locknuts to help ensure proper fastening.
2. Tighten or loosen the two extend chain adjustment
loosening all three chain locknuts (6 and 7) and
locknuts (6) located at the rear of the boom. Be sure
moving the rear intermediate retract chain clevis (8)
each of the locknuts are adjusted equally so that
from the original mounting hole (9) in the anchor
each extend chain maintains the same tension.
plate to the next hole (10).
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 the instructions in Section 3.7.4, a. “Component/
10
9
MH1780 11

tighten the retract chain locknut (7) at the front on
the underside of the outer boom. MA9450

Model 8042, 10042, 10054 Legacy Rev. 03/04 3.135

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. A distance of less
than 8.5" (216 mm) could result in interference and cause
3 OA0512
3. To increase the separation distance: Loosen the

retract chain locknut (7) on the bottom of the outer
boom one or two turns and tighten the two extend
chain locknuts (8) equally the same number of turns.
A minimum of one full thread on the clevis must
protrude beyond the elastic collar of the locknut.
2
1 8
OH2861
If the distance is less than 8.5" (216 mm) or greater than

11" (279 mm):
1. Verify that the retract chain clevis (4) is not mounted
in the last hole (5) in the anchor plate (6) .
6
5
4 MH1780
4. To decrease the separation distance: Loosen the

extend chain locknuts (8) at the rear of boom equally
one or two turns and tighten the retract chain
locknut (7) the same number of turns. A minimum of
one full thread on the clevis must protrude beyond
the elastic collar of the locknut.
Note: If the secondary intermediate to primary
MA9450 intermediate boom separation distance cannot be
2. Make sure that the chain system is properly achieved, contact the local Sky Trak distributor or the
tensioned. Refer to Section 3.7.3, “Boom Chain JLG Service Department at 1-877-554-5438 or
Tension Check,” and Section 3.7.4, “Intermediate 1-717-485-6657.
Boom Chains Tension Adjustment.”
3.136 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
3.7.5 Inner Boom Chain Tension

Adjustment
Note: Always perform the Section 3.7.3, “Boom Chain 11
Tension Check,” before adjusting the inner boom extend
chain tension.
MH1780

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):

1.5" (38 mm), tighten the extend chain adjustment
locknut (11).
2.5" (64 mm), loosen the extend chain adjustment
locknut (11).
10 OH0660

loosening both chain locknuts (11 and 12) and
moving the rear retract chain clevis (1) from the
original mounting hole (2) in the anchor plate to the
next hole (3).
OA0492
the instructions in Section 3.7.5, a. “Component/
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.137

Boom
5 9
3
6
4 8
7
OH2870
If the distance is less than 13.75" (349 mm) or greater

than 14.25" (362 mm):
1. Verify that the retract chain clevis (1) is not mounted
MH4070
in the last hole (5) in the anchor plate (6) .
5. Recheck chain tension. (Refer to Section 3.7.3, 2. Make sure that the chain system is properly
“Boom Chain Tension Check.”) tensioned. Refer to Section 3.7.3, “Boom Chain
Tension Check,” and Section 3.7.5, “Inner Boom
a. Component/Assembly Verification Chain Tension Adjustment.”
3. To increase the separation distance: Loosen the
The inner (7) to secondary intermediate (8) boom
retract chain locknut (12) on the bottom of the
separation should be checked when assembling new
primary intermediate boom one or two turns and
boom sections or chains, or when the rear retract chain
tighten the extend chain locknut (11) the same
clevis has been moved forward on the anchor plate.
number of turns. A minimum of one full thread on the
Measure the separation between the secondary clevis must protrude beyond the elastic collar of the
intermediate and inner boom top plates. The distance (9) locknut.
should be at least 13.75" (349 mm) and not greater than
4. To decrease the separation distance: Loosen the
14.25" (362 mm) with the boom fully retracted and the
extend chain locknut (11) at the rear of boom one or
chains properly tensioned. A distance of less than
two turns and tighten the retract chain locknut (12)
13.75" (349 mm) could result in interference and cause
on the bottom of the primary intermediate boom the
same number of turns. A minimum of one full thread
on the clevis must protrude beyond the elastic collar
of the locknut.
Note: If the secondary intermediate to primary
intermediate boom separation distance cannot be
achieved, contact the local Sky Trak distributor or the
JLG Service Department at 1-877-554-5438 or
1-717-485-6657.
3.138 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
3.7.6 Boom Extend and Retract Chains 5. Remove and replace the intermediate boom extend
Removal and Replacement chains one at a time. Remove the right side elastic
locknut (15) and flat washer (16) holding the right
a. Intermediate Boom Extend Chains Removal and side intermediate boom extend chain clevis (17) to
Replacement the anchor plate (18) on the secondary intermediate
boom (19). Save the flat washer and discard the
elastic locknut.
6. At the front of the outer boom, remove the
capscrews (20) and elastic locknuts (21) holding the
(N) NEUTRAL, move the neutral lock lever to (N)
intermediate boom extend chain clevis’ (22) to the
yoke plates (23). Discard the elastic locknuts.
7. Inspect the capscrews (20) for signs of wear or
damage. Replace with new capscrews if damaged or
flat washer (12) holding the rear cover (13) to the
worn.
straight up until the capscrew in the top of the cover 20
clears the retaining hole in the top of the outer boom. 23
22
14 13
21 SH1810
8. At the front of the primary intermediate boom,

remove the capscrew (24) and lockwasher (25)
holding the extend chain sheave pin (26) to the
12
sheave mount bracket on the primary intermediate
11 boom. Remove the pin from the mount bracket and
10 the extend chain sheave (27). Remove the extend
MH5690
chain sheave from the mount.
4. At the rear of the boom, locate the intermediate

boom extend chain elastic locknuts (15). Record the
amount of threads extending beyond the elastic 27
locknuts. This measurement will be the starting point
for adjustment of the extend chains after installation. 24
18 15
15
19
26
16
17 25 MH2580
MH2570
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.139

Boom
9. At the rear of the boom, attach one end of a wire (1)

to the threaded clevis (2) on the right side 4
intermediate boom extend chain. Loop the wire 6
around and twist together to form a loop. Route the
wire around the right side of the clevis anchor plate (3).
8
2
3
1
7 5
~
9
10 MH2600
15. While one person guides the intermediate boom

1 MH2590 extend chain into the front of the boom, a second
person should pull the wire (1) and threaded clevis
10. Have a second person assist with the removal of the toward the rear of the boom. Guide the threaded
intermediate boom extend chain. One person should clevis (2) into the hole in the anchor plate (3).
pull the chain from the front of the boom while the
second person guides the wire into the boom from
the rear. Remove the wire from the clevis, but not
from inside the boom.
11. Coat the threads of the threaded clevis (6) with multi-
purpose grease.
12. Lay the new intermediate boom extend chain (4) on
top of the outer boom (5) with the threaded clevis (6)
toward the front of the boom.
13. Attach the wire (7) to the threaded clevis (6) of the
new intermediate boom extend chain. Loop the wire
through the clevis and twist together to form a loop.
14. Pull the intermediate boom extend chain forward and
place in between the chain sheave mounts (8).
Guide the wire and the threaded clevis into the boom
by placing the threaded clevis between the top of the
secondary intermediate boom (9) and the primary
intermediate boom (10).
3.140 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom

16. Place the flat washer (14), saved, onto the threaded 17
end of the threaded clevis (15) and assemble a new
elastic locknut (16). Thread elastic locknut onto the 19
threaded clevis until the threads are flush with the
top of the nut.
17. Cut the loop in the wire and remove the wire from the
clevis.
16 18
20 MH2580
21. Pull the anchor clevis’ (21) up around the double

14 chain sheave and position the clevis’ one at a time
between the yoke plates (22).
15
22. Coat the capscrews (23), saved, with anti-seize
compound. Insert the capscrews through the yoke
plates and clevis’ and secure in place with new
elastic locknuts (24). Tighten each locknut securely,
but the chain clevis’ must pivot freely.
MH2570
23
18. Repeat Steps 9 thru 17 and remove and replace the 22
left side intermediate boom extend chain.
21
19. After both of the chains are replaced inside the
boom, assemble the double sheave to the mount at
the front of the primary intermediate boom.
between the mounts and under the extend chains at 24 SH1810
the front of the primary intermediate boom. Insert
the sheave pin (18), saved, through the mounts and 23. At the rear of the boom, tighten the two elastic
the double sheave. Line up the mounting hole in the locknuts (15) on the secondary intermediate boom
sheave pin with the threaded hole in the sheave extend chain clevis’ until the amount of threads
mount and secure in place with the capscrew (19), protruding beyond each elastic locknut is the same
saved, and the lockwasher (20), saved. Tighten as the measurement recorded during removal of the
securely. extend chains.
24. Check and adjust the intermediate boom retract
chain tension. (Refer to Section 3.7.3, “Boom Chain
Tension Check.”)
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.141

Boom
b. Inner Boom Extend Chains Removal and 6. At the front of the boom, disconnect the inner boom
Replacement extend chain clevis (11) from the anchor plates on
the primary intermediate boom. Remove the elastic
locknut (12) holding the shoulder bolt (13) to the
2. Fully retract the boom and raise the boom to a anchor plates. Pull the extend chain clevis from
horizontal position. Place the travel select lever in between the plates and lay over the front of the inner
(N) NEUTRAL, move the neutral lock lever to (N) boom (14). Save the shoulder bolt and discard the
NEUTRAL LOCK position, engage the parking brake elastic locknut.
13
the outer boom (5). Lift the rear cover straight up 11
5 4
12
14
3
MH1790
2
1
MH5690
holding the inner boom extend chain sheave (17) to
the front of the secondary intermediate boom (18).
4. At the rear of the boom, locate the inner boom Use a brass punch and a rawhide hammer to
extend chain elastic locknut (6). Record the amount remove the sheave pin (19).
of threads extending beyond the elastic locknut. This 8. Inspect the sheave pin (19) for corrosion or damage.
measurement will be the starting point for If the pin is damaged, it should be replaced. Minor
adjustment of the extend chain after installation. corrosion can be repaired with fine emery cloth.
Save the chain sheave (17), pin (19) and
capscrew (16). Discard the elastic locknut.
6
9
6 16
10
7 18
8 17
MH5710 19

15
holding the inner boom extend chain clevis (8) to the
anchor plate (9) on the boom (10). Save the flat
washer and discard the elastic locknut. MH1800
3.142 Model 8042, 10042, 10054 Legacy Rev. 03/04

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 24
23
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).
21
22
27 26
20
25
28
29
20 MH5720 MH5730
10. Have a second person assist with the removal of the 15. While one person guides the inner boom extend
inner boom extend chain. One person should pull chain into the front of the boom, a second person
the chain from the front of the boom while the should pull the wire (20) and threaded clevis toward
second person guides the wire into the boom from the rear of the boom. Guide the threaded clevis (21)
the rear. Remove the wire from the clevis, but not into the hole in the anchor plate (22).
from inside the boom.
11. Coat the threads of the threaded clevis (23) with locknuts to help ensure proper fastening.
16. Place the saved flat washer (7) onto the threaded
12. Lay the new inner boom extend chain (24) on top of
end of the threaded clevis (8) and assemble a new
the outer boom (25) with the threaded clevis (23)
elastic locknut (6). Thread the elastic locknut onto
toward the front of the boom.
the threaded clevis until the threads are flush with
13. Attach the wire (26) to the threaded clevis (23) of the the top of the nut.
new inner boom extend chain. Loop the wire through
17. Cut the loop in the wire and remove the wire from the
the clevis and twist together to form a loop.
clevis.
14. Pull the inner boom extend chain forward and place in
between the chain sheave mounts (27). Guide the
wire and the threaded clevis into the boom by
placing the threaded clevis between the secondary
intermediate boom (28) and the top of the inner
boom (29).
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.143

Boom
18. After the chain is replaced inside the boom,

assemble the sheave to the mount at the front of the 9
19. Place the saved inner boom extend chain sheave (1) 7
between the mounts at the front of the secondary
intermediate boom. Insert the sheave pin (2), saved,
through the mounts and the sheave. Use a tapered
punch to line up the mounting hole in the pin with the
mounting hole in the hub. Secure in place with the 10
capscrew (3), saved, and a new elastic locknut (4).
Tighten securely. 6
20. After the sheave is assembled, apply a good grade
of multi-purpose grease to the grease fitting (5) at
MH2520
the end of the pin (2). Turn the sheave by hand to
distribute the grease evenly.
23. At the rear of the boom, tighten the elastic
locknut (11) on the inner boom extend chain clevis
3 until the amount of threads protruding beyond the
5 elastic locknut is the same as the measurement
recorded during removal of the extend chain.
1
11
11
2
MH2510
21. Pull the inner boom extend chain (6) up and around
the sheave (7) at the front of the secondary
intermediate boom. MH5710
Note: ALWAYS replace elastic locknuts with new elastic 24. Check and adjust the inner boom extend chain
locknuts to help ensure proper fastening. tension. (Refer to Section 3.7.3, “Boom Chain
22. Place the extend chain clevis (8) between the Tension Check.”)
mounting plates at the front of the secondary
intermediate boom. Coat the saved shoulder bolt (9)
with anti-seize compound and insert through the
plates and clevis. Secure the shoulder bolt in place
with a new elastic locknut (10). Tighten securely, but
the chain clevis should pivot freely.
3.144 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
c. Secondary Intermediate Boom Retract Chain

Removal and Replacement
2. Fully retract the boom and raise the boom to a 22
(N) NEUTRAL, move the neutral lock lever to (N)
straight up until the capscrew in the top of the cover
21 20 MH1110
6. The chain clevis may have a threaded hole on the
end of the clevis (25). A string or wire can be
19 18 attached to the retract chain clevis using a threaded
eye (23) or a flat washer tack welded to a capscrew
(24) or through the clevis fingers. 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
17
16
15 25
MH5690
4. At the front underside of the boom, locate the

intermediate boom retract chain elastic locknut (20).
Record the amount of threads extending beyond the
elastic locknut. This measurement will be the
starting point for adjustment of the retract chain after
installation.
5. At the front underside of the outer boom, remove the MH4610
24 23
elastic locknut (20) and flat washer (21) holding the
retract chain threaded clevis (22) to the mounting
tab. Save the flat washer and discard the elastic 7. Attach a string or wire to the threaded eye (23 or 24),
locknut. that was installed in Step 6. The string or wire must
be long enough to pull the clevis and chain through
the outer boom.
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.145

Boom
Note: Record the location of the shoulder bolt to ensure Guide the threaded clevis out as the person at the
correct installation. rear of the boom pushes the retract chain. Keep the
8. At the rear of the boom, locate the two retract chain
and pull the threaded clevis down to the tab (8) at
anchor plates (1) holding the secondary
the front underside of the outer boom.
intermediate boom retract chain to the secondary
intermediate boom, just in front of the retract chain
sheave (2). Remove the elastic locknut (3) and 7
shoulder bolt (4) holding the secondary intermediate 6
boom 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 secondary intermediate boom.
4
1
8
5
9
MH4630
3 14. Reassemble the flat washer (10), saved, and a new

elastic locknut (11) onto the threaded clevis. Tighten
the locknut until the threaded end of the clevis is
2 flush with the top of the locknut.
MH2550
9. From the rear of the boom, pull the secondary

intermediate boom retract chain out of the rear of the
boom. 13
10. Disconnect the string, wire or rod from the retract
chain clevis, and allow it to hang out the rear of the 12
boom.
11. Coat the threads of the threaded clevis (6) with multi-
purpose grease.
the new secondary intermediate boom retract chain in
between primary intermediate and outer boom assemblies.
11
12. At the rear of the boom, attach the string, wire or rod
to the retract chain threaded clevis end (6). 10 MH2560
13. From the rear of the boom, a person should push the 15. At the rear of the boom, place the retract chain (5)
threaded clevis end (6) of the new retract chain (7) up and over the chain sheave (2). Place the clevis
under the chain sheave and down between the between the two anchor plates (1). Line up the hole
intermediate boom and the outer boom, while in the clevis with the anchor plate hole position
another person pulls the retract chain through the recorded during removal.
boom using the previously attached string or wire Note: ALWAYS replace elastic locknuts with new elastic
(9). If the string or wire was attached to the clevis, locknuts to help ensure proper fastening.
the person at the front of the boom can guide the
clevis through tab (8) using a Phillips screwdriver 16. Insert the shoulder bolt (4), saved, through the
(12). Insert the screwdriver though the tab and catch plates and clevis and secure in place with a new
the countersunk hole (13) in the end of the clevis. elastic locknut (3). Tighten the locknut securely.
3.146 Model 8042, 10042, 10054 Legacy Rev. 03/04

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 17

Replacement
(N) NEUTRAL, move the neutral lock lever to the (N)
straight up until the capscrew in the top of the cover OH0660

Remove the cover from the outer boom. 7. Return to the operator’s cab, start the engine and
slowly retract the boom all the way back, and then
extend the boom approximately 1" (25 mm) or just
16 15 until all the tension on the inner boom retract chain is
relieved. Shut the engine OFF.
Note: Record the location of the shoulder bolt to ensure
correct installation.
anchor plates (18) holding the inner boom retract
chain (19) to the inner boom, just in front of the hose
14 reel assembly (20). Remove the elastic locknut (21)
and shoulder bolt (22) holding the inner boom retract
13
chain clevis to the anchor plates. Discard the elastic
12 locknut and save the shoulder bolt. The two anchor
MH5690
plates can remain in place on the inner boom.
4. Start the engine and extend the boom until the inner
boom retract chain adjustment nut (17) on the 22
bottom of the primary intermediate boom is visible. 18
5. At the front underside of the boom, locate the 19
intermediate boom retract chain elastic locknut (17). 20
Record the amount of threads extending beyond the
elastic locknut. This measurement will be the
starting point for adjustment of the retract chain after 21
installation.
6. Loosen the elastic locknut (17) 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. MH2670
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.147

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 6
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. 5
the retract chain between the primary and secondary
intermediate boom assemblies.
10. One person should start the engine, slowly extend
the boom while the second person guides the inner
boom retract chain with the wire attached into the
back of the boom. Extend the boom until the inner 7
boom retract chain adjustment nut (1) on the lower MH5950
left side of the primary intermediate boom (2) can be
accessed and removed. Turn the engine OFF. 13. If a threaded eye or capscrew with flat washer was
installed in step 7, attach a 17 gauge wire to the end
of the retract chain clevis. The wire must be long
boom. The wire must be heavy enough, 17 gauge or
1 4 heavier, to pull the weight of the entire chain back
If there is no threaded hole on the end of the clevis, a
tow wire and guide wire will need to be attached to
~
the clevis before pulling the chain out of the boom.

The tow wire must be long enough to pull the clevis
3 2 and chain through the length of the primary
intermediate boom and must be heavy enough, 17
gauge or heavier, to pull the weight of the entire chain
back through the boom during the reassembly. The
guide wire is used only to pull the tow wire through
MH2660 the boom to be used for installing the new chain.
11. If the chain clevis has a threaded hole on the

10
end (5), 17 gauge wire can be attached to the retract
chain clevis using a threaded eye (6) or a flat washer 8
tack welded to a capscrew (7). The outside diameter 11
of the eye or flat washer must be smaller than the
diameter of the threads on the clevis.
~
holding the threaded clevis (4) on the inner boom
retract chain to the tab in the primary intermediate
boom. Save the flat washer and discard the elastic
locknut.
9
MH5960
3.148 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
Wrap 24 gauge steel wire (8) tightly into the threads Once the 17 gauge wire is installed to the end of the
of the clevis (9). Start the coils as close to the tab as clevis of the new chain:
possible. Make sure the end (10) has enough of a tail 20. Remove the 6 foot piece of wire attached to the rear
to wrap into a knot at the top of the clevis. Push the anchor clevis of the old chain and attach it to the rear
clevis (9) and guide wire (8) into the primary anchor clevis of the new chain.
intermediate boom (11), so that only the guide wire is
hanging out of the tab. 21. Coat the threads of the threaded clevis on the new
chain with multi-purpose grease.
22. Have a second person assist with the next steps.
14
From the front of the boom, one person should pull
8
15 on the tow wire (12) while the person at the rear of
the boom guides the chain clevis between the two
center hoses of the hose reel and under the chain
sheave (16), on the left side of the boom (in front of
~ the hose reel assembly not shown for clarity) and
down the boom between the secondary intermediate
boom (17) and the primary intermediate boom (18).
16
12 17
13
MH6050
Twist the tow wire (12), 17 gauge or heavier, securely

onto the guide wire (8). This will allow the tow wire to
be pulled back through the hole (13) in the tab (14) on
the primary intermediate boom (15) along with the
18 MH6020
guide wire attached to the chain clevis.
14. From the rear of the boom, using the wire attached
to the rear anchor clevis, pull the inner boom retract 23. The person at the back of the boom should keep the
chain through the middle of the two center hoses on retract chain (19) lined up squarely with the chain
the chain reel and over the top of the chain reel and sheave and help feed the retract chain in while the
out of the rear of the boom. second person pulls on the wire (20) from the front of the
If a threaded eye or capscrew with flat washer was boom.
installed to the end of the clevis: 24. The person at the front of the boom should guide the
15. Remove the threaded eye (6) or capscrew with flat threaded end of the clevis (21) through the hole in
washer (7), with the 17 gauge wire still attached, from the tab (22) on the primary intermediate boom.
the clevis on the old chain.
16. Install the threaded eye or capscrew with flat washer,
with the 17 gauge wire still attached, to the new chain
clevis.
21 19
If no threaded eye or capscrew with flat washer was
installed to the end of the clevis:
17. Remove the 17 gauge tow wire (12) from the guide
wire (8) attached to the clevis on the old chain.
18. Install a threaded eye or capscrew with flat washer
into the threaded hole in the end of the clevis on the
new chain.
19. Attach the tow wire (12) to the threaded eye or 20 22
capscrew with flat washer, installed on the new chain. MH5990
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.149

Boom
25. Remove the wire, and the threaded eye or capscrew

with flat washer, from the end of the clevis. 6
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.
3 7
2
MH1790
30. Remove the wire from the anchor clevis at the rear of
the boom. At the rear of the boom, place the retract
1 chain (8) up and over the chain sheave in front of the
hose reel assembly (9). Place the clevis between the
two anchor plates (10). Line up the hole in the clevis
with the anchor plate hole position recorded during
removal.
MH2660
27. At the front of the boom, disconnect the inner boom
extend chain clevis (13) from the anchor plates on 31. Insert the shoulder bolt (11), saved, through the
the primary intermediate boom. Remove the elastic plates and clevis and secure in place with a new
locknut (14) holding the shoulder bolt (15) to the elastic locknut (12). Tighten the locknut securely.
anchor plates. Pull the extend chain clevis from
between the plates and lay over the front of the inner 11
boom (16). Save the shoulder bolt and discard the 10
elastic locknut.
28. Return to the operator’s compartment and start the 8
engine and slowly retract the boom. To avoid having 9
the inner boom retract chain becoming entangled,
keep tension on the chain coming out the back of the
boom. Retract the boom as far as possible with the
extend/retract cylinder. Turn the engine OFF. 12
29. The inner boom will not retract completely and must
be manually pushed in. To avoid having the inner
boom retract chain becoming entangled, keep
tension on the chain coming out the back of the
boom while the inner boom is pushed in. MH2670
IMPORTANT: Care should be taken not to push the

inner boom in too far. If the inner boom is pushed in too
far it could damage the hose reel at the back of the
boom.
3.150 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
32. Pull the inner boom extend chain (1) up and around 3.8 HOSE CARRIER ASSEMBLY - FOUR
the sheave (2) at the front of the secondary SECTION BOOM (10054)
intermediate boom.
Note: ALWAYS replace elastic locknuts with new elastic 3.8.1 Hose Carrier Assembly Removal
33. Place the extend chain clevis (3) between the
intermediate boom. Coat the saved shoulder bolt (4)
with anti-seize compound and insert through the
plates and clevis. Secure the shoulder bolt in place WARNING: Wear protective footwear
with a new elastic locknut (5). Tighten securely, but with reinforced toe caps and slip-resistant
the chain clevis should pivot freely. soles. Failure to comply can result in foot injury
from falling objects or other bodily injury from
16 slipping or falling.
15 WARNING: NEVER lift a heavy object

without the help of an assistant or a suitable
sling and hoist. Failure to comply can result in
14
serious personal injury.
2. Park the vehicle on a hard, level surface. Be sure

17 there is enough room in front of the vehicle to allow
the inner boom section to be removed from the front
13 of the boom assembly.
MH2520 horizontal position. Place the travel select lever in
34. Return to the operator’s compartment and start the NEUTRAL LOCK position, engage the parking brake
engine. Slowly extend the boom to gain access to switch and shut the engine OFF. Allow the hydraulic
the inner boom retract chain adjustment nut (3) on oil to cool before proceeding.
the lower left side of the primary intermediate boom.
4. Move the Attachment Tilt joystick in both directions
35. Tighten the adjustment nut until the threads of the system. Move the auxiliary hydraulic joystick in both
threaded clevis are flush with the top edge of the nut. directions to relieve any trapped pressure in the
This will be a starting point for adjustment of the auxiliary hydraulic system.
inner boom retract chain.
36. Check and adjust the inner boom retract chain
tension. (Refer to Section 3.7.3, “Boom Chain
Tension Check.”)
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.151

Boom
5. Locate the two hoses (1) attached to the base of the 8. Remove the thumbscrew (8), lockwasher (9) and flat
Attachment Tilt cylinder (2) inside the gooseneck (3). washer (10) holding the rear cover to the rear of the
6. Label and remove the hoses (1) from the elbow outer boom (12). Lift the rear cover straight up until
fittings (4) on the Attachment Tilt cylinder. Plug the the capscrew (11) in the top of the cover clears the
hose ends and cap the elbow fittings on the retaining hole in the top of the outer boom. Remove
Attachment Tilt cylinder to prevent dirt and debris the cover from the outer boom.
from entering the hydraulic system and/or cylinder.
11
12
10
1
9
4 8
MH5690
2
MH1760
7. Label and remove the two auxiliary hydraulic 9. At the front of the outer boom, label and remove the
hoses (5) from the bulkhead fittings (6) inside the Attachment Tilt hoses (13 and 14) from the tube
gooseneck (7). Plug the hose ends and cap the assemblies (15) at the mounting plate. Cap the hose
bulkhead fittings to prevent dirt and debris from ends. Tie a string to each of the hoses to aid in the
entering the hydraulic system. installation of the new hoses.
13 14
16
17
7
13 15
16
6 5 17
14
MH1770
MH0840
3.152 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
10. Label and remove the auxiliary hoses (16 and 17) After the hoses are removed, insert the
from the tube assemblies (15) at the mounting plate. capscrew (24) through the plates, inserting the
Cap the hose ends. Tie a string to each of the hoses spacers (25) between the plates as the capscrew is
to aid in the installation of the new hoses. inserted. Reassemble the elastic locknut (23) to hold
11. Label and remove the four hoses from the hose reel. the capscrew in place; DO NOT fully tighten.
The center bolt (18) can remain in place to hold the 15. At the rear of the boom, locate the inner boom
hose reel and side plates together. extend chain locknut (26). Measure the amount of
12. Remove the elastic locknut (19) and flat washer (20) threads protruding beyond the elastic locknut and
from the lower retaining shoulder bolt (21). While record that measurement for reassembly.
pulling the shoulder bolt out, catch the spacers (22) 16. Using a 1-7/16" socket and a 12" extension, loosen
from between the plates as the bolt is removed. Pull the elastic locknut (26) until the nut is held on by a
the bolt out far enough to remove the hoses from the couple of threads. DO NOT remove the elastic
hose reel. locknut at this time.
13. Pull the four hoses from the lower part of the hose
reel out from between the outer boom and the
primary intermediate boom sections. Remove the 26
strings from the hoses, but leave the strings inside
the boom. Carefully lay the hoses out behind the
back of the boom.
After the hoses are removed from between the outer
and primary intermediate boom sections, insert the
shoulder bolt (21) through the plates, inserting the
spacers (22) between the plates as the bolt is
inserted. Reassemble the flat washer (20) and
elastic locknut (19) to hold the shoulder bolt in place;
DO NOT fully tighten at this time.
MH1780
25 17. Return to the operator’s cab, start the engine and

extend the boom approximately 2" (51 mm). Retract
23 the boom slightly until there is slack in the inner
boom extend chain. Shut the engine OFF.
19
20
22 24
21 18 MH1690
14. Remove the elastic locknut (23) from the upper

retaining capscrew (24). While pulling the capscrew
out, catch the spacers (25) from between the plates
as the capscrew is removed. Pull the capscrew out
far enough in order to remove the hoses from the
hose reel.
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.153

Boom
18. At the front of the boom, disconnect the inner boom 20. At the front of the secondary intermediate boom
extend chain clevis (1) from the anchor plates on the (11), remove the capscrews (12), lockwashers (13)
primary intermediate boom. Remove the elastic and flat washers (14) holding the side wear pads
locknut (2) holding the shoulder bolt (3) to the anchor (15) and shims (16) to the inside of the secondary
plates. Pull the extend chain clevis from between the intermediate boom. Label the wear pads and shims
plates and lay over the front of the inner boom (4). as “Secondary Intermediate Left Upper/Lower” and
Save the shoulder bolt and discard the elastic “Secondary Intermediate Right Upper/Lower”. Save
locknut. the shims, capscrews, flat washers, lockwashers and
3
1
11
17
4 12
15
16 14 13 MH2720
MH1790

19. At the front of the secondary intermediate boom (5), 3.9.1, “Wear Pad Inspection.”)
remove the capscrews (6) and lockwashers (7)
22. Inside the secondary intermediate boom, loosen, but
holding the top wear pads (8) and spacers (9) to the
DO NOT remove the two capscrews (18) securing
inside of the secondary intermediate boom. Label
the upper left side wear pad and hose clamp support
the wear pads and spacers as “Secondary
bracket (19) to the top of the secondary intermediate
Intermediate Top Left” and “Secondary Intermediate
boom.
Top Right” sides. Save the spacers, capscrews,
lockwashers and wear pad inserts (10). 23. Remove the two capscrews (20) and
lockwashers (22) holding the stack clamps (22) and
hose clamp support bracket (18) to the left side of
the secondary intermediate boom. Remove the
6 clamps and the clamp support bracket from the
19
21
9
7 20
19
8 5
10 MH2710
22
18
MH2840
3.154 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
24. Start the engine and extend the boom until the inner
boom retract chain adjustment nut (23) on the 28
bottom of the primary intermediate boom is visible. 24
25. Loosen the elastic locknut (23) on the inner boom 25
retract chain clevis. DO NOT remove the elastic
locknut at this time, but loosen the nut as far as
26
possible to gain as much slack as possible in the
retract chain. 27
23
MH2670
28. Remove the two capscrews (29) and

lockwashers (30) holding the hose carrier
support (31) and the lower wear pad to the
29. Pull the hose carrier support with the hose carrier
attached toward the rear of the boom. Reinstall the
capscrews (29) and lockwashers (30) back through
the holes in the bottom of the secondary
intermediate boom to hold the wear pad in place. DO
NOT fully tighten the capscrews.
OH0660
26. Return to the operator’s cab, start the engine and 29

slowly retract the boom all the way back and then
30
extend the boom approximately 1" (25 mm) or just
until all the tension on the inner boom retract chain is
relieved. Shut the engine OFF.
anchor plates (24) holding the inner boom retract
chain (25) to the inner boom, just in front of the hose
reel assembly (26). Remove the elastic locknut (27)
and shoulder bolt (28) holding the inner boom 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.
31 MH1850
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.155

Boom
30. Remove the four capscrews (1) and locknuts (2)

holding the hose carrier support (3) to the hose 12 9
carrier (4). To access the capscrews, it will be 11
necessary to move the hoses to the side. Save the
capscrews and hose carrier support. Discard the 13
locknuts.
10
1
4 14 MH1910
Note: Record the hose locations before removing them

3 from the hose carrier assembly, to ensure correct
installation.
2 MH1860
35. Tilt the back of the hose carrier guide (15) up. Use a
31. Pull the inner boom straight out of the secondary light to look inside the inner boom, and note which
intermediate boom. Guide the four hose ends into hoses go into which channels on either side of the
the rear of the boom as the inner boom is being boom:
removed. Reposition the slings as needed so that a. Right side outer hose (16) goes to “Auxiliary
the inner boom balances when removed from the Female Coupler” and the right side inner
secondary intermediate boom. Set the inner boom hose (17) goes to “Attachment Tilt Extend.”
down on a hard, level surface. Support the boom as
b. Left side outer hose (18) goes to “Auxiliary Male
needed to prevent it from tipping over. Nipple” and the left side inner hose (19) goes to
32. Inside the rear of the inner boom (5), remove the four “Attachment Tilt Retract.”
elastic locknuts (6) and capscrews (7) holding the 36. Hold the rear of the hose carrier guide up, pull the
hose carrier assembly (8) to the bottom of the inner hoses from the channels inside the inner boom. Lay
boom. Save the capscrews and discard the locknuts. the hoses out behind the inner boom.
37. After the hoses are removed from the boom, remove
5 the hose carrier guide (15) by pulling the guide out
the back of the boom.
6
19 17
18
16
7
MH2450 15
33. On each side of the inner boom, remove the rear

elastic locknuts (9), capscrews (10) and flat
washers (11) holding the rear of the hose carrier
guide (12) in place. Save the capscrews and flat
washers. Discard the locknuts.
34. Loosen, but DO NOT remove the capscrews (13)
holding the front of the hose carrier guide and the
top wear pad (14) to each side of the inner boom.
MH1920
3.156 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
38. Remove the hose carrier assembly (20) from the 42. Disassemble the hose channel assembly to replace
inner boom by carefully pulling the hose carrier any parts that are bent, twisted or damaged.
straight out the rear of the inner boom (21). Pull both Remove the capscrews (27) and lockwashers (28)
the upper and lower portion of the hose carrier holding the mounting clips (29) to the channels (30).
assembly out at the same time. Remove the retainer nuts (31) from the mounting
clips.
43. At the front of the hose channel assembly, remove
the capscrews (32) and elastic locknuts (33) holding
the channels to the front guide (34). Save all
hardware and discard the elastic locknuts. Replace
any damaged parts with new parts and reassemble
20 the hose channel assembly.
27
29
28
21 31
MH1930 30
39. Use a light to inspect the hose channel assembly

inside the inner boom. If no damage is noted,
proceed to Section 3.8.2, “Hose Carrier Assembly
Replacement.” 30
If the hose channel assembly is damaged, remove
and disassemble the channel assembly. 32
holding the hose channel assembly mounting 33
clips (24) to the sides of the inner boom. Remove 34 MH1960
only the capscrews holding the hose channel
assembly mounting clips to the boom. The rear wear 44. Carefully slide the hose channel assembly (26) into
pad mounting bolts can remain in place. Save the the rear of the inner boom.
capscrews, lockwashers and wear pad inserts (25).
45. Apply Loctite® 242 threadlocker to the threads of the
capscrews (22), saved. Insert a capscrew with a
22 lockwasher (23), saved, through the lower hole in the
mounting clip (24) and the front mounting hole of the
lower wear pad in the side plates of the inner boom.
23 46. Place the wear pad inserts (25), saved, into the wear
24
pad cavity. Be careful not to push the wear pad
inserts out of the wear pad.
26
47. Torque all wear pad mounting capscrews to 31 ±3 lb-ft
(42 ±4 Nm).
25
MH2730
48. Repeat Steps 45 thru 47 to install the upper
mounting capscrews on both sides.
41. Carefully slide the hose channel assembly out the
rear of the inner boom.
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.157

Boom
3.8.2 Hose Carrier Assembly Replacement

1. Carefully lay the new hose carrier assembly out flat 7
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 6
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. 8
3. If the hoses are not equal in length or not to the

specified dimension, the hoses must be repositioned
in the hose carrier assembly. Cut the tie wraps (5)
holding the hoses to the hose carrier and reposition MH2380
the hoses as required in either direction. Be sure all

the hoses are to the specified dimension and 5. Fold the new hose carrier assembly (9) in half and
assemble new tie wraps back in place. slide into the inner boom. Be careful while folding the
hose carrier in half.
IMPORTANT: The hose carrier only folds one way,
1 DO NOT force it. DO NOT twist the hose carrier while
folding.
6. Ensure the “female” ends (10) of the hoses are on
the bottom and carefully slide the folded hose carrier
3 into the inner boom (11). Guide the hose carrier
assembly in between the channels of the hose
5
channel assembly.
2
9
4 11
5
MH2740
10
4. With the hose carrier assembly (6) laid out flat on a
level surface, stretch the four “male” ends of the
hoses out straight from the hose carrier assembly.
Measure from the end of the male end (7) of each
hose back toward the hose carrier assembly 196"
(498 cm) and apply tape (8) around each hose at
that point. The tape is for proper tensioning of the MH2750
hoses during reassembly of the hose clamps.
3.158 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
Note: ALWAYS replace elastic locknuts with new elastic 10. Label each end of the hoses of the new hose carrier
locknuts to help ensure proper fastening. assembly for proper identification during reassembly:
7. Line up the lower mounting holes in the hose carrier Right side outer hose (18) goes to “Auxiliary Female
assembly (12) with the holes in the bottom of the Coupler” and the right side inner hose (19) goes to
inner boom. Insert the four capscrews (13), saved, “Attachment Tilt Extend.”
through the bottom boom plate and up through the Left side outer hose (20) goes to “Auxiliary Male
hose carrier mounts. Secure the capscrews in place Nipple” and the left side inner hose (21) goes to
with new elastic locknuts (14). Tighten all four “Attachment Tilt Retract.”
locknuts securely.
18 19
20
21
14
18
19
20
21
12
13
MH2450
MH2750
8. Lift up the upper part of the hose carrier assembly
and place the hose carrier guide (15) under the hose 11. With the hose guide (1) tilted up in the back, insert
carrier with the angled guides toward the front. Slide the female ends of the two left side hoses (2) (from
the hose guide into the inner boom and place the the hose carrier) one at a time over the top of the
front notches onto the rear wear pad mounting angled guide (3) on the front side of the hose guide.
capscrew (16). Be sure the notch in the side of the Push the hoses into the hose channel (4) on the left
hose guide is under the flat washer (17) on each side of the inner boom and down to the front of the
side of the boom. inner boom. Repeat this procedure to insert the two
right side hoses (5) into the hose channel on the
9. Rotate the back of the hose guide up toward the top
right side of the inner boom.
of the inner boom as far as it will go. Tighten the rear
wear pad mounting capscrews (16) only enough to
hold the hose guide in this position.
15
16
17 15
MH2460
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.159

Boom

2 5 locknuts to help ensure proper fastening.
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
4 9
7
MH2470 8
12. Loosen the wear pad mounting bolts (6) holding the MH2480
hose guide (7) and wear pads (8) to the side of the
inner boom. Remove the wear pad mounting bolts 16. Run the hose carrier out and in by hand to check for
(one at a time) with washers. interference.
13. Apply Loctite® 242 threadlocker to the threads of the
the hose guide and wear pad mounting bolt (6).
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.
3.160 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
IMPORTANT: DO NOT allow the hoses to cross inside e. Reassemble Inner Boom
the inner boom.
17. At the front of the inner boom, pull the two hoses that the inner boom with LPS3 or equivalent.
were labeled “Attachment Tilt - Retract” (12) left side
2. Lift the inner boom up. While guiding the hoses into
and “Attachment Tilt - Extend” (13) right side out of
the secondary intermediate boom, carefully slide the
the opening in the back of the gooseneck. Let the
inner boom into the front of the secondary
hoses hang out of the back of the gooseneck.
intermediate boom.
18. At the front of the inner boom, pull the two hoses that
3. Have a second person guide the “male” ends of the
were labeled “Auxiliary - Female Coupler” (14) left
four hoses from the hose carrier into the secondary
side and “Auxiliary - Male Nipple” (15) right side out
intermediate boom. Have the second person pull the
the opening in the gooseneck and down to the
hoses out the rear of the boom as the inner boom is
bulkhead plate where the auxiliary hydraulic
being inserted.
couplers are to be mounted. Let the hoses hang
inside the gooseneck. 4. Reassemble the hose carrier support (16), saved, to
the hose carrier (17). Inside the inner boom, pull the
hose carrier out enough to gain access to the
mounting pivot on the end of the carrier.
5. With the lower mounting plate on the hose carrier
support (16) on the right side, line up the four holes
in the top plate with the holes in the pivot mount of
the hose carrier (17).
12
6. Insert the capscrews (18), saved, through the hose
13 carrier pivot mount and the support bracket. Secure
in place with new elastic locknuts (19). Tighten
securely.
18
17
14
16
15 19 MH1860
MH2490
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.161

Boom

holding the lower wear pad to the bottom of the 7
secondary intermediate boom. 6
8. Apply Loctite® 242 threadlocker to the threads of the 4
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.
5 8
9. Torque all wear pad mounting capscrews to 31 ±3 lb ft
(42 ±4 Nm).
1
2
MH2670
Note: Shim ALL side wear pads as needed to maintain

12. Install the side wear pads to the secondary
intermediate boom:
a. Slide the inner boom over to one side as far as it
will go, to allow wear pad installation.
cavities of the side wear pads (10), saved.
3 MH1850 c. Fill all wear pad cavities with a good grade of
10. At the rear of the boom, place the retract chain (4) d. Place the shims (11), saved, onto the wear pad
up and over the chain sheave in front of the hose and line up the holes.
reel assembly (5). Place the clevis between the two
e. Apply Loctite® 242 threadlocker to the threads of
anchor plates (6). Line up the hole in the clevis with
the capscrews (12), saved. Slide the wear
the second hole from the rear of the anchor plates. pad (10) with shims (11) in between the inner
Note: ALWAYS replace elastic locknuts with new elastic boom and the secondary intermediate boom with
locknuts to help ensure proper fastening. the offset of each wear pad toward the top of the
boom. Line up the holes and secure with the
11. Insert the shoulder bolt (7), saved, through the capscrews (12), lockwashers (13), saved, and
plates and clevis, and secure in place with a new flat washers (14), saved. Be careful not to push
elastic locknut (8). Tighten the locknut securely. the wear pad inserts (9) out of the wear pads.
f. Torque all wear pad mounting capscrews to
31 ±3 lb-ft (42 ±4 Nm).
g. Repeat Steps a thru f to install the wear pads on
the other side of the secondary intermediate
boom.
3.162 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
14. Place the inner boom extend chain (20) up and

around the sheave (21) at the front of the secondary
intermediate boom.
15. Place the extend chain clevis (22) between the
9 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). Tighten
securely; but the chain clevis should pivot freely.
10 14
11 13 12
MH2720
23
secondary intermediate boom:
a. Place the wear pad inserts (15), saved, into the 22
b. Fill the cavities of the wear pad with a good 21
grade of lithium-based EP grease.
and spacer (18), saved, between the inner boom 24
and the secondary intermediate boom with the
offset of each wear pad toward the center. Line 20
up the holes and secure in place with the
capscrews (17) and lockwashers (19), saved. Be
MH2520
the wear pads.
31 ±3 lb-ft (42 ±4 Nm).
17
18
19
16
15 MH2710
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.163

Boom
IMPORTANT: Keep the four hoses in line (left to right)

as they come out of the hose carrier assembly at the rear 4
of the secondary intermediate boom. 4
16. Place a lockwasher (1), saved, onto each 4
3
capscrew (2), saved. Insert the capscrews through
the hose clamp support bracket (3), saved. Insert 8
the capscrews from the side as shown. 1
17. Place a hose clamp half (4), saved, onto the 7 2
capscrews. Place the right auxiliary hydraulic 6
hose (5) and another hose clamp half (4) onto the 4 4
capscrews. 5
10
18. Place another hose clamp half (4), saved, the right
Attachment Tilt hose (6) and another hose clamp 9
half (4) onto the capscrews.
19. Place two more hose clamp halves (4), the left 11
half onto the capscrews.
20. Place another hose clamp half (4), saved, the left 8
auxiliary hydraulic hose (8) and another hose clamp 7
half (4) onto the capscrews. Assemble the 6
capscrews to the left side of the inner boom. Tighten 5 MH2530
the capscrews only enough to hold the hoses in

place. IMPORTANT: Keep the hoses in the same order as they
come from the hose clamps. DO NOT allow the hoses to
21. Remove the capscrews (9) and lockwashers (10) cross.
holding the upper left side wear pad to the
secondary intermediate boom. 25. While pulling the upper retaining capscrew (12) out,
catch the spacers (13) from between the plates as
22. Apply Loctite® 242 threadlocker to the threads of the the capscrew is removed. Pull the capscrew out far
capscrews, and insert the capscrews with lockwashers enough to place the hoses around the hose reel:
through the notches in the hose clamp support
a. Place the left side auxiliary hydraulic hose (14)
bracket (3) and into the wear pad inserts. Be careful
into the left position on the hose reel.
not to push the wear pad inserts out of the wear
pads. b. Place the left side Attachment Tilt hose (15) into
the second position from the left on the hose
23. Torque all wear pad mounting capscrews to 31 ±3 lb-ft reel.
(42 ±4 Nm).
c. Place the right side Attachment Tilt hose (16) into
24. Position each of the four hoses with the edge of the the second position from the right on the hose
tape (11) at the hose clamps. Hold the hoses in this reel.
position and tighten the two capscrews securely to d. Place the right side auxiliary hydraulic hose (17)
hold the hoses in this position. into the right position on the hose reel.
26. Insert the retaining capscrew (12) through the plates
of the hose reel, inserting the spacers (13) back in
position between the plates as the capscrew is
inserted. Secure the retaining capscrew in place with
a new elastic locknut (18). Tighten the elastic locknut
securely.
3.164 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
27. Remove the elastic locknut (19) and flat washer (20) IMPORTANT: Keep the hoses in the same order as they
from the lower retaining shoulder bolt (21). While come off the hose reel. DO NOT allow the hoses to
pulling the shoulder bolt out, catch the spacers (22) cross.
from between the plates as the shoulder bolt is 30. Working from the front of the boom, pull each hose
removed. Place the Attachment Tilt hoses and the through the boom assembly:
auxiliary hydraulic hoses around the hose reel.
Note: ALWAYS replace elastic locknuts with new elastic through the boom assembly.
locknuts to help ensure proper fastening. b. Pull the right side Attachment Tilt hose (24)
28. Insert the shoulder bolt (21) through the plates of the through the boom assembly. Keep the right side
hose reel, inserting the spacers (22) between the Attachment Tilt hose to the left of the right side
plates as the shoulder bolt is inserted. Place the flat auxiliary hydraulic hose.
washer (20) onto the shoulder bolt and secure in c. Pull the left side Attachment Tilt hose (25)
place with a new elastic locknut (19). Tighten through the boom assembly, using the hoses
securely. already down the boom as a guide. Keep the left
side Attachment Tilt hose to the left of the hoses
already installed.
d. Pull the left side auxiliary hydraulic hose (26)
14 through the boom assembly, using the hoses
13
already down the boom as a guide. Keep the left
18 side auxiliary hydraulic hose to the left of the
hoses already installed.
e. Pull the hoses out the opening (27) at the bottom
of the outer boom.
19 17 31. Remove the strings from the hoses.
23 24
20
25
22 12 26
15
16 21 24
MH1690
25
23
29. Tie the strings (positioned inside the outer boom
during the outer boom installation) to the male end of 26
each of the Attachment Tilt and auxiliary hydraulic
hoses, coming off the bottom hose reel assembly. 27
MH1410
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.165

Boom
32. At the front of the outer boom, assemble the hose 7 1

assemblies and tube assemblies to the mounting 4
plate:
Note: Where the hose assemblies come out of the outer 10
boom, lubricate the radius in the outer boom with soap
and water to allow proper tensioning of hoses.
a. Assemble the right side Attachment Tilt hose (1)
right side hole (2) on the mounting plate. Insert
the male end of the right side hose through the
upper right side hole. Tighten the upper right side
Attachment Tilt tube assembly (3) to the hose 6
assembly. Tighten the tube assembly nut 3
securely to hold the tube and hose to the plate. 5
2
b. Assemble the left side Attachment Tilt hose (4) 9
left side hole (5) on the mounting plate. Insert the 1
male end of the left side hose through the upper
left side hole. Tighten the upper left side
Attachment Tilt tube assembly (6) to the hose
assembly. Tighten the tube assembly nut 8 12
securely to hold the tube and hose to the plate. 7
c. Assemble the right side auxiliary hydraulic
10 4
hose (7) as it comes down the outer boom to the 11 MH1450
lower right side hole (8) on the mounting plate.
Insert the male end of the right side hose through
the lower right side hole. Tighten the lower right 33. Assemble the Attachment Tilt hoses from the
side auxiliary hydraulic tube assembly (9) to the backside of the gooseneck to the fittings on the base
hose assembly. Tighten the tube assembly nut end of the Attachment Tilt cylinder:
securely to hold the tube and hose to the plate. a. Assemble the left side hose (13) labeled as
d. Assemble the left side auxiliary hydraulic “Retract” to the retract port (upper) elbow (14) on
hose (10) as it comes down the outer boom to the base end of the Attachment Tilt cylinder.
the lower left side hole (11) on the mounting Index the hose to remove any undo tension and
plate. Insert the male end of the left side hose tighten the hose end completely.
through the lower left side hole. Tighten the lower b. Assemble the right side hose (15) labeled as
left side auxiliary hydraulic tube assembly (12) to “Extend” to the extend port (lower) elbow (16) on
the hose assembly. Tighten the tube assembly the base end of the Attachment Tilt cylinder.
nut securely to hold the tube and hose to the Index the hose to remove any undo tension and
plate. tighten the hose end completely.
3.166 Model 8042, 10042, 10054 Legacy Rev. 03/04

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
15 rear cover. Tighten the thumbscrew securely.
21
14
16
22
13
MH1760
34. Assemble the left auxiliary hydraulic hose (17)

labeled “Female Coupler” from inside the gooseneck 23
to the female coupler (18) bulkhead fitting. Tighten
securely. 24
35. Assemble the right auxiliary hydraulic hose (19) 25 MH0850
labeled “Male Nipple” from inside the gooseneck to
the male nipple (20) bulkhead fitting. Tighten
securely.
19
20
17
18
MH0840
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.167

Boom
3.9 BOOM WEAR PADS 3.9.1 Wear Pad Inspection

Inspect all wear pads (3) for wear. If the angle
The wear pads (1) on this vehicle are flat rectangular
indicators (4) on the ends of the wear pads are visible, the
wear pads with metal inserts (2).
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 MA2070
3.9.2 Boom Wear Pad Replacement

2 When replacing a wear pad on the boom, replace both
1 wear pads on that side of the boom; e.g.: replace top front
left and top front right wear pads at the same time.
1
1 Usually, shimming will remain the same when installing
2 new wear pads. All wear pads are secured to the boom
2
using different capscrews and washers. When installing
new wear pads, apply Loctite® #242 (blue) to all wear pad
MH4390 mounting capscrews and torque to 33 to 38 lb-ft
(46 - 52 Nm).
On the 8042 and 10042 a total of 32 wear pads are
installed on the outer, intermediate and inner booms.
Seven wear pads are attached to the inner boom, 16 to
the intermediate boom, and nine to the outer boom.
On the 10054 a total of 47 wear pads are installed on the
outer, intermediate and inner booms. Seven wear pads
are attached to the inner boom, 16 to the primary
intermediate boom, 15 to the secondary intermediate
boom and nine to the outer boom.
Note: All shims are used to maintain a maximum total
gap of 0.09" (2,3 mm), between the wear pad and the
boom.
3.168 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
a. Inner Boom b. 8042/10042 Intermediate Boom

All inner boom wear pads (5) are mounted on the rear Coat all wear pad capscrews with Loctite 242® (blue)
outside of the inner boom. 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
5 wear pads. Mark or otherwise label each pad, spacer/
shim and hardware set for ease of installation later. Top
wear pads are secured to the boom with washers and
capscrews; side wear pads are secured with washers
and capscrews. Use Loctite® 242 (blue) on all wear pad
capscrews.
5
MH400
Use shims (6) under the upper rear wear pads as required
to maintain a maximum gap of 0.09" (2,3 mm) (7) at the
front edge of the top wear pads and maintain a total
maximum gap of 0.09" (2,3 mm) on the boom sides. 8
Shims are available in two thicknesses, 0.06'' and 0.13''.
MH4410
7
Use shims (6) under the upper rear wear pads (9) as
required, to maintain a maximum gap of 0.09"
(2,3 mm) (7) at the rear edge of the pads and maintain a
minimum gap of 0.09" (2,3 mm) between the wear pad
and boom surface.
6
MU4080
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.169

Boom
c. 10054 Secondary Intermediate Boom d. 10054 Primary Intermediate Boom

Coat all wear pad capscrews with Loctite 242® (blue) Coat all wear pad capscrews with Loctite 242® (blue)
before installation. before installation.
The wear pads (1) on the front of the intermediate boom The wear pads (5) on the front of the intermediate boom
can be replaced by removing the fasteners securing them can be replaced by removing the fasteners securing them
to the top, sides and bottom of the boom. to the top, sides and bottom of the boom.
When removing pads, move the boom sections as When removing pads, move the boom sections as
needed to gain access for removal and installation of needed to gain access for removal and installation of
wear pads. Mark or otherwise label each pad, spacer/ wear pads. Mark or otherwise label each pad, spacer/
shim and hardware set for ease of installation later. Top shim and hardware set for ease of installation later. Top
wear pads are secured to the boom with washers and wear pads are secured to the boom with washers and
capscrews; side wear pads are secured with washers capscrews; side wear pads are secured with washers
and capscrews. Use Loctite® 242 (blue) on all wear pad and capscrews. Use Loctite® 242 (blue) on all wear pad
capscrews. capscrews.
2 6
1 5 MH4420
MH4430
Use shims (3) under the upper rear wear pads (2) as Use shims (3) under the upper rear wear pads (6) as
required, to maintain a maximum gap of 0.09" required, to maintain a maximum gap of 0.09"
(2,3 mm) (4) at the rear edge of the pads and maintain a (2,3 mm) (4) at the rear edge of the pads and maintain a
minimum gap of 0.09" (2,3 mm) between the wear pad minimum gap of 0.09" (2,3 mm) between the wear pad
and boom surface. and boom surface.
MU4080
3.170 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
e. Outer Boom 3.10 QUICK ATTACH ASSEMBLY

All outer boom pads (7) are mounted on the front of the
This vehicle is equipped with a quick attach system for
outer boom. Remove the top wear pads before removing
easy attachment changes.
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 3.10.1 Disconnecting from an Attachment
pockets (8) of the top rear boom wear pads with multi- 1. Park the vehicle on a hard, level surface.
purpose grease. Use Loctite® 242 (blue) on all wear pad 2. Ground the attachment, place the travel select lever
capscrews. in the (N) NEUTRAL position, place the neutral lock
Use shims as required to maintain a maximum gap of lever in the (N) NEUTRAL LOCK position and
0.09" (2,3 mm) between the side wear pad and boom engage the parking brake switch.
surface. 3. Extend the boom approximately 10 ft (3,05 m) and
tilt the carriage backward. Shut the engine OFF.
7 4. Exit the vehicle using both hand holds.
Note: If removing a standard carriage with forks, spread
the forks apart on the carriage shaft. This will help give
the carriage better support to stand alone.
5. Raise the quick attach pin lock lever (9) and pull out
the lock pin (10) at the bottom of the quick attach.
9
7
10
7
7
OS03312
MH4390
6. Return to the operator’s compartment, fasten the
seat belt and lower the attachment to the ground in a
8 level position. Tilt the attachment forward. This will
rotate the quick attach link back away from the
attachment.
7. Lower and then retract the boom until the
MS0610 attachment pivot pins have disconnected from the
attachment.
3.9.3 Boom Wear Pad Lubrication
The boom has been factory lubricated for proper wear pad
break-in and will normally not require further lubrication.
However, after replacing any wear pad(s), or after
prolonged periods of inoperation, light lubrication of the
boom wear surfaces with a rust inhibitor/lubricant such as
LPS 3, or equivalent, is recommended to keep the boom
wear surfaces lubricated properly. Light lubrication of the
boom wear surfaces is also recommended in salt air
climates, and when the vehicle is stored, to help prevent
rusting.
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.171
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 2
5. Tilt the attachment up slightly. The quick attach link
should be tight up against the rear of the attachment, 1
~
and the holes in the link and the attachment should
be aligned. 4
6. Place the travel select lever in the (N) NEUTRAL MH0940
position, place the neutral lock lever in the (N)

NEUTRAL LOCK position, engage the parking brake 4. Remove the elastic locknut (5) and capscrew (6)
switch, unbuckle the seat belt and exit the vehicle holding the quick attach pivot pin (7) to the quick
using both hand holds. attach assembly (8). Save the capscrew and discard
the elastic locknut. Place a support under the quick
7. Lift the quick attach lever. Insert the quick attach pin attach assembly to prevent it from dropping when
completely through the attachment and the quick the pivot pin is removed.
attach link. Be sure that the quick attach lock lever
has lowered and seated itself into the groove in the 5. Use a brass punch and rawhide hammer to remove
quick attach pin. the quick attach pivot pin (7) from the quick attach
assembly and the bushings in the gooseneck.
WARNING:
Record the location and quantity of the shim
DO NOT operate the vehicle washers (9) as the pin is being removed. Save the
unless you are in the operator’s seat with the washers (10) from each side of the quick attach.
seat belt fastened around you. Death or serious
6. Inspect the pin (7) for nicks or surface corrosion. Use
injury could result if the seat belt is not
fine emery cloth to repair minor nicks or corrosion. If
securely fastened.
damaged or if it cannot be repaired, the pin must be
8. Return to the cab, fasten the seat belt and resume replaced.
operation.
3.10.3 Quick Attach Removal

8
holding the Attachment Tilt cylinder rod end pin (3)
to the quick attach assembly (4). Save the capscrew
and discard the elastic locknut.
2. Support the rod end of the Attachment Tilt cylinder.
Use a brass punch and rawhide hammer to remove
the rod end pin (3) from the quick attach assembly. 5
~
10
3. Inspect the pin (3) for nicks or surface corrosion. Use
fine emery cloth to fix minor nicks or corrosion. If
damaged or if it cannot be repaired the pin must be 9
replaced.
6 7
9
10 MH0950
3.172 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
3.10.4 Quick Attach Installation Note: ALWAYS replace elastic locknuts with new elastic
1. Assemble the quick attach to the gooseneck. Line up
the quick attach (11) between the mounts on the 5. Insert the rod end pivot pin (17) through the lined-up
gooseneck. Assemble a washer (12), saved, on holes. Use a tapered punch to line up the capscrew
each side of the quick attach. Reassemble the hole in the pivot pin and the mounting hole in the
shims (13), saved, between the quick attach and the quick attach hub. Insert the capscrew (20), saved,
gooseneck. DO NOT put all the shims on one side. through the quick attach hub from the backside and
The quick attach should be centered in the secure in place with a new elastic locknut (21).
gooseneck. Tighten securely.
2. Coat the quick attach pivot pin (14) with an anti-seize
compound. Insert the quick attach pivot pin through
the gooseneck, washers, shims and quick attach.
Use a tapered punch to line up the hole in the pivot
pin with the hole in the quick attach.
3. Insert the capscrew (15), saved, through the quick
attach and pin. Secure the capscrew in place with a
new elastic locknut (16). Tighten securely.
18
20
21
~
19
11 17 MH0940
12 16
14
13
15
13
12 MH1720
4. Coat the rod end pivot pin (17), saved, with an anti-
seize compound. Swing the rod end (18) of the
Attachment Tilt cylinder up and line up the rod end
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.173

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. Boom will not extend or 1. Broken hydraulic hose(s) or 1. Locate break, replace hose(s)
retract. tube(s) and/or connections or tube(s), tighten connections.
leaking.
2. Extend/Retract hydraulic system 2. Refer to Section 8, “Hydraulic
not operating properly. System.”
3. Faulty Extend/Retract cylinder. 3. Repair cylinder (Refer to Section
8.13.6, “Extend/Retract
Cylinder.”)
4. Broken chains or anchors. 4. Replace chains as needed. Refer
to Section 3.4.5, “Boom Extend
and Retract Chains Removal
and Replacement,” - 8042 &
10042 or Section 3.7.6, “Boom
Extend and Retract Chains
Removal and Replacement,” -
10054.
2. Boom will not fully extend 1. Extend/Retract hydraulic system 1. Refer to Section 8, “Hydraulic
(10054 only). not operating properly. System.”
3. Boom shifts to right or left 1. Boom pivot pin improperly 1. Re-shim the boom to a maximum
when extending. shimmed. total gap of .10" (2.5 mm) with
shims distributed evenly on both
sides of the boom pivot pin.
2. Incorrect wear pad gap or 2. Shim wear pads to correct gap.
shimming, or wear pads Replace wear pads as needed.
excessively worn. Refer to Section 3.9.2, “Boom
Wear Pad Replacement.”
4. Excessive boom pivot pin 1. Insufficient lubrication. 1. Lubricate at regular intervals.

noise and/or wear. (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. Replace bearing(s) and
lubricate at regular intervals
(Refer to appropriate owners
3.174 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom
Boom Troubleshooting (Continued)

5. Excessive Slave cylinder 1. Insufficient lubrication. 1. Lubricate at regular intervals.
pivot pin noise and/or wear. (Refer to appropriate owners
2. Worn bearing(s). 2. Replace bearing(s) and
lubricate at regular intervals.
6. Dropping chain, or jerky 1. Chain(s) tension not properly 1. Adjust chain(s). (Refer to
boom extend or retract adjusted. Section 3.4.3, “Boom Chain
functions. Tension Check,” - 8042 and
Chain Tension Check,” - 10054.)
2. Chain(s) stretched or binding. 2. Replace chains as needed.
(Refer to Section 3.4.5, “Boom
8042 and10042 or Section
3.7.6, “Boom Extend and
Retract Chains Removal and
Replacement,” - 10054.)
3. Wear pads loose, contaminated, 3. Replace wear pad. Refer to
excessively worn or damaged. Section 3.9.2, “Boom Wear Pad
Replacement.”
4. Contaminated, corroded or 4. Remove contamination and/or
rusted wear pad sliding corrosion from wear pad sliding
surfaces. surfaces and lubricate. If the
surfaces cannot be reconditioned,
replace the boom section(s).
5. Extend/Retract hydraulic system 5. Refer to Section 8, “Hydraulic
not operating properly. System.”
6. Damaged boom section. 6. Replace the damaged boom
section. (Refer to Section 3.3,
“Boom Assembly Maintenance
(8042 and 10042),” or Section
3.6, “Boom Assembly
Maintenance (10054).”)
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.175

Boom

7. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes 1. Locate break, replace hose(s)
and/or connection leaks. or tube(s), tighten connections.
2. Lift/Lower hydraulic system not 2. Refer to Section 8, “Hydraulic
operating properly. System.”
3. Faulty Lift/Lower cylinders. 3. Repair cylinder. (Refer to
Section 8.13.7, “Lift/Lower
Cylinder.”)
4. Seized boom pivot pin bearing. 4. Replace bearing.
8. Excessive Lift/Lower cylinder 1. Insufficient lubrication. 1. Lubricate at regular intervals.

pivot pin noise and/or wear. (Refer to appropriate owners
2. Worn self-aligning bearing(s). 2. Replace bearing(s) and
lubricate at regular intervals.
9. Rapid boom pad wear. 1. Incorrect wear pad gap. 5. Check wear pad gaps and
correct as needed. Refer to
Section 3.9.2, “Boom Wear Pad
Replacement.”
2. Rapid cycle times with heavy 6. Reduce cycle times.
loads.
3. Contaminated, corroded or 7. Remove contamination and/or
rusted wear pad sliding corrosion from wear pad sliding
surfaces. surfaces and lubricate. If the
surfaces cannot be
reconditioned, replace the boom
section(s).
4. Operating in extremely dusty/ 8. Clean equipment frequently.
abrasive conditions.
10. Auxiliary hydraulics will not 1. Auxiliary hydraulic system not 1. Refer to Section 8, “Hydraulic
operate. operating properly. System.”
3.176 Model 8042, 10042, 10054 Legacy Rev. 03/04

Boom

11. Excessive chain wear. 1. Improper chain adjustment. 1. Adjust to correct tension. (Refer
to Section 3.4.3, “Boom Chain
Tension Check,” - 8042 and
Chain Tension Check,” - 10054.)
Replace chains as needed.
8042 and 10042 or Section
2. Chain sheave(s) not properly 2. Lubricate chain sheave. (Refer
lubricated. to appropriate owner’s manual
for lubrication points.)
3. Chain sheave(s) not rotating 3. Lubricate chain sheave. (Refer
freely. to appropriate owners manual
for lubrication points.) Repair or
replace chain sheave(s) as
needed.
4. Improper chain lubrication. 4. Lubricate at regular intervals.
Replace chains as needed.
8042 and 10042 or Section
Model 8042, 10042, 10054 Legacy Rev. 03/04 3.177

Boom
3.178 Model 8042, 10042, 10054 Legacy Rev. 03/04

Section 4
Cab and Covers
Contents

4.1 Operator’s Cab and Covers Component Terminology. . . . . . . . . . . . . . . . . . . . . 4.2
4.2 Operator’s Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.2.1 Operator’s Cab Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.2.2 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.3 Open Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
4.3.1 Seat/Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
4.3.2 Steering Wheel, Column and Shifter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
4.3.3 Steering Column/Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.3.4 Brake Pedal and Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
4.3.5 Throttle Pedal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
4.3.6 Joystick Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
4.3.7 Auxiliary Hydraulic Joystick Assembly Replacement . . . . . . . . . . . . . . . . 4.17
4.3.8 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
4.3.9 Miscellaneous Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20
4.4 Enclosed Cab (Optional) Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
4.4.1 Windshield Wiper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
4.4.2 Roof Wiper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
4.4.3 Windshield/Skylight Washer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
4.4.4 Heater/Defroster System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
4.4.5 Heater/Defroster System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24
4.4.6 Door and Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25
4.4.7 Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.26
4.5 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27
4.6 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.31
4.7 Access Panels and Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.34
4.7.1 Access Panel and Cover Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . 4.34
Model 8042, 10042, 10054 Legacy Rev. 10/03 4.1

Cab and Covers
4.1 OPERATOR’S CAB AND COVERS

COMPONENT TERMINOLOGY
locations of the major assemblies of the vehicle cab and
covers. The following illustration identifies the
components that are referred to throughout this section.
Operator’s
Protective
Structure
Boom Extend/Retract
and Lift/Lower Joystick
Attachment Tilt/
Frame Sway Joystick
Auxiliary
Hydraulic
Steering Joystick
Wheel (Optional)
Transmission
Travel and Gear
Selector Lever
Accelerator
Pedal
Service Brake
Seat
MH3321
4.2 Model 8042, 10042, 10054 Legacy Rev. 10/03

Cab and Covers
To help ensure optimum safety, protection and

WARNING: DO NOT service the vehicle performance, replace the cab if it is damaged. Refer to
without following all safety precautions as the appropriate parts manual for ordering information.
outlined in the “Safety Practices” section of this
The cab contains the seat, operating controls, numerous
manual. Failure to follow the safety practices
panels, steering and brake components, and more.
Covers and mirrors on the vehicle exist for safety,
protection and appearance. They are relatively simple to
4.2 OPERATOR’S CAB
remove and replace.
4.2.1 Operator’s Cab Description 4.2.2 Serial Number Decal

The welded metal cab features a modular design, allowing The cab serial number decal (1) is located on the left side
for a relatively quick, simple exchange of the entire cab of the cab, behind the seat. Information specified on the
and/or component parts. The cab is bolted directly to the serial number plate includes the cab model number, the
frame. cab serial number and other data. Write this information
The cab is available in either an open (standard) or down in a convenient location to use in cab
enclosed (optional) cab configuration. The enclosed cab correspondence.
option includes a heater/window defroster system, and
windshield and roof window wipers.
The operator’s cab is a protective structure. The cab itself
contains rollover protective and falling object protective
structures (ROPS/FOPS) for the operator. 1
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.
DO NOT weld, grind, drill, repair or modify the cab in any

way. Any modification or damage to cab structural
components requires cab replacement. The lives of the
operator and others are potentially at stake.
Front MA8550
Model 8042, 10042, 10054 Legacy Rev. 10/03 4.3

Cab and Covers
4.3 OPEN CAB COMPONENTS 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
4.3.1 Seat/Seat Belt nuts (17). Transfer these parts and two tethers (6-
right and 7-left) to the replacement seat with the
a. Seat Removal
seat out of the cab.
1. Park the vehicle on a firm, level surface. Level the
vehicle, ground the attachment, place the travel 2 3 4
select lever in the (N) NEUTRAL position, place the 5 6 10
neutral lock lever in the (N) NEUTRAL LOCK 13
14
position, engage the parking brake switch and shut 16
the engine OFF.
ignition key switch and steering wheel, stating that
5 4
the vehicle should not be operated. (Refer to Section 7
1.5, “Accident Prevention Tags.”) 15 17 3
3. Disconnect the battery negative (-) ground cable or
cables (1) at the battery negative (-) terminal. 16
2
17
15 14 12
1
11
9
8
MA8750
b. Seat Installation
Note: ALWAYS replace elastic-lined nuts with new
1
elastic-lined nuts to help ensure proper fastening.
MH4510 1. Position the seat (10) on the seat riser (11). Align the
studs on the seat with the mounting holes in the seat
4. Remove the two capscrews (2), two lockwashers (3), riser. Secure the seat to the riser with four flat
two flat washers (4) and two spacers (5) securing the washers (9) and four new elastic locknuts (8). Torque
tethers (right-6 and left-7) to the seat riser. nuts to 20 lb-ft (27 Nm).
5. Remove the four elastic locknuts (8) and four flat 2. Anchor the tethers (right-6 and left-7) to the seat
washers (9) securing the seat (10) to the seat riser riser (11) using two spacers (5), two flat washers (4),
(11). two lockwashers (3) and two capscrews (2).
6. Carefully remove the seat (10) from the cab.
4.4 Model 8042, 10042, 10054 Legacy Rev. 10/03

Cab and Covers
4.3.2 Steering Wheel, Column and Shifter b. Steering Wheel Installation

The steering wheel and transmission travel and gear 1. Install the steering wheel (21) onto the splined
select lever are mounted on the steering column. steering column shaft.
2. Secure the steering wheel with a M18-1,5 thin nut
a. Steering Wheel Removal (20). Torque the nut to 50 lb-in (68 Nm).
1. Park the vehicle on a firm, level surface. Level the 3. Connect the horn switch lead (19), then press the horn
vehicle, ground the attachment, place the travel button (18) into the recess in the steering wheel.
4. Connect the battery negative (-) cable or cables.
position, engage the parking brake switch and shut
c. Transmission Travel and Gear Select Lever
the engine OFF.
Removal
2. Place an Accident Prevention Tag on the ignition key
switch, stating that the vehicle should not be 1. Park the vehicle on a firm, level surface. Level the
operated. (Refer to Section 1.5, “Accident vehicle, ground the attachment, place the travel select
Prevention Tags.”) lever in the (N) NEUTRAL position, place the neutral
lock lever in the (N) NEUTRAL LOCK position, engage
3. Disconnect the battery negative (-) cable or cables at the parking brake switch and shut the engine OFF.
the battery negative (-) terminal.
4. Carefully pry the horn button (18) out of its recess in ignition key switch and steering wheel, stating that
the steering wheel. Disconnect the horn switch lead the vehicle should not be operated. (Refer to Section
(19). 1.5, “Accident Prevention Tags.”)
5. Mark the steering wheel and shaft to ensure proper 3. Disconnect the battery negative (-) cable or cables at
installation. Remove the M18-1,5 thin nut (20) securing the battery negative (-) terminal.
the steering wheel (21) to the splined steering
column shaft. 4. Remove the four button-head capscrews securing
the left dash panel (22) to the cab; DO NOT
6. Use a steering wheel puller to remove the steering disconnect the wiring connectors. Set the dash
wheel (21) from the splined shaft. panel aside.
5. Remove the four button-head capscrews securing the
18 right dash panel (23) to the cab; DO NOT disconnect
19 21
the wiring connectors. Set the dash panel aside.
22 23
~
~
20
MA8660
MA8560
Model 8042, 10042, 10054 Legacy Rev. 10/03 4.5

Cab and Covers
6. Working through the right dash panel opening, d. Transmission Travel and Gear Select Lever
disconnect the transmission travel and gear select Installation
lever wiring connector (1).
1. Position the transmission travel and gear select lever
(3) onto the steering column, aligning the pin (5) with
1 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).
Tighten the screws and nuts securely, but DO NOT
overtighten. Overtightening will cause the select
lever to break.
3. Plug the wiring connector (1) into the harness
connector.
4. Install the left dash panel (7), and secure with four
button-head capscrews.
5. Install the right dash panel (8), and secure with four
MA8640
7 8
7. Remove two hex socket-head screws (2), securing
the transmission travel and gear select lever (3) to
the steering column.
8. Remove the transmission travel and gear select
~
lever (3) and collar (4). ~
~
3 5
4
9 MA8560
2 6. Connect the battery negative (-) cable or cables.
4.3.3 Steering Column/Valve Replacement
a. Steering Column and Valve Removal

6
vehicle, ground the carriage, place the travel select
lever in the (N) NEUTRAL position, place the neutral
MA8650 lock lever in the (N) NEUTRAL LOCK position,
engage the parking brake and turn the engine OFF.
2. Place an Accident Prevention Tag on the ignition key
switch, stating that the vehicle should not be
operated. (Refer to Section 1.5, “Accident
Prevention Tags.”)
4.6 Model 8042, 10042, 10054 Legacy Rev. 10/03

Cab and Covers
3. Unlock and open the rear door. Allow the engine and 10
hydraulic fluid to cool.
4. Disconnect the battery negative (-) cable or cables at
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. “Transmission Travel
and Gear Select Lever Removal.”)
WARNING: Hydraulic fluid leaking under

pressure can penetrate the skin, cause infection,
gangrene, and death or serious personal
injury. If injured, see a doctor immediately.
Relieve all pressure before disconnecting any
component, part, line or hose. Slowly loosen
parts and allow release of residual pressure
12 13
11 MA8670
WARNING: Wait for the hydraulic fluid

to cool before servicing any hydraulic component.
Hot hydraulic oil can cause severe burns.
8. Working through the right dash panel opening, label,

disconnect and cap the four hoses (10 thru 13) from
the side of the steering valve. Cap the fittings on the
steering valve.
Model 8042, 10042, 10054 Legacy Rev. 10/03 4.7

Cab and Covers
9. Working through the right dash panel opening, label, 4

5
disconnect and plug the load sense hose (1) at the top
of the steering valve. Cap the fitting on the steering
valve.
10. Disconnect the horn button wire (2) from the cab
wiring harness.
MA8860
3
2 b. Steering Column and Valve Installation

MA8680
1. Install the steering column (6) and steering valve (3),
11. Support the bottom of the steering valve (3), and by inserting them through the lower dash panel
remove the four hex-flange capscrews (4) and four opening. Position steering valve in the cab, with the
lockwashers (5). Remove the steering valve through “LS” port (7) pointing forward (away from the operator).
the lower dash panel opening. Secure the steering valve and column with four hex-
flange capscrews (4) and four lockwashers (5).
12. Remove the steering column (6), by pushing it down,
Torque capscrews to 13 lb-ft (18 Nm).
and removing it through the lower dash panel
opening. Note: ALWAYS use new o-rings when servicing the
vehicle.
2. Install new o-rings into the fittings. Lubricate the o-rings
3. Connect the load sense hose (1) to the “LS” port at
the top of the steering valve.
4. Connect the horn button wire (2) to the cab wiring
harness.
4.8 Model 8042, 10042, 10054 Legacy Rev. 10/03

Cab and Covers
Note: ALWAYS use new o-rings when servicing the 11. Start the engine and check the operation of steering
vehicle. system. Check for hydraulic fluid leaks. Check the
hydraulic fluid level in the tank and add fluid as
5. Install new o-rings into the fittings. Lubricate the o-rings
required.
12. Install the lower dash panel (12) and secure with four
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.
12 MA8560
11
9 10 MA8670
7. Install the transmission travel and gear selector

lever. (Refer to Section 4.3.2, d. “Transmission Travel
and Gear Select Lever Installation.”)
8. Install the steering wheel. (Refer to Section 4.3.2, b.
“Steering Wheel Installation.”)
9. Connect the battery negative (-) cable or cables at
10. Carefully examine all connections one last time
before engine start-up. Rectify any faulty conditions.
WARNING: Hydraulic oil leaking under

Model 8042, 10042, 10054 Legacy Rev. 10/03 4.9

Cab and Covers
4.3.4 Brake Pedal and Valve 7. Remove the service brake pedal (6) from the cab.
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

1. Park the vehicle on a firm, level surface. Level the 5
vehicle, ground the attachment, place the travel 3
the engine OFF. 4
3 3
ignition key switch and steering wheel, stating that 5
the vehicle should not be operated. (Refer to Section 2
1.5, “Accident Prevention Tags.”)
4
3
4. Disconnect the battery negative (-) cable or cables at 6 MA8690

5. Remove the four button-head capscrews securing d. Service Brake Pedal Installation
the lower dash panel (1) to the cab. Remove the 1. Position the service brake pedal (6) in its mounting
lower dash panel. location within the cab.
2. Insert two brake pedal pivots (4) into their mounting
locations on the service brake pedal.
3. Install one flat washer (3) onto a capscrew (2). Work
the capscrew through one side of the brake pedal-to-
cab mounting support. Secure with a flat washer (3)
and a hex nut (5). Repeat for the other side.
4. Adjust the brake switch as needed (refer to Section
9.14.19, c. “Service Brake Switch Adjustment.”)
5. Install and secure the lower dash cover (1) with four
~ button-head capscrews.
6. Connect the battery negative (-) cable or cables to
1 MA8560
6. Remove the two capscrews (2), four flat washers (3),

two pivots (4), and two hex nuts (5) securing the
service brake pedal (6) to the cab.
4.10 Model 8042, 10042, 10054 Legacy Rev. 10/03

Cab and Covers
4.3.5 Throttle Pedal Replacement b. Throttle Pedal Installation

1. Install the hex jam nut (13) and flat washer (14) onto
8042 S/N 13198 thru 18990
the end of the throttle cable (15). Secure the cable to
10042 S/N 13198 thru 19030
the throttle pedal (10). Secure the cable to the
10054 S/N 13198 thru 19079
throttle pedal (10), with the cable clamp (17) and two
locknuts (16).
a. Throttle Pedal Removal
2. Attach one end of the extension spring (12) to the
1. Park the vehicle on a firm, level surface. Level the throttle pedal lever beneath the pedal. Attach the
vehicle, ground the attachment, place the travel other end of the spring to the cable clamp (17).
neutral lock lever in the (N) NEUTRAL LOCK 3. Align the throttle pedal assembly (10) with its mount
position, engage the parking brake switch and shut holes in the cab floor (11).
the engine OFF. 4. Install three capscrews (7), three lockwashers (8)
2. Place an Accident Prevention Tag on both the and three flat washers (9) securing the throttle pedal
ignition key switch and steering wheel, stating that assembly to the cab floor (11). Torque the capscrews
the vehicle should not be operated. (Refer to Section to 9 lb-ft (12 Nm).
1.5, “Accident Prevention Tags.”) 5. Connect the battery negative (-) cable to the battery
3. Disconnect the battery negative (-) cable at the negative (-) terminal.
battery negative (-) terminal.
c. Throttle Adjustment
4. Remove three capscrews (7), three lockwashers (8)
and three flat washers (9) securing the throttle pedal 1. From within the cab, lightly depress the accelerator
assembly (10) to the cab floor (11). pedal (18) to the full-throttle position. As needed,
adjust the limit-stop screw (19) until it touches the
5. Remove the extension spring (12) from the throttle
pedal. Tighten the locknut (20) to 120-125 lb-in
pedal assembly.
(13,6-14,1 Nm).
6. Remove the hex jam nut (13) and flat washer (14)
securing the throttle cable (15) to the throttle pedal
assembly (10). 18
7. Remove two locknuts (16), cable clamp (17) and
extension spring (12). Remove the throttle cable
from the throttle pedal assembly. 19
8. Remove the throttle pedal assembly (10) from the cab.
20
7 8
9
15
10 17
13
14
16
MA01912
12
IMPORTANT: During the full throttle check:
• DO NOT operate any hydraulic function.
11
MS0930 • DO NOT steer or apply any pressure to the steer-
ing wheel.
• Keep the transmission in (N) NEUTRAL.
2. Check the engine rpm at full throttle. If the rpm is not
2600-2800 rpm, readjust the throttle limit-stop screw
at the throttle pedal within the cab.
Model 8042, 10042, 10054 Legacy Rev. 10/03 4.11

Cab and Covers
8042 S/N 18991 and After b. Throttle Pedal Installation

10042 S/N 19031 and After
1. Position the throttle pedal in the cab. Line up the
10054 S/N 19080 and After
mounting holes in the throttle pedal with the
mounting holes in the cab floor.
a. Throttle Pedal Removal
2. Secure the throttle pedal (2) in place with the flat
1. Park the vehicle on a firm, level surface. Level the washers (5), lockwashers (4) and capscrews (3).
vehicle, ground the attachment, place the travel Tighten securely.
neutral lock lever in the (N) NEUTRAL LOCK 3. Reconnect the wire harness plug (1) to the front of
position, engage the parking brake switch and shut the throttle pedal (2). Snap the plug securely in
the engine OFF. place.
2. Place an Accident Prevention Tag on both the 4. Connect the battery negative (-) cables to the battery
ignition key switch and steering wheel, stating that negative (-) terminals.
the vehicle should not be operated. (Refer to Section
3. Disconnect the battery negative (-) cables at the
battery negative (-) terminals.
4. Disconnect the wire harness plug (1) from the front
side of the throttle pedal (2).
5. Remove the capscrews (3), lockwashers (4) and flat
washers (5) holding the throttle pedal (2) to the cab
floor. Save all hardware for reassembly.
6. Remove the throttle pedal from the cab.
5
1
MH4280
4.12 Model 8042, 10042, 10054 Legacy Rev. 10/03

Cab and Covers
Model 8042, 10042, 10054 Legacy Rev. 10/03 4.13

Cab and Covers
4.3.6 Joystick Assembly Replacement 6. Repeat Step 5 to remove the boom extend/retract
control cable (8).
Joystick Assembly Removal
1. Park the vehicle on a firm, level surface. Set the park 6 7
brake, ground the carriage, place the travel select
lock lever in the (N) NEUTRAL LOCK position,
engage the parking brake and turn the ignition OFF.
4. Remove six hex nuts, six lockwashers and six flat
washers (1) securing the upper (2) and lower (3)
transmission covers to the frame. Remove the 4
covers.
2 1 5 8 MA8480
Note: Record the distance (9) from the outer jam nut to
~ the end of the ferrule on all cables, to ensure correct
adjustment when reinstalling cables.
Note: Record the location, and label all cables to ensure
1 correct installation.
~
7. Disconnect the attachment tilt control cable (10):

a. Remove the spring pin (11) and anchor pin. Save
3 the spring pin and anchor pin for installation.
b. Loosen and remove the inner jam nut (12), and
MA8620
remove the attachment tilt control cable from the
bracket. Save the jam nut for installation.
Note: Record the distance (4) from the outer jam nut to c. Route the cable through the opening at the
the end of the ferrule on all cables, to ensure correct bottom of the frame.
adjustment when reinstalling cables.
8. Repeat Step 7 to remove the frame sway control
Note: Record the location, and label all cables to ensure cable (13).
5. Disconnect the boom lift/lower control cable (5):
the spring pin and anchor pin for installation.
b. Loosen the outer jam nut (7), and remove the
boom lift/lower control cable from the bracket.
Save the jam nut for installation.
c. Route the cable through the opening at the
bottom of the frame.
4.14 Model 8042, 10042, 10054 Legacy Rev. 10/03

Cab and Covers
16 17
16
11
~
12
MA8630
13 Joystick Assembly Installation

10 9 1. Route the control cables through the opening, the
MA8490
console, and through the opening at the bottom of
the cab. Secure the joystick panel assembly (17)
9. Remove four button-head capscrews (14) and with four button-head capscrews (16).
remove the console panel (15). 2. Route the control cables through the opening at the
3. Connect the frame attachment tilt control cable to
the main control valve assembly:
a. Install the cable in the bracket, and slide the jam
nut (12) over the end of the attachment tilt control
cable (10). DO NOT tighten the jam nuts at this
time.
14 b. Connect the end of the cable to the shaft from
the control valve. Secure with an anchor pin and
spring pin (11).
~ c. Adjust the jam nuts until the distance (9) from the
14 inner jam to the end of the ferrule is the same as
recorded during removal. Tighten the jam nuts.
4. Repeat Step 3 to install the frame sway control cable
15 OH2430
(13).
10. Remove four button-head capscrews (16) and
remove the joystick panel assembly (17) from the
vehicle.
Model 8042, 10042, 10054 Legacy Rev. 10/03 4.15

Cab and Covers
5. Connect the boom lift/lower control cable to the main 9. Test the boom extend/retract and boom lift/lower
control valve assembly: joystick (6) function:
a. Install the cable in the bracket, and slide the jam a. Move the joystick handle rearward, activating the
nut (1) over the end of the boom lift/lower control boom lift function. The boom should RISE.
cable (2). DO NOT tighten the jam nuts at this b. Move the joystick handle forward, activating the
time. boom lower function. The boom should LOWER.
b. Connect the end of the cable to the shaft from c. Move the joystick handle to the right, activating
the control valve. Secure with an anchor pin and the boom extend function. The boom should
spring pin (3). EXTEND.
c. Adjust the jam nuts until the distance (4) from the d. Move the joystick handle to the left, activating the
outer jam to the end of the ferrule is the same as boom retract function. The boom should
recorded during removal. Tighten the jam nuts. RETRACT.
6. Repeat Step 5 to install the boom extend/retract 10. Test the attachment tilt/frame sway joystick (7)
control cable (5). function:
Note: If any tie wraps were removed from the joystick a. Move the joystick handle rearward, activating the
cables beneath the vehicle frame, bundle the cables and attachment tilt function. The attachment should
secure with new tie wraps as required to prevent the TILT UP
cables from contacting any sharp edges or moving parts. b. Move the joystick handle forward, activating the
attachment tilt function. The attachment should
3 1 TILT DOWN.
c. Move the joystick handle to the right, activating
the frame sway function. The boom should frame
SWAY RIGHT.
d. Move the joystick handle to the left, activating the
frame sway function. The boom should frame
SWAY LEFT.
11. Install the console panel (9) and secure using four
button-head capscrews (8).
6
7
2 5 MA8480
8
the battery negative (-) terminal. ~
8. Start the engine. 8
9 OH2430
4.16 Model 8042, 10042, 10054 Legacy Rev. 10/03

Cab and Covers
12. Install the upper (11) and lower (10) transmission Note: Record the distance (13) from the outer jam nut to
covers; secure using six hex nuts, six lockwashers the end of the ferrule on cable, to ensure correct
and six flat washers (12). adjustment when reinstalling cable.
6. Disconnect the boom auxiliary hydraulic control
11 12 cable:
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
12 ~ installation.
c. Route the cable through the opening at the
10
MA8620
4.3.7 Auxiliary Hydraulic Joystick Assembly

Replacement
a. Auxiliary Hydraulic Joystick Removal

14
1. Park the vehicle on a firm, level surface. Allow
sufficient overhead and side clearance for cab
removal. Level the vehicle, ground the attachment,
place the travel select lever in the (N) NEUTRAL
position, place the neutral lock lever in the (N)
~

the battery negative (-) terminal. 16 13 MA8490
washers (12) securing the upper (11) and lower (10) 7. Remove four button-head capscrews (8) and remove
transmission covers to the frame. Remove the the console panel (9).
covers.
Model 8042, 10042, 10054 Legacy Rev. 10/03 4.17

Cab and Covers
8. Remove three capscrews (1), three lockwashers and c. Adjust the jam nuts until the distance (6) from the
three flat washers. outer jam nut to the end of the ferrule is the same
as recorded during removal. Tighten the jam
9. Remove the auxiliary hydraulic joystick assembly (2) nuts.
from the vehicle.
~
3
4 6 MA8490
1 MA8530
4. Install the console panel (7) and secure using four

b. Auxiliary Hydraulic Joystick Installation button-head capscrews (8).
1. Route the control cable through the opening at the
bottom of the cab.
2. Secure the auxiliary hydraulic joystick assembly (2)
to the cab console with three capscrews (1), three
lockwashers and three flat washers.
3. Connect the auxiliary hydraulic control cable to the
main control valve:
a. Slide the inner jam nut (3) over the end of the 8
auxiliary hydraulic control cable (4), and install
the cable in the bracket with one nut on either
side of the bracket. DO NOT tighten the jam nuts ~
at this time. 8
b. Connect the end of the cable to the shaft from
the control valve. Secure with an anchor pin and 7 OH2430
spring pin (5).
4.18 Model 8042, 10042, 10054 Legacy Rev. 10/03

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 ~
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 4.19

Cab and Covers
4.3.9 Miscellaneous Cab Components
4
2 3
1
16
15
14
13
12
13
8 7 6
5
10
9
11 10
MA8810
1. Mirror Assembly 5. Lock Nut (4) 10. Flat Washer (4) 14. Arm Rest
2. Lockwasher (2) 6. Lock Nut (3) 11. Hex Hd. 15. Self-Tapping Screw (6)
3. Hex Hd. 7. Flat Washer (3) Capscrew (4) 16. Brush Strip
Capscrew (2) 8. Document Holder 12. Lock Nut (2) Assembly (2)
4. Tilt Angle Gauge 9. Step 13. Flat Washer (2)
4.20 Model 8042, 10042, 10054 Legacy Rev. 10/03

Cab and Covers
4.4 ENCLOSED CAB (OPTIONAL) 6. Place a funnel at the base of the radiator to channel
COMPONENTS 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
4.4.1 Windshield Wiper Assembly allow the coolant to drain. Replace the drain plug, or
Refer to Section 9.12.2, “Windshield Wiper Motor,” for close the petcock.
removal and installation information.
4.4.2 Roof Wiper Assembly

Refer to Section 9.12.4, “Skylight Wiper Motor,” for
removal and installation information.
17
4.4.3 Windshield/Skylight Washer
Assembly
OH2640
Refer to Section 9.12.6, “Windshield/Skylight Washer
Reservoir and Pump,” for removal and installation
information. 7. Transfer the coolant to a container with a cover, and
label as “Used Antifreeze.” Dispose of the used
4.4.4 Heater/Defroster System coolant at an approved recycling facility.
Note: Label all hoses to ensure correct installation.
a. Heater Assembly Removal
8. Remove four button-head capscrews (18) and four
1. Park the vehicle on a firm, level surface. Level the acorn nuts (19). Remove the heater access panel
vehicle, ground the attachment, place the travel (20).
9. Loosen the hose clamps (21 and 22), and
neutral lock lever in the NEUTRAL LOCK position,
disconnect the two heater hoses (23 and 24).
engage the parking brake switch and shut the
engine OFF. 10. Pull the hoses (23 and 24) through the grommets.
ignition key switch and the steering wheel, stating 19
that the vehicle should not be operated. (Refer to 23 21
Section 1.5, “Accident Prevention Tags.”)
3. Unlock and open the rear door. Allow the engine and
hydraulic fluid to cool. Draining the cooling system
while the engine block is hot can cause cracks in the
engine block. 20
4. Disconnect the battery negative (-) cable or cables at 19
18
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. Wear 22
24
protective clothing and safety glasses. MA8720
5. Place a suitable container beneath the radiator drain

plug (17) or petcock. Slowly turn the radiator cap
(not shown) to the first stop, and allow any pressure
to escape. Remove the radiator cap.
Model 8042, 10042, 10054 Legacy Rev. 10/03 4.21

Cab and Covers
Note: The button-head capscrew (1) at the lower rear 10

position on each side of the heater will be secured with
an insert nut (2).
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
b. Heater Assembly Installation
1 1. Connect the wiring harness connections (7) to the

blower.
Note: The button-head capscrew (1) at the lower rear
MA8730 position on each side of the heater will be secured with
an insert nut (2).
14. If the heater assembly is to be replaced: Remove 2. Slide the heater/mounting bracket assembly (6) into
four hex-slotted capscrews (9), and remove the the seat riser (8), and secure with eight button-head
mounting bracket (10) from the heater assembly capscrews (1 and 3), six lockwashers (5) and six
(11). nuts (4).
4.22 Model 8042, 10042, 10054 Legacy Rev. 10/03

Cab and Covers
3. Pull the hoses (12 and 13) through the grommets, 5. Fill the cooling system completely with a 50/50
and connect to the heater. Secure with two hose mixture of ethylene glycol and water, allowing time
clamps. for the coolant to fill the engine block. The cooling
4. Install the heater access panel (14) and secure with system capacity is listed in Section 2.5.8, “Fluid and
four button-head capscrews (15) and four acorn nuts Lubricant Capacities.”
(16). 6. Connect the battery negative (-) cable or cables to
15 IMPORTANT: When the engine is initially started, run it
12 briefly at low idle and check the vehicle for any visual
sign of fluid leakage. STOP the engine immediately if
any leakage is noted, and make any necessary repairs
before continuing.
14 WARNING: The cooling system is under

16 pressure, and escaping coolant can cause
severe burns and eye injury. To prevent
15 personal injury, NEVER remove the radiator
cap while the cooling system is hot. Wear
safety glasses. Turn the radiator cap to the first
stop and allow pressure to escape before
13 removing the cap completely.
MA8720
7. Wait for the engine to cool and check the coolant
level. Add coolant to the overflow bottle as required
to bring the coolant to the proper level.
Model 8042, 10042, 10054 Legacy Rev. 10/03 4.23

Cab and Covers
4.4.5 Heater/Defroster System Components
6 7
1
2 5
3
4
8
12
9
11
10
11
19 13
27 14
28
2 2
15
21 16 16
20 18
22 2 17 17
23
26 2 22
23
2 2
1
24
2
25 MA8740
1. Heater Hose 9. Wire Tie 18. Heater Duct 25. Heater Control Valve
(return to engine) 10. Hose Adapter 19. Heater Assembly 26. Heater Hose
2. Hose Clamp (10) 11. Carriage Bolt (6) 20. 90° Elbow - Lower (from engine)
3. Reducer 12. Self-Drilling Screw (4) Heater Hose 27. Reducer
4. Wiring Harness 13. O-ring 21. 90° Elbow - Lower 28. Valve
5. Hose Clamp 14. Air Filter Heater Hose
6. Defroster Duct 15. Filter Access Plate 22. Grommet (2)
7. Heater/Fan Control 16. Lockwasher (6) 23. 5/8" Copper Spice (2)
8. Defroster Hose 17. Acorn Nut (6) 24. Heater Hose
4.24 Model 8042, 10042, 10054 Legacy Rev. 10/03

Cab and Covers
4.4.6 Door and Latches
40 41
36
37
31
39 32
34
38
33
42 31
32
45 30
33
29 31
32
44 43
33
31
35 MA8760
29. Door Assembly 34. Upper Door Section 39. Female Door Retainer 44. Striker Assembly
30. Strap 35. Lower Door section 40. Acorn Nut 45. Nut Plate
31. Cap (6) 36. Acorn Nut (2) 41. Lockwasher
32. Hex Head Capscrew (3) 37. Lockwasher (2) 42. Door Bumper
33. Hex Nut (3) 38. Screw (2) 43. Lockscrew (2)
Model 8042, 10042, 10054 Legacy Rev. 10/03 4.25

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.
4
8
1
7 9
6 4
5 5
4
3 10 9
5
18 8
3
11
7
23 4
5 6
18
12
17
19
18 14
11
22 13
20
21
16 15 MA8770
1. Slider Window 6. Bushing (2) 12. Left Side Rear Glass 18. Setting Block (8)
Assembly 7. Grommet (2) 13. Roll Pin 19. Double “D” Bulb Seal
2. Skylight Glass 8. Hinge (2) 14. Torx Screw (2) 20. Lower Windshield
3. Rear Window Hinge 9. Acorn Nut (2) 15. Washer (2) Plate
Block (2) 10. Rear Window 16. Rear Window Mount 21. Self-Tapping Screw (5)
4. Torx Screw (6) 11. T-Handle Latch (with Latch 22. Windshield Glass
5. Flat Washer (4) mounting hardware) 17. Dent Ring Pin 23. Upper Windshield Clip
4.26 Model 8042, 10042, 10054 Legacy Rev. 10/03

Cab and Covers
4.5 CAB REMOVAL 1. Park the vehicle on a firm, level surface. Allow
sufficient overhead and side clearance for cab
WARNING:
removal. Level the vehicle, ground the attachment,
Risk of death or serious place the travel select lever in the (N) NEUTRAL
personal injury. NEVER modify, weld or drill position, place the neutral lock lever in the
the cab. NEUTRAL LOCK position, engage the parking brake
WARNING: The protection offered by 2. Unlock and open the rear door. Allow the engine and
this ROPS/FOPS will be impaired if subjected hydraulic fluid to cool.
to any modification or structural damage, at 3. Disconnect the battery negative (-) cable or cables at
which time replacement is necessary. ROPS/ the battery negative (-) terminal.
FOPS must be properly installed using
fasteners of correct size and grade, and Note: Steps 4 thru 8 apply to vehicles equipped with
torqued to their specified value. optional heater (enclosed cab models only). If your
vehicle does not have the optional heater, proceed to
IMPORTANT: To help ensure safety and optimum Step 9.
performance, replace the cab if it is damaged. Refer to
the appropriate parts manual for ordering information.
Before performing any inspection, maintenance or WARNING: Hot coolant can cause
service operation, thoroughly clean the vehicle. DO NOT severe burns or eye injury. NEVER remove the
spray water or cleaning solution in, on, near or around the radiator cap while the engine is hot. The
operator’s dash panels and electrical components. cooling system is under pressure. Wear
protective clothing and safety glasses.
Inspect the cab, its welds and mounts. If modification,
damage, a cracked weld and/or fatigued metal is 4. Place a suitable container beneath the radiator drain
discovered, replace the cab. Contact the Sky Trak plug or petcock (24). Slowly turn the radiator cap
distributor or the JLG Service Department at (not shown) to the first stop, and allow any pressure
1-877-554-5438 or 1-717-485-6657, with any questions to escape. Remove the radiator cap.
about the suitability or condition of a cab.
5. Place a funnel at the base of the radiator to channel
the drained coolant into the container. Open the
radiator drain plug or petcock (24) located on the
right side or the right side bottom of the radiator and
allow the coolant to drain. Replace the drain plug, or
soles. Failure to comply can result in foot injury
close the petcock.
from falling objects or other bodily injury from
slipping or falling.

suitable sling or hoist. Failure to comply can 24
IMPORTANT: Remove and label cab components as

OH2640
needed before removing the cab from the vehicle. Label,
disconnect and cap hydraulic hoses. Transfer cab parts
to the replacement cab after the replacement cab is 6. Transfer the coolant to a container with a cover, and
securely mounted on the vehicle. label as “Used Antifreeze.” Dispose of the used
coolant at an approved recycling facility.
Model 8042, 10042, 10054 Legacy Rev. 10/03 4.27

Cab and Covers
7. Working under the cab, loosen the clamp screw (1) 10. Disconnect the two cab-to-wiring harness
and disconnect the heater control cable (2) from the connectors (10 and 11). Push the harness
heater control valve (3). connectors through the opening (12) at the bottom of
the cab.
Note: Label all hoses to ensure correct installation.
8. Loosen the hose clamps (4 and 5), and disconnect
10 11
the heater hoses (6 and 7).
2
1
3 6 4
12 MA8470
7 5
MA8780
Note: Record the location, and label all cables to ensure
9. Remove four button-head capscrews (8) and remove
the console panel (9). 11. Disconnect control cables at the joystick:
a. Push the control lever to expose the flats (13) on
the slider head. Place a wrench on the flats to
hold the slider head, and loosen the cable nut
(14).
b. Loosen the upper jam nut (15), and remove the
boom extend/retract cable (16) from the bracket.
c. Push the cable through the opening at the
bottom of the cab.
8
d. Repeat Steps a thru c to disconnect the boom lift/
lower (17), attachment tilt (18) and frame sway
(19) control cables.
~
8
9 OH2430
4.28 Model 8042, 10042, 10054 Legacy Rev. 10/03

Cab and Covers
13. Working under the cab, label and disconnect the

13 hydraulic hoses (20 thru 27) at the cab fittings. Plug
the hoses and cap the fittings.
22 23
21
20
24
14
15
27 26 25
16 17
MA8500
18 transmission covers to the frame. Remove the
19 covers.
MA8520
29
28
12. Vehicles equipped with auxiliary hydraulic only:
Remove the auxiliary hydraulic joystick assembly.
(Refer to Section 4.3.7, a. “Auxiliary Hydraulic ~
Joystick Removal.”)
WARNING: Hydraulic fluid leaking under 28
~
pressure can penetrate the skin, cause
infection, gangrene, and death or serious
personal injury. If injured, see a doctor 30
immediately.
Relieve all pressure before disconnecting any MA8620
component, part, line or hose. Slowly loosen
parts and allow release of residual pressure 15. Unlock and open the right engine access door.
WARNING: Wait for the hydraulic fluid

to cool before servicing any hydraulic component.
Hot hydraulic oil can cause severe burns.
Model 8042, 10042, 10054 Legacy Rev. 10/03 4.29

Cab and Covers
Follow steps 16 thru 18 for: 8042 S/N 13198 thru 18990, 12 11

10042 S/N 13198 thru 19030 or 10054 S/N 13198 thru 10 9
19079. 14 13
16. Remove one elastic locknut (1). Disconnect the 11
8 12
throttle cable rod end (2) at the throttle lever
extension bracket (3).
17. Remove two slotted pan-head screws (4) two
lockwashers, two hex nuts and clamp (5) from the
13
throttle cable bracket (6). 14
18. Cut the wire ties securing the throttle cable to the
hydraulic hoses on the right side of the frame, and
route the throttle cable (7) out of the engine
compartment and through the opening in the bottom
of the frame. Allow the cable to hang beneath the cab.
MH3330
22. Remove the mirrors and all other cab components,

refer to Section 4.4.5, “Heater/Defroster System
4
Components,” Section 4.4.6, “Door and Latches,”
and Section 4.4.7, “Windows,” as needed, if not
previously removed.
3
23. Carefully begin to lift the cab. Stop and check that all
wiring, hydraulic hoses and fasteners are
disconnected or removed. If the throttle cable (for
1 8042 S/N 13198 thru 18990, 10042 S/N 13198 thru
5
19030 or 10054 S/N 13198 thru 19079) is still
attached to the cab, reposition or remove the throttle
~
cable as necessary.
4
24. When all wiring, hydraulic hoses and fasteners are
disconnected or removed, carefully and slowly lift the
6 cab and remove it from the frame. Readjust the
2 MA8610 position of the sling as needed to help balance the
7 cab during removal.
25. When the cab is completely clear of the vehicle,
19. Attach a clevis (8 and 9) to each of the cab lifting
carefully lower it to the ground. Block up or support
brackets. Route a sling (10) with a suitable lifting
the cab so that it does not move or fall. Assure that
capacity to carry the weight of the cab through the
no personnel enter the cab while it is being removed
clevis’ to a hoist or overhead crane. Make sure the
from the vehicle.
sling is centered between the clevis’ to ensure even
lifting. 26. Inspect the condition of the fittings, clamps, hydraulic
hoses, etc. Replace parts as indicated by their
20. Remove the two upper cab-to-frame capscrews (11)
condition.
and two flat washers (12).
27. Inspect and replace other vehicle parts that are
21. Remove the two lower cab-to-frame capscrews (13)
exposed with the cab removed. Repair or replace as
and two flat washers (14).
required.
4.30 Model 8042, 10042, 10054 Legacy Rev. 10/03

Cab and Covers
4.6 CAB INSTALLATION 7. Secure the throttle cable to the hydraulic hoses
using wire ties.

8. Install the throttle cable (7) on the throttle cable
bracket (6), using a clamp (5) and two slotted pan-
head screws (4), two lockwashers and two hex nuts.
soles. Failure to comply can result in foot injury
from falling objects or other bodily injury from Note: ALWAYS replace elastic-lined nuts with new
slipping or falling. elastic-lined nuts to help ensure proper fastening.
9. Connect the throttle cable rod end (2) to the throttle
WARNING: NEVER lift a heavy object lever extension bracket (3) using one new elastic
without the help of at least one assistant or a locknut (1).
suitable sling or hoist. Failure to comply can Continue with next step for all serial numbers.
10. Vehicles equipped with auxiliary hydraulic only:
1. Block all four wheels to help prevent the vehicle from Install the auxiliary hydraulic joystick assembly.
moving. Assure that there is sufficient overhead and (Refer to Section 4.3.7, b. “Auxiliary Hydraulic
side clearance for cab installation. Joystick Installation.”)
2. Attach a clevis (8 and 9) to each of the cab lifting Note: ALWAYS use new o-rings when servicing the
brackets. Route a sling (10) with a suitable lifting vehicle.
capacity to carry the weight of the cab through the 11. Install new o-rings into the fittings. Lubricate the o-rings
clevis’ to a hoist or overhead crane. Make sure the with clean hydraulic oil.
sling is centered between the clevis’ to ensure even
lifting. 12. Working under the cab, connect the hydraulic hoses
(15 thru 22) at the cab fittings.
3. Use a hoist or overhead crane and sling attached to
the cab. Carefully begin to align the cab with the
mounting holes in the frame. Stop and check that 17 18
15 16
wiring, hydraulic hoses, cables, etc., will not be
pinched or damaged as the cab is positioned.
Readjust the position of the sling as needed to help
balance the cab during installation. 19
4. Install the two upper capscrews (11) and two flat
washers (12). Torque the capscrews to 480 lb-ft
(651 Nm).
5. Install the two lower capscrews (13) and two flat
washers (14). Torque the capscrews to 480 lb-ft
(651 Nm). 22 21 20
6. Route the throttle cable (on serial numbers so
MA8500
equipped) through the opening in the bottom of the
frame, along the front of the transmission, along the
hydraulic hoses on the right side of the frame and
through the openings in the frame to the engine
compartment.
Model 8042, 10042, 10054 Legacy Rev. 10/03 4.31

Cab and Covers
13. Route the control cables through the opening at the 15. Route the wiring harness connectors through the
bottom of the cab. opening (9) at the bottom of the cab and up into the
14. Connect control cables at the joystick: side console.
a. Install the end of the boom extend/retract cable (1) 16. Connect the two cab-to-wiring harness connectors
into the slider head (4) as recorded during (10 and 11).
removal. Tighten the upper jam nut (2).
b. Loosely install the cable nut (3) into the slider 10 11
head (4).
c. Engage the control lever to expose the flats (5)
on the slider head. Place a wrench on the flats to
hold the slider head, and tighten the cable nut (3)
to a maximum of 55 lb-ft (75 Nm).
d. Repeat Steps a thru c to connect the boom lift/
lower (6), attachment tilt (7) and frame sway (8)
control cables.
9 MA8470
4
17. Install the console panel (12), and secure using four
3 button-head capscrews (13).
1
6
13
7
~
8
13
MA8520
12 OH2430
4.32 Model 8042, 10042, 10054 Legacy Rev. 10/03

Cab and Covers
18. Install the lower (14) and upper (15) transmission 21. Fill the cooling system completely with a 50/50 mixture
covers; secure using six hex nuts, six lockwashers of ethylene glycol and water, allowing time for the
and six flat washers (16). coolant to fill the engine block. The cooling system
capacity is listed in Section 2.5.8, “Fluid and
Lubricant Capacities.”
15 16
~ 23. Carefully examine all cab components, fasteners,
etc., one last time before engine start-up. Rectify any
faulty conditions.
16 ~
14 pressure can penetrate the skin and cause
MA8620
Note: Steps 19 thru 21 apply to vehicles equipped with protection from spraying hydraulic oil. Use a
optional heater (enclosed cab models only). If your vehicle piece of cardboard or paper to search for leaks.
does not have the optional heater, proceed to Step 22.
24. Start the engine and check the operation of all controls.
19. Working under the cab, connect the coolant hoses
Check for hydraulic fluid leaks. Check the hydraulic
(17 and 18) to the heater hoses. Secure with two
fluid level in the tank and add fluid as required.
hose clamps (19 and 20).
IMPORTANT: When the engine is initially started, run it
20. Connect the heater control cable (21) to the heater
briefly at low idle and check the vehicle for any visual
control valve (22). Tighten the hose clamp screw
sign of fluid leakage. STOP the engine immediately if
(23).
any leakage is noted, and make any necessary repairs
before continuing.
21
23 WARNING: The cooling system is under
22 17 pressure, and escaping coolant can cause
19 severe burns and eye injury. To prevent
personal injury, NEVER remove the radiator
cap while the cooling system is hot. Wear
safety glasses. Turn the radiator cap to the first
stop and allow pressure to escape before
removing the cap completely.
25. Wait for the engine to cool and check the coolant
level. Add coolant to the overflow bottle as required
to bring the coolant to the proper level.
18 20
MA8780
Model 8042, 10042, 10054 Legacy Rev. 10/03 4.33

Cab and Covers
4.7 ACCESS PANELS AND COVERS
4.7.1 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.
1 5
MH3340
1. Hydraulic Oil Reservoir/ 4. Transmission Cover, 6. Transmission Cover 7. Rear Door Weldment
Fuel Tank Cover Upper (Model 8042, (Model 8042, 10042, 8. Side Door Cover, Left
2. Counterweight Cover 10042, 10054, S/N 10054, S/N 14052 &
3. Transmission Cover, 14053 & After) Before)
Lower (Model 8042, 5. Side Door Cover,
10042, 10054, S/N Right
14053 & After)
4.34 Model 8042, 10042, 10054 Legacy Rev. 10/03

Section 5
Axles, Drive Shafts, Wheels and Tires
Contents

5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . 5.2
5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3 Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3.1 Axle Assembly Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3.2 Axle Assembly Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3.3 Axle Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
5.3.4 Axle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
5.3.5 Axle Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
5.3.6 Axle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
5.3.7 Axle Service and Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
5.3.8 ZF Axle Repair Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
5.3.9 Axle Assembly and Drive Shaft Troubleshooting. . . . . . . . . . . . . . . . . . . . 5.13
5.3.10 Axle Internal Component Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 5.16
5.4 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
5.4.1 Drive Shaft Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
5.4.2 Drive Shaft Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
5.4.3 Drive Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
5.4.4 Drive Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
5.4.5 Drive Shaft Cleaning and Drying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
5.4.6 Drive Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
5.4.7 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
5.5 Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
5.5.1 Removing Wheel and Tire Assembly from Vehicle . . . . . . . . . . . . . . . . . . 5.24
5.5.2 Wheel Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
5.5.3 Wheel Inspection and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
5.5.4 Installing Wheel and Tire Assembly onto Vehicle . . . . . . . . . . . . . . . . . . . 5.25
5.5.5 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29
5.6.1 Brake Disk Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29
Note: 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.”)
Model 8042, 10042, 10054 Legacy Rev. 10/03 5.1

5.1 AXLE, DRIVE SHAFT AND WHEEL

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.
Engine-to-Transmission
Drive Shaft
Vehicle
Frame
Stabilizer
Cylinder
Frame Sway
Cylinder
Steering
Cylinder
(Rear)
Rear Axle
Steering Assembly
Cylinder
(Front)
Rear Drive
Front Axle Shaft
Assembly Front Drive
Shaft MH3240
5.2 Model 8042, 10042, 10054 Legacy Rev. 10/03

5.3.2 Axle Assembly Operation

WARNING: DO NOT service the vehicle
Power from the engine is transmitted to the transmission
without following all safety precautions as
by way of a driveshaft. The transmission distributes
outlined in Section 1, “Safety Practices,” of this
power through the output drive shafts to the front and rear
manual. Failure to follow the safety practices
axle differentials. The axles work through gearing to turn
the wheel and tire assemblies and to ultimately cause the
vehicle to move.
5.2 GENERAL INFORMATION The front differential is equipped with limited-slip, self-
locking gears supported by bearings. The design of the
IMPORTANT: To help ensure optimum performance, the
differential permits adjustment to the bevel gear set.
drive shaft assemblies are specially balanced as a unit at Internal axle service and adjustment procedures are not
the factory. When servicing any flange yoke, slip yoke or the scope of this publication and are thoroughly covered
drive shaft tube, order a complete assembly if in the appropriate ZF axle manual. The beveled ring gear
components are bent or damaged. Refer to the is adjusted by means of ring nuts located opposite each
appropriate parts manual for ordering information. other. The position of the pinion, supported by two
Before performing any inspection, maintenance or bearings, is adjusted through the addition or subtraction
service operation, thoroughly clean the unit. The axles of adjusting shims.
and drive shafts should be checked and repaired only by The wheel hubs containing the planetary reduction gears
experienced service technicians who are aware of all are supported by two tapered roller bearings. The oil-bath
safety instructions and particular component features. (wet) disc type brakes are located in the center housing,
Use suitable products to thoroughly clean all and are operated by an annular piston. The parking brake
disassembled mechanical parts to help prevent personal is located in the center section of the front axle. The brake
is spring-applied, hydraulically released (SAHR). The
injury to the worker and prevent damage to the parts.
parking brake uses the same discs as the service brakes.
Carefully inspect the integrity of all moving parts
(bearings, yokes, tubes, gears, shafts, etc.) and fasteners A double-rod hydraulic steering cylinder is mounted on
(nuts, bolts, washers, etc.) as they are subject to major the differential support. Directional steering input is
stress and wear. Always replace elastic locknuts and any transmitted to the axles by means of articulated track
damaged, worn, cracked, seized or otherwise improper rods that allow toe-in adjustments.
parts that could affect the safe and proper functioning of The axles are attached to the chassis by a pivot pin. The
the vehicle, axles and drive shafts. pin allows the axle to pivot freely, each limited by the
hydraulic cylinder attached to one of the bridge casting
5.3 AXLE ASSEMBLIES bearing lugs.
Note: Detailed axle service instructions (covering the
5.3.1 Axle Assembly Description axle, differential, brakes and wheel-end safety, repair,
disassembly, reassembly, adjustment and
The front (parking brake equipped) and rear (no parking troubleshooting information) are provided in the ZF Axle
brake) ZF axles are designed for heavy-duty, off-road Repair Manuals. (Refer to Section 5.3.8, “ZF Axle Repair
industrial use. Each axle consists of a beam-type axle Manuals.”)
case, housing the differential center section, inboard wet-
The Model 8042 uses a wheel type with nominal
disc brakes, a pair of trumpet-like shaft housings and
dimensions of 9" x 24". An optional wheel type with a
stub-axle/wheel-hub units at each end. O-rings and oil
nominal dimension of 13" x 25" is available.
seals retain fluid within the axle. The axles have a semi-
floating mounting configuration. Each axle center is Models 10042 and 10054 uses wheels with nominal
secured to the vehicle frame with a pivot pin, and at one dimensions of 13" x 25".
side with a cylinder, anchor and pins.
The frame sway cylinder is mounted on the right side of
the front axle, and the stabilizer cylinder is mounted on
the left side of the rear axle. Steering cylinders and ball
joints are mounted inboard on each axle.
Model 8042, 10042, 10054 Legacy Rev. 10/03 5.3

All wheels are a one-piece design with, ten, one-inch Several special axle service tools are required to properly
diameter holes equally spaced on a 13.18" diameter bolt service the axle assemblies. Contact the local JLG parts
circle. distributor or ZF dealer for ordering information.
CAUTION:
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, Risk of personal injury.
and a 17.5 x 25 Radial, 12-ply (or better) directional-tread Exercise extreme care when using snap rings
tire can be used on the 10042/10054. Tires are filled only or spring-loaded retention devices.
with air when the vehicle is shipped from the factory.
5.3.3 Axle Serial Number Plate WARNING: Risk of death or serious

personal injury if components are assembled
The front axle serial number plate (1) is located on a improperly, if incompatible, worn or damaged
mounting pad on the inboard portion of the right beam components are used, or if components are
trumpet. The rear axle serial number plate is located on a used in a non-approved application. Obtain
mounting pad on the inboard portion of the left beam proper training, follow recommended
trumpet. Information on the serial number plate is procedures, and use proper tools and safety
required in correspondence regarding the axle. equipment. Wear safety glasses at all times
when working on the vehicle and vehicle
components.
WARNING: An improperly supported

vehicle can fall, causing death or serious
injury. When removing the axle assembly from
the vehicle, properly support the vehicle. If
servicing axle components with the axle
attached to the vehicle, securely support the
1 MT0220 carrier, differential, pinion assemblies and
wheel ends.
Supply information from the axle serial number plate
when communicating about an axle assembly or axle IMPORTANT: When replacing a fastener, replace it with
components. one of equal or higher grade and quality. Torque
fasteners to the specified value for the application.
5.3.4 Axle Specifications
General axle specifications are found in Section 2, IMPORTANT: The use of replacement parts provided by
“General Information and Specifications.” Axle other than the original manufacturer is not recommended, as
(differential housing) fluid information is found in Section such use may cause axle failure and affect vehicle safety.
2.6.1, “Axle (Differential Housing).” Wheel end fluid • Some service operations require the use of tools
information is found in Section 2.6.2, “Axle Wheel Ends.” specifically designed for the purpose. Use the
special tools when and as recommended.
5.3.5 Axle Maintenance
• DO NOT pound, beat or hammer on end yokes
Note: Detailed axle service instructions (covering the and flanges to remove or to install them. Damage
axle, differential, brakes and wheel-end safety, repair, to axle components can occur. Remove and install
disassembly, reassembly, adjustment and end yokes and flanges by following the recom-
troubleshooting information) are provided in the ZF Axle mended procedures in the appropriate ZF axle
Repair Manuals. (Refer to Section 5.3.8, “ZF Axle Repair service manual.
Manuals.”)
• DO NOT attempt carrier and differential removal
and installation, and differential and pinion disas-
sembly and assembly, without thoroughly under-
standing the instructions in the appropriate ZF
publications.
5.4 Model 8042, 10042, 10054 Legacy Rev. 10/03

• Before disassembling any parts inside the car- 1. Park the vehicle on a firm, level surface, level the
rier, remove the entire axle assembly from the vehicle, ground the attachment, retract the boom,
vehicle and securely support it with the pinion lower the outriggers; but DO NOT allow the outriggers
facing up in an appropriate stand or rack. to touch the ground; place the travel select lever in the
• DO NOT reuse oil or grease seals. (N) NEUTRAL position, place the neutral lock lever in
the (N) NEUTRAL LOCK position, engage the parking
CLEANING: Clean parts with machined or ground brake switch, straighten all wheels and shut the
surfaces (such as gears, bearings and shafts) with engine OFF.
emulsion cleaners or petroleum-based cleaners. DO
NOT steam clean internal components and the interior of 2. Place an Accident Prevention Tag on both the
the planetary hub and axle housing. Water can cause ignition key switch and steering wheel, stating that
corrosion of critical parts. Rust contamination in the the vehicle should not be operated. (Refer to Section
lubricant can cause gear and bearing failure. Remove old 1.5, “Accident Prevention Tags.”)
gasket material from all surfaces. 3. Unlock and open the engine compartment cover. Allow
DRYING: Use clean, lintless towels to dry components the engine, transmission and hydraulic fluid to cool.
after cleaning. DO NOT dry bearings by spinning them 4. Label and disconnect the wiring harness connectors
with compressed air; this can damage mating surfaces at both outrigger cylinder pressure switches (2 and 3).
due to lack of lubrication. After drying, lightly coat Remove the wire ties securing the wiring harness to
components with oil or a rust-preventive chemical to help the outrigger cylinders.
protect them from corrosion. If storing components for a 5. Tie a length of string to each pressure switch wiring
prolonged period, wrap them in wax paper. connector, and pull the harness out through the
PERIODIC OPERATION REQUIREMENT: Every two openings (4) at the rear of the outrigger housing.
weeks, drive the vehicle far enough to cause the drive- 6. Untie the strings from the wiring connectors and
train components to make several complete revolutions. tape, or otherwise secure the ends of the strings to
This will help ensure that internal components receive the outrigger housing. These strings will be used to
lubrication to minimize deterioration caused by pull the harness through the housing during
environmental factors such as high humidity. installation.
SUBMERSION: If the vehicle has been exposed to water
deep enough to cover the hubs, disassemble the wheel
ends and inspect for water damage and contamination. If
the carrier housing was submerged in water, especially if
the water level was above the vent tube (breather), drain
the axle and inspect internal parts for water damage and 2
contamination. Before assembling and refilling the unit
with the specified lubricant(s), clean, examine and
replace damaged parts as necessary.
Note: Use a suitable puller for bearing removal. Clean,
inspect and lubricate all bearings just prior to
reassembly. If replacement of a damaged bearing cup or 4 3
cone is necessary, replace the cup and cone as a set.
5.3.6 Axle Replacement
a. Outrigger Removal (10042, 10054 Only)

MH3280
Note: Proceed to Section 5.3.6, c. “Axle Removal” for
Model 8042.
On Models 10042 and 10054 equipped with outriggers, it
is necessary to removal the outrigger assembly before
removing the front axle.
Model 8042, 10042, 10054 Legacy Rev. 10/03 5.5

7. Label, disconnect and plug the left (3) and right (4) 8. Connect the wiring connectors to the outrigger
outrigger cylinder hydraulic hoses. Cap all fittings. cylinder pressure switches (1 and 2). Secure the
8. Support the outrigger assembly (5) using a suitable harnesses to the cylinders with wire ties.
jack, hoist or overhead crane.
9. Remove the eight capscrews (6), eight hex nuts (7),
eight flat washers (8) and two mount plates (9).
Note: Record the number and thickness of shims (10) to 1
ensure correct installation.
10. Remove the outrigger assembly (5) using a suitable
jack, hoist or overhead crane. Remove the
shims (10) from the pivot pin (11).
11. Move the outrigger assembly (5) away from the
vehicle and carefully lower it to the ground. Block up 2
or support the assembly so that it does not move or
fall.
12. Inspect the pivot bearing (12). Replace the bearing if
worn or damaged.
b. Outrigger Installation MH3280
1. Using a suitable jack, hoist or overhead crane and 9. Check the hydraulic reservoir oil level.
sling, remove the outrigger assembly from its
supports. Balance the assembly and prevent it from
tipping, turning or falling while positioning it on the
vehicle. DO NOT raise or otherwise disturb the
vehicle while installing the outrigger assembly. Keep
exhaust fumes can result in death or severe
the assembly supported and balanced on the jack,
personal injury.
hoist or overhead crane and sling throughout the
installation procedure.
2. Place the same number and thickness of shims (10) WARNING: Escaping hydraulic fluid
on the pivot pin (11), as recorded during removal. under pressure can penetrate the skin, causing
3. Position the outrigger assembly (5) onto the vehicle, death or serious injury. Before starting the
aligning the hole in the assembly (5) on the axle engine, tighten all hydraulic connections and
pivot pin (11) and the mounting plate (9) under the remove all tools from the vehicle. NEVER
axle flanges. check for leaks using any part of the human
body; use a piece of cardboard or wood
4. Install the two mount plates (9) onto the top of the instead. Wear heavy, protective gloves and
axle, and secure with eight capscrews (6), eight flat eye protection.
washers (8) and eight hex nuts (7).
Note: ALWAYS use new o-rings when servicing the 10. Start the engine. Turn the steering wheel several
vehicle. times lock to lock, operate the frame tilt function
several times in both directions and check the
5. Install new o-rings into the fittings. Lubricate the o-rings function of the brakes. Check for hydraulic leaks, and
with clean hydraulic oil. tighten or repair as necessary.
6. Uncap and connect the left (4) and right (3) outrigger
cylinder hydraulic hoses to the fittings.
7. Tie the strings left in the outrigger housing during
removal to each pressure switch wiring connector,
and pull the harness through the outrigger housing.
5.6 Model 8042, 10042, 10054 Legacy Rev. 10/03

11
3
10
12
8
7
MH3270
Model 8042, 10042, 10054 Legacy Rev. 10/03 5.7

c. Axle Removal 5. Models 10042 and 10054, Front Axle Only:

Remove outrigger assembly. Refer to Section 5.3.6,
WARNING: An improperly supported
a. “Outrigger Removal (10042, 10054 Only).”
vehicle can fall, causing death or severe 6. If the axle will be disassembled after removal, place
personal injury. Safely raise and adequately a suitable receptacle under the axle drain plug (1).
support the vehicle so that it will remain stable Remove the drain plug and allow the axle oil to drain
and in place before attempting to remove an axle. into the receptacle. Transfer the used axle oil into a
suitable covered container, and label the container
as “Used Oil.” Dispose of used oil at an approved
WARNING: Hot hydraulic fluid can cause recycling facility.
severe burns. Wait for the hydraulic fluid to cool
before servicing any hydraulic component.
WARNING: Relieve hydraulic pressure

Escaping hydraulic fluid under pressure can
penetrate the skin, causing death or serious
injury.
The front and rear axle assemblies differ in that the front
axle assembly is equipped with a parking brake
mechanism and a limited-slip feature; the rear axle has
neither. The following steps outline a typical axle removal 1 OH24102
procedure, suitable for either the front or the rear axle

assembly. 7. Label, disconnect and cap the steering and brake
lines at the axle. Wipe up any spilled oil.
Cleanliness is extremely important. Before attempting to
remove the axle, thoroughly clean the vehicle. Avoid 8. Block the front and rear of both tires on the axle that
spraying water or cleaning solution on the stabilizer is not being removed. Ensure that the vehicle will
solenoids and other electrical components. If using a remain in place during axle removal before
steam cleaner, seal all openings before steam cleaning. proceeding.
IMPORTANT: Clear the work area of all debris, 9. Raise the vehicle using a suitable jack or hoist.
unnecessary personnel, etc. Allow sufficient space to Place suitable supports under both sides of the
raise the vehicle and to remove the axle. frame and lower the vehicle onto the supports.
Ensure that the vehicle will remain in place during
1. Park the vehicle on a firm, level surface, level the
axle removal.
vehicle, ground the attachment, place the travel select
lever in the (N) NEUTRAL position, place the neutral 10. Support the axle that is being removed with a suitable
lock lever in the (N) NEUTRAL LOCK position, engage jack, hoist or overhead crane and sling. DO NOT
the parking brake switch, straighten all wheels and raise the axle or the vehicle.
shut the engine OFF. 11. Mark and remove both wheel and tire assemblies
2. Place an Accident Prevention Tag on both the from the axle that is being removed. (Refer to
ignition key switch and steering wheel, stating that Section 5.5.1, “Removing Wheel and Tire Assembly
the vehicle should not be operated. (Refer to Section from Vehicle.”)
1.5, “Accident Prevention Tags.”) Note: The wheel and tire assemblies must be re-installed
3. Unlock and open the engine compartment cover. later with the directional tread pattern “arrows” facing in
Allow the engine, transmission and hydraulic fluid to the direction of forward travel.
cool.
12. Remove the drive shaft assemblies (2-Front or 3-Rear).
4. Disconnect the battery negative (-) cable at the (Refer to Section 5.4.3, “Drive Shaft Removal.”)
battery negative (-) terminal to prevent the engine
from starting accidentally.
5.8 Model 8042, 10042, 10054 Legacy Rev. 10/03

13. Remove the capscrew (4) and locknut (5) securing 15. Remove the pivot pin (11) and shims (12).
the lower position cylinder-mount pin (6) to the 16. Remove the axle (13-Front or 14-Rear) from the
cylinder (7-Front or 8-Rear). Tap the cylinder mount vehicle using the jack, hoist or overhead crane and
pin out, and move the cylinder to prevent it from sling supporting the axle. DO NOT raise or otherwise
interfering with axle removal. disturb the vehicle while removing the axle. Balance
14. Remove the capscrew (9) and locknut (10) securing the axle and prevent it from tipping, turning or falling
the axle pivot pin (11) to the frame. while removing it from beneath the vehicle. Place the
axle on a suitable support or holding stand.
Note: Record the number and location of shims (12) to
ensure correct installation.
8 11
12 9
7
10
5
11 4
5 6 9 6
4 12
10 14
12
3
12 13
2 MH3250
Model 8042, 10042, 10054 Legacy Rev. 10/03 5.9

d. Axle Inspection, Internal Service and Repair 5. Coat the axle pivot pin (4) with a light film of clean
engine or hydraulic oil; DO NOT use an anti-seize
Detailed axle service instructions (covering the axle,
compound.
differential, brakes and wheel-end safety, repair,
disassembly, reassembly, adjustment and Note: ALWAYS replace elastic locknuts with new elastic
troubleshooting information) are provided in the ZF Axle locknuts to help ensure proper fastening.
Repair Manuals. (Refer to Section 5.3.8, “ZF Axle Repair
6. Install the axle pivot pin (4) and shims (5). Add or
Manuals.”)
remove shims until a maximum gap of 0.6" (1.5 mm)
The axle should be checked, serviced and repaired only is obtained. Balance the number and thickness of
by experienced service technicians who are aware of all shims equally on both sides. Secure the pivot pin
safety instructions and particular component features. with one capscrew (5) and a new locknut (6).
e. Axle Installation Note: If new frame sway (front) or stabilizer (rear)

cylinder bearings (8) have been installed in the axles or
The front and rear axle assemblies differ in that the front vehicle frame, the fracture (1) in the bearing race must
axle assembly is equipped with a parking brake be positioned at the 9 o’clock position as shown below.
mechanism and limited-slip feature; the rear axle has
neither. The steps below outline a typical axle installation
procedure, suitable for either the front or the rear axle
assembly.
1. Before proceeding, ensure that the vehicle will
remain in place during axle installation. Block the
front and rear of both tires on the axle that is already 1
installed on the vehicle.
2. If applicable, raise the vehicle using a suitable jack
or hoist. Place suitable supports beneath the frame
and lower the vehicle onto the supports, allowing
MM5530
enough room for axle installation. Ensure that the
vehicle will remain in place during axle installation.
3. Using a suitable jack, hoist or overhead crane and 7. Move the cylinder (9-Front or 10-Rear) into position
sling, remove the axle (2-Front or 3-Rear) from its on the axle cylinder anchor (11). Insert a cylinder-
support or holding stand. Balance the axle and mount pin (12) through the cylinder and cylinder
prevent it from tipping, turning or falling while anchor. Secure the cylinder-mount pin (12) with one
positioning it beneath the vehicle. DO NOT raise or capscrew (13) and a new locknut (14).
otherwise disturb the vehicle while installing the axle. 8. Apply multi-purpose grease through the self-tapping
Keep the axle supported and balanced on the jack, lube fitting (15) to lubricate the self-align bearing (8)
hoist or overhead crane and sling throughout the and the cylinder-mount pin (12).
installation procedure. 9. Install the drive shaft assemblies (16 and 17). (Refer
4. Position the axle (2-Front or 3-Rear) under the to Section 5.4.7, “Drive Shaft Installation.”)
frame, and align the pivot pin bearings with the holes
in the frame.
5.10 Model 8042, 10042, 10054 Legacy Rev. 10/03

8
10 4
6
5
9
8 7
12
14
15
13
12 4
11
11 14 6
15
5
13 7
3
5
17
5 2
16 MH3250
Model 8042, 10042, 10054 Legacy Rev. 10/03 5.11

10. If reinstalling an axle previously removed from the 5.3.7 Axle Service and Troubleshooting
vehicle, position the driveshaft yoke on the axle
This section provides an easy reference guide covering
according to the alignment marks made earlier. If
the most common problems that may occur during
installing a new axle, note the position of the
operation of the axles.
driveshaft yoke at the transmission. Align the
driveshaft yoke on the axle in the same plane as the Note: Contact the Sky Trak distributor or the JLG
yoke on the transmission. Service Department at 1-877-554-5438 or
11. Install the wheel and tire assemblies. (Refer to 1-717-485-6657, if internal axle repair is required during
Section 5.5.4, “Installing Wheel and Tire Assembly the warranty period.
onto Vehicle.”) Detailed axle service instructions (covering the axle,
12. Carefully remove the jack, hoist or overhead crane differential, brakes and wheel-end safety, repair,
and sling supporting the axle. disassembly, reassembly, adjustment and
troubleshooting information) are provided in the ZF Axle
13. Carefully raise the vehicle using a suitable jack or
Repair Manuals. (Refer to Section 5.3.8, “ZF Axle Repair
hoist. Remove the supports from beneath the frame
Manuals.”)
and lower the vehicle to the ground.
The axle should be checked, serviced and repaired only
14. Remove the blocks from the front and rear of both
by experienced service technicians who are aware of all
tires on the other axle.
safety instructions and particular component features.
vehicle.
15. Install new o-rings into the fittings. Lubricate the
o-rings with clean hydraulic oil.
16. Uncap and connect the steering and brake lines at
their axle fittings.
17. Models 10042 and 10054, Front Axle Only: Install
outrigger assembly. Refer to Section 5.3.6, b.
“Outrigger Installation.”
18. Check the hydraulic reservoir oil level.

exhaust fumes can result in death or severe
personal injury.
WARNING: Escaping hydraulic fluid

under pressure can penetrate the skin, causing
death or serious injury. Before starting the
engine, tighten all hydraulic connections and
remove all tools from the vehicle. NEVER
check for leaks using any part of the human
body; use a piece of cardboard or wood
instead. Wear heavy, protective gloves and
eye protection.
19. Start the engine. Turn the steering wheel several

times lock to lock, operate the frame tilt function
several times in both directions and check the
function of the brakes. Check for hydraulic leaks, and
tighten or repair as necessary.
5.12 Model 8042, 10042, 10054 Legacy Rev. 10/03

5.3.8 ZF Axle Repair Manuals
Model ZF Model Axle P/N ZF P/N
8042/10042/10054 MS-T 3060 FRONT, with Parking Brake 8990430 5871 560 002
8042 MS-T 3045 REAR, without Parking Brake 8990419 5871 550 002
10042 S/N 13198 thru 17977 MS-T 3045 REAR, without Parking Brake 8990419 5871 550 002
10054 S/N 13198 thru 17974 MS-T 3045 REAR, without Parking Brake 8990419 5871 550 002
10042 S/N 17978 and After MS-T 3055 REAR, without Parking Brake 8990419 5871 550 002
10054 S/N 17975 and After MS-T 3055 REAR, without Parking Brake 8990419 5871 550 002
5.3.9 Axle Assembly and Drive Shaft Troubleshooting

1. Excessive axle noise while 1. Oil level too low. 1. Fill oil to correct level. (Refer to
driving. appropriate owners/operators
manual.)
2. Axle and/or wheel end housings 2. Drain axle and/or wheel end
filled with incorrect oil or oil level housings and fill to correct level
low. with Universal Tractor Fluid.
(Refer to appropriate owners/
operators manual.)
3. Incorrect alignment of ring and 3. Correct alignment by adding or
pinion gears. removing shims as needed.
4. Incorrect pinion (input) shaft 4. Correct bearing preload by
bearing preload. adding or removing shims as
needed.
5. Worn or damaged bearings. 5. Replace bearings as needed.
6. Worn or broken gear teeth. 6. Replace gears as needed.
7. Contamination in the axle. 7. Drain axle and/or wheel end
housings and fill to correct level
with Universal Tractor Fluid.
operators manual.)
8. Axle housing damaged. 8. Replace damaged parts.
2. Intermittent noise when 1. Universal joint(s) worn or 1. Repair or replace universal
traveling. damaged. joints as needed.
2. Differential ring and/or pinion 2. Determine cause and repair as
gears damaged. needed.
Model 8042, 10042, 10054 Legacy Rev. 10/03 5.13

5.3.9 Axle Assembly and Drive Shaft Troubleshooting (Continued)

3. Vibration or intermittent noise 1. Drive shaft universal joint 1. Tighten capscrews to correct
when traveling. assembly(ies) incorrectly torque.
tightened.
2. Drive shaft universal joint(s) 2. Repair or replace universal
worn or damaged. joints as needed.
3. Drive shaft(s) damaged/ 3. Replace drive shaft(s) as
unbalanced. needed.
4. Oil leaking from axle 1. Drain and/or inspection plugs 1. Replace o-rings as needed and
(differential housing and/or loose and/or o-rings damaged tighten plugs to 96 lb-ft
axle housings). or missing. (130 Nm).
2. Hose fittings loose. 2. Tighten fittings.
3. Axle shaft seal damaged or 3. Replace seal and/or joint
missing and/or worn or coupling fork shaft (axle shaft).
damaged shaft sealing
surfaces.
4. Input shaft multi-seal ring 4. Replace multi-seal ring and/or
damaged or missing and/or input shaft. Adjust ring and
worn or damaged pinion (input) pinion alignment and bearing
shaft sealing surfaces. preload as described in the ZF
Repair Manuals.
5. Axle casing to brake housing 5. Replace o-rings and seals.
and/or brake housing to
differential assembly o-rings
and/or seals worn or damaged.
6. Axle housing mounting nuts and 6. Tighten housing nuts and
capscrews loose. capscrews to 288 lb-ft (390
Nm).
7. Differential and/or axle 7. Replace housing(s) as needed.
housing(s) damaged.
5. Oil leaking from wheel end 1. Oil level plugs loose and/or 1. Replace o-rings as needed and
housing (planet carrier). o-rings damaged or missing. tighten plugs to 96 lb-ft
(130 Nm).
2. O-ring between hub and 2. Replace o-ring.
housing (planet carrier)
damaged or missing.
3. Shaft seal damaged or missing 3. Replace seal and/or fork joint
and/or worn or damaged shaft shaft.
sealing surfaces.
4. Housing capscrews loose. 4. Tighten housing capscrews to
41 lb-ft (55 Nm).
5. Housing (planet carrier) damaged. 5. Replace housing (planet carrier).
5.14 Model 8042, 10042, 10054 Legacy Rev. 10/03

5.3.9 Axle Assembly and Drive Shaft Troubleshooting (Continued)

6. Oil leaking from steering 1. Hose fittings loose. 1. Tighten fittings.
cylinder. 2. Steering cylinder o-rings and/or 2. Replace o-rings and seals.
seals worn or damaged.
3. Piston rod seal worn or 3. Replace piston rod seal.
damaged.
4. Cylinder tube damaged. 4. Replace cylinder tube.
7. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level with
Universal Tractor Fluid. (Refer
to appropriate owners/operators
manual.)
2. Axle and/or wheel end housings 2. Drain axle and fill to correct
filled with incorrect oil or oil level with Universal Tractor
contaminated or oil level low. Fluid. (Refer to appropriate
owners/operators manual.)
8. High steering effort required. 1. Steering (hydraulic) system not 1. Refer to Section 8.8, “Hydraulic
operating properly. Circuits and Troubleshooting.”
2. Excessive joint housing swivel 2. Correct bearing preload by
bearing preload. adding or removing shims as
needed.
3. Worn or damaged swivel 3. Replace swivel bearings as
bearings. needed.
9. Slow steering response. 1. Steering (hydraulic) system not 1. Refer to Section 8.8, “Hydraulic
2. Steering cylinder leaking 2. Repair or replace steering
internally. cylinder as needed.
10. Excessive noise when brakes 1. Brake discs worn. 1. Check brake discs for wear.
are engaged. (Refer to appropriate owners/
operators manual.)
2. Brake discs damaged. 2. Replace brake discs.
11. Brakes will not engage. 1. Brake (hydraulic) system not 1. Refer to Section 8.8, “Hydraulic
2. Brake piston o-rings and seals 2. Replace o-rings and seals.
damaged (leaking).
12. Brakes will not hold the 1. Brake discs worn. 1. Check brake discs for wear.
vehicle or braking power (Refer to appropriate owners/
reduced. operators manual.)
2. Brake (hydraulic) system not 2. Refer to Section 8.8, “Hydraulic
3. Brake piston o-rings and seals 3. Replace o-rings and seals.
damaged (leaking).
Model 8042, 10042, 10054 Legacy Rev. 10/03 5.15

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 1. Incorrect alignment of ring and • Replace ring and pinion gears.
broken on the heel of the pinion gears (excessive play). • Adjust ring and pinion alignment
tooth. 2. Incorrect pinion (input) shaft and bearing preload as described
bearing preload. in the ZF Repair Manuals.
2. Differential ring gear teeth 1. Incorrect alignment of ring and • Replace ring and pinions gears.
broken on the toe of the pinion gears (insufficient play). • Adjust ring and pinion alignment
tooth. 2. Incorrect pinion (input) shaft and bearing preload as described
bearing preload. in the ZF Repair Manuals.
3. Rapid differential ring and 1. Insufficient lubrication. • Replace ring and pinion gears.
pinion gear teeth wear. 2. Lubricant contaminated. • Drain axle and fill to correct level with
3. Incorrect lubricant. Universal Tractor Fluid. (Refer to
appropriate owners/operators
manual.)
4. Differential ring and pinion 1. Insufficient lubrication. • Determine the cause of the prob-
gear teeth overheated. 2. Lubricant contaminated. lem and correct.
3. Incorrect lubricant or level. • Replace ring and pinions gears.

• Drain axle and fill to correct level
operators manual.)
5. Gear teeth pitted. 1. Insufficient lubrication. • Determine the cause of the prob-
2. Lubricant contaminated. lem and correct.
3. Foreign objects in oil. • Replace gears.

operators manual.)
6. Worn or pitted bearings. 1. Incorrect bearing preload. • Determine the cause of the prob-
2. Insufficient lubrication. lem and correct.
3. Lubricant contaminated. • Replace bearings.

• Adjust bearing preload as described
in the ZF Repair Manuals.
operators manual.)
5.16 Model 8042, 10042, 10054 Legacy Rev. 10/03

5.4 DRIVE SHAFTS 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
5.4.1 Drive Shaft Inspection and Service 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). A few moments 2
spent doing this can help prevent further problems and
down time later.
Inspect areas where the drive shaft flange yokes and slip 1 3
yokes mount to the drive shafts. Attempt to turn each
drive shaft in both directions. Look for excessive 4
looseness, missing parts, cracks or other damage. Worn 5
or damaged drive shafts (1) and cross and bearing
assemblies may cause an excessive amount of vibration
or noise.
Individually inspect each cross (2) the needle bearings
and cap (4) for signs of wear or for missing parts. 6
Note: Replace the cross and bearings as a complete
assembly if any parts are worn or missing. If all parts of
7
the cross and bearing assemblies are in good condition, 8
pack the bearing caps with a premium grade of multi- 9
purpose wheel-bearing grease. Reattach the bearing 2
cap to the cross, assuring that all needle bearings are 10
present. Then, reassemble the cross and bearing
4
assembly into the drive shaft yoke.
5
Note: Yoke flange (3) is used on the engine-to-
transmission drive shaft assembly only. 1. Yoke shaft (1) 6. Grease fitting (1)
2. Cross (2) 7. Dust cap (1)
1. Replace the felt seal (9) if worn or damaged. 3. Yoke Flange (1) 8. Washer (1)
2. Replace the entire drive shaft assembly if any flange 4. Needle bearings 9. Felt seal (1)
yoke, slip yoke or drive shaft tube is severely dented and cap (8) 10. Slip yoke (1)
or damaged. 5. Snap ring (8) MA8910
Model 8042, 10042, 10054 Legacy Rev. 10/03 5.17

5.4.2 Drive Shaft Maintenance 5. (SN 18991 (8042), 19031 (10042), 19080 (10054) &
After Only) Disconnect the battery negative (-)
Refer to the appropriate owners/operators manual for
ground cables (2) at the battery negative (-)
information regarding the lubrication of the grease fittings
terminals to prevent the engine from starting
on the drive shafts.
accidentally.
5.4.3 Drive Shaft Removal
2
drive shaft assemblies are specially balanced as a unit at
the factory. When servicing any flange yoke, slip yoke or
drive shaft tube, order a complete assembly if
components are bent or damaged. Refer to the appropriate
parts manual for ordering information.
Note: The drive shaft assemblies are balanced
assemblies. Mark the yoke and axle, transmission,
transfer case, 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 MH4440
must be in the same plane to help prevent excessive

vibration. 6. The drive shaft assembly is a balanced assembly.
Mark the yoke and axle, transmission and the shaft
a. Transmission-to-Axle Drive Shafts and slip yoke so that these components can be
returned to their original positions when reinstalled.
1. Level the vehicle, ground the carriage, place the travel Yokes at both ends of the drive shaft must be in the
select lever in the (N) NEUTRAL position, place the same plane to help prevent excessive vibration.
position, engage the parking brake switch and shut 7. Remove the four 12-point capscrews (3) and two
the engine OFF. straps (4) securing the bearing cross to the
transmission output shaft flange.
ignition key switch and steering wheel, stating that 8. Remove the four capscrews (5) and two straps (6)
the vehicle should not be operated. (Refer to Section securing the bearing crosses to the axle.
1.5, “Accident Prevention Tags.”) 9. Remove the front drive shaft assembly (7).
3. Unlock and open the right, left and rear engine 10. Repeat Steps 6 thru 9 to remove the rear drive shaft.
compartment access doors. Allow the engine,
transmission and hydraulic fluid to cool. To Transmis-
4. (SN 18990 (8042), 19030 (10042), 19079 (10054) & sion
Before Only) Disconnect the battery negative (-)
ground cable (1) at the battery negative (-) terminal
to prevent the engine from starting accidentally. 7
1 4
3
To 6
Axle MT0350
OH2420
5.18 Model 8042, 10042, 10054 Legacy Rev. 10/03

b. Engine-to-Transmission Drive Shaft 5.4.4 Drive Shaft Disassembly

1. Level the vehicle, ground the carriage, place the travel IMPORTANT: To help ensure optimum performance, the
select lever in the (N) NEUTRAL position, place the drive shaft assemblies are specially balanced as a unit at
neutral lock lever in the (N) NEUTRAL LOCK the factory. When servicing any flange yoke, slip yoke, or
position, engage the parking brake switch and shut drive shaft tube, order a complete assembly if
the engine OFF. components are bent or damaged. Refer to the
2. Place an Accident Prevention Tag on both the appropriate Parts Manual for ordering information.
the vehicle should not be operated. (Refer to Section a. Transmission-to-Axle Drive Shafts
1.5, “Accident Prevention Tags.”) 1. Use an approved, non-flammable cleaning fluid to
3. Unlock and open the right and left engine thoroughly clean the drive shaft assembly with a
compartment access doors. Allow the engine, brush. Wipe dry before disassembling.
transmission and hydraulic fluid to cool.
4. (SN 18990 (8042), 19030 (10042), 19079 (10054) &
CAUTION: Avoid using excess force
when clamping the drive shaft in a vise. Apply
Before Only) Disconnect the battery negative (-)
only enough force to hold the drive shaft
ground cable (1) at the battery negative (-) terminal
securely. Excessive force can damage the
to prevent the engine from starting accidentally.
drive shaft, resulting in an unbalanced condition.
5. (SN 18991 (8042), 19031 (10042), 19080 (10054) &
After Only) Disconnect the battery negative (-) 2. Place the drive shaft assembly in a bench vise.
ground cables (2) at the battery negative (-) 3. Use a pair of pliers to pinch the ends of the snap
terminals to prevent the engine from starting rings (14) securing the cross (15) and bearing (16)
accidentally. assemblies to the yoke (17 or 18). Remove the snap
6. The drive shaft assembly is a balanced assembly. rings from their grooves in the yoke.
Note: If the snap rings fail to readily snap out of their
and slip yoke so that these components can be
grooves in the yokes, tap the end of the bearing cap
returned to their original positions when reinstalled.
lightly to help relieve pressure against the snap rings.
Yokes at both ends of the drive shaft must be in the
same plane to help prevent excessive vibration.
7. Remove the four capscrews (8) and two straps (9)
15
securing the bearing cross to the transmission input
shaft flange. 17
8. Remove the four capscrews (10), four
lockwashers (11) securing the flange yoke (12) to the 16
engine output flange.
9. Remove the drive shaft assembly (13). 14
11 To
10 Engine
To 12
Transmission 15
13 18
16
8
14 MA8910
9 MA8900
Model 8042, 10042, 10054 Legacy Rev. 10/03 5.19

4. Use a soft, round drive pin with a flat face 6

approximately 1/32" (0,8 mm) smaller than the hole
diameter in the yoke to drive on one end of the cross 2
and bearing assembly until the opposite bearing
4
assembly comes out of the yoke.
5. Turn the yoke over and tap on the exposed end of
the cross until the opposite bearing assembly comes 3
out of the yoke.
1
6. Remove the cross (2) from the yoke (4 or 5).
7. Repeat Steps 2 thru 6 to remove the cross and
bearing assembly on the other end of the drive shaft.
8. Engine-to-Transmission Drive Shaft Only: Use a
pair of pliers to compress the snap rings holding the 10
cross (2) and bearing assemblies (3) to the flange
yoke (6). Remove the snap rings from the grooves in
the yokes.
7
9. Use a soft, round drive pin with a flat face 8
approximately 1/32" (0,8 mm) smaller than the hole 9
diameter in the yoke to drive on one end of the cross 2 5
and bearing assembly until the opposite bearing
assembly comes out of the yoke. 3
10. Mark the yoke shaft (4) and slip yoke (5) so that they 1 MA8910
can be properly aligned when reassembled. Yokes at
both ends of the drive shaft must be in the same
plane to help prevent excessive vibration. 5.4.5 Drive Shaft Cleaning and Drying
11. Unscrew the dust cap (7) and slide the slip yoke (5) 1. Disassemble and clean all parts using an approved
off of the drive shaft splines. cleaning fluid. Allow to dry.
12. Remove the dust cap (7), split retaining ring (8) and 2. Remove any burrs or rough spots from all machined
felt seal (9) from the shaft assembly. surfaces. Re-clean and dry as required.
5.20 Model 8042, 10042, 10054 Legacy Rev. 10/03

5.4.6 Drive Shaft Assembly

To Transmis-
1. Install the dust cap (7), split retaining ring (8) and felt sion
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 12
drive shaft and slip yoke. 11
3. Slide the slip yoke (5) onto the splines of the drive
shaft and tighten the dust cap (7) securely. DO NOT
14
overtighten or the cap will break.
4. Install the cross and bearing assembly into the yoke. To 15
Axle MT0350
5. Secure the cross and bearing assembly into the yoke
with snap rings (1). Pinch each snap ring with a 4. (SN 18990 (8042), 19030 (10042), 19079 (10054) &
pliers and insert them into their grooves in the yoke. Before Only) Connect the battery negative (-)
6. Apply grease to grease fitting (10). (Refer to Section ground cable (16) at the battery negative (-) terminal.
2.6.7, “Drive Shaft Splines.”)
5.4.7 Drive Shaft Installation 16
drive shaft assemblies are specially balanced as a unit at
the factory. When servicing any flange yoke, slip yoke or
drive shaft tube, order a complete assembly if
components are bent or damaged. Refer to the
appropriate parts manual for ordering information.
a. Transmission-to-Axle Drive Shafts

1. Raise the drive shaft assembly (11) into position.
The slip-yoke end of the drive shaft mounts toward OH2420
the axle. If reinstalling a drive shaft previously
removed, align the flange yokes according to the 5. (SN 18991 (8042), 19031 (10042), 19080 (10054) &
alignment marks made during removal. After Only) Connect the battery negative (-) ground
IMPORTANT: Yokes at both ends of the drive shaft must cables (17) at the battery negative (-) terminals.
be in the same plane to help prevent excessive vibration.
2. Install the four capscrews (12) and two straps (13) 17
securing the bearing crosses to the transmission.
Torque the capscrews to 60 lb-ft (81 Nm).
3. Install the four capscrews (14) and two straps (15)
securing the bearing crosses to the axle. Torque the
capscrews to 60 lb-ft (81 Nm).
MH4440
Model 8042, 10042, 10054 Legacy Rev. 10/03 5.21

b. Engine-to-Transmission Drive Shaft 10. (SN 18991 (8042), 19031 (10042), 19080 (10054) &
After Only) Connect the battery negative (-) ground
6. The drive shaft assembly is a balanced assembly.
cables (7) at the battery negative (-) terminals.
and slip yoke so that these components can be
returned to their original positions when reinstalled. 7
Yokes at both ends of the drive shaft must be in the
same plane to help prevent excessive vibration.
7. Position the flange yoke (1) on the engine output
flange. Secure the yoke with four capscrews (2), four
lockwashers (3). Torque the capscrews to 48 lb-ft (65
Nm).
8. Raise the slip yoke end of the drive shaft, and
position the bearing cross into the transmission input
shaft flange. Secure the drive shaft with two
straps (4) and four capscrews (5). Torque the MH4440
capscrews to 35 lb-ft (47 Nm).
3 To
2 Engine
To Transmis- 4
sion MA8900
9. (SN 18990 (8042), 19030 (10042), 19079 (10054) &

Before Only) Connect the battery negative (-)
ground cable (6) at the battery negative (-) terminal.
OH2420
5.22 Model 8042, 10042, 10054 Legacy Rev. 10/03

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 9
stability and may cause vehicle to tip over.
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".
The specified size and ply rating (star rating for radial tires)
for this vehicle is 13.00-24, 12-ply or optional 15.5 x 25
Radial, directional tread (8042), or 17.5 x 25 Radial,
directional tread (10042/10054). Make sure the
replacement tire is of the same size and ply rating (star
rating for radial tires) as all of the other tires. A higher ply
rating (star rating for radial tires) can be used, but only
when all four tires have the same ply rating.
In standard configuration, the tires are filled with air only
when the vehicle leaves the factory. There is a foam fill MS07012
option available if the use of a tire-filling substance is
desired. Having tires filled has a positive effect on the
weight, stability and handling characteristics of the vehicle,
especially under load. JLG does not recommend the use
of hydrofill as a tire-fill substance because of possible
environmental impact.
Large-bore valve stems are used to help expedite tire
inflation and deflation. An inner tube may be used if a tire
does not provide an airtight seal. Check tire inflation
pressures when the tires are cold. When mounting a tire
on the wheel, the tire must be mounted on the wheel
respective of the directional tread pattern of the tire; this
produces a left or right tire and wheel assembly.
The wheel and tire assemblies must be installed with the
directional tread pattern “arrows” (8 and 9) facing in the
direction of forward travel.
Model 8042, 10042, 10054 Legacy Rev. 10/03 5.23

5.5.1 Removing Wheel and Tire Assembly 4. Loosen but DO NOT remove the lug nuts on the
from Vehicle wheel and tire assembly to be removed.
5. Place a suitable jack under the axle pad closest to
WARNING: Risk of death or serious the wheel being removed. Raise the vehicle and
personal injury, if proper safety procedures are position a suitable support beneath the axle. Allow
not followed. When removing the wheel and sufficient room to lower the vehicle onto the support
tire assembly from the vehicle, follow the and to remove the wheel and tire assembly.
instructions in the “Wheel Removal Instruction” 6. Lower the vehicle onto the support.
box that follows:
7. Remove lug nuts and lug washers in an alternating
pattern (A thru K).
Wheel Removal Instructions: A

• Position the vehicle on a flat, hard surface and H
support the vehicle with approved jack stands E
or suitable supports.
• Use appropriate safety glasses, safety shoes
and appropriate clothing and equipment.
• DO NOT wear rings or jewelry. DO NOT wear J D
hair or clothing that could become caught in
machinery or pinch points such as those cre-
ated between the tire and the hub.

vehicle, ground the attachment, place the travel select C K
lock lever in the (N) NEUTRAL LOCK position, engage
the parking brake switch, straighten all wheels and
shut the engine OFF.
2. Place an Accident Prevention Tag on both the F
G
the vehicle should not be operated. (Refer to Section B OT0310

8. Remove the wheel and tire assembly from the
3. Disconnect the battery negative (-) ground cable at vehicle.
the battery negative (-) terminal, to prevent the
engine from starting accidentally.
5.24 Model 8042, 10042, 10054 Legacy Rev. 10/03

5.5.2 Wheel Cleaning 5.5.4 Installing Wheel and Tire Assembly

onto Vehicle
WARNING: Dirt and rust prevent the tire IMPORTANT: The wheel and tire assemblies must be
from seating properly on the wheel, which installed with the directional tread pattern “arrows” facing
could result in an explosive separation. Such in the direction of forward travel.
explosions could result in death or severe
personal injury to the tire installer and to those
in the area.
Tread “arrows”
Remove all rust, corrosion, dirt and other foreign material
must point forward
from all metal surfaces. In particular, the bead area (tire-
to-wheel mounting surface) must be especially clean.
5.5.3 Wheel Inspection and Replacement
WARNING: Damaged, modified,

repaired or mis-matched wheels and tires, or
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.
• NEVER rework, heat, weld or braze a
wheel rim.
Install tires onto
• Clean and inspect the wheel rim before wheels to rotate in
installing a new tire. Verify that the wheel proper direction
rim diameter exactly matches the tire
rim diameter molded into the tire. MH3300
• Inspect the inside of the tire for dirt, for-

eign material, loose cords, cuts, pene-
trating objects, and other damage. DO
NOT use tires with irreparable damage.
Check all surfaces of the wheel for rust, corrosion,

cracks, bent flanges, deep marks or gouges. Replace a
damaged, worn or cracked wheel. NEVER rework, heat,
weld or braze a wheel rim.
Inspect the valve core and stem. Replace the entire valve
if either component is damaged.
Model 8042, 10042, 10054 Legacy Rev. 10/03 5.25

1. Position wheel onto studs on wheel end of axle.

Wheel Dismounting Instructions:
2. Install wheel lug washers.
• Use safety chains, or place the wheel and tire
3. Install lug nuts and tighten in an alternating pattern assembly in a safety cage when deflating a tire
(A thru K). Torque to 430 to 470 lb-ft or when inflating a newly mounted tire.
(583 to 637 Nm).
• Deflate tire completely before servicing.
NEVER attempt to unseat the beads of an
A
inflated tire.
H • NEVER re-inflate a tire that has been run flat or
E
seriously under-inflated, without removing the tire
from the wheel and checking for tire and wheel
(rim) damage.
• NEVER hit a tire or wheel rim with a hammer or
J D ANY object.
• Use the appropriate specialty tools and equip-
ment for mounting a tire to a wheel or for dis-
mounting a tire from a wheel, or have a qualified
professional perform the work. DO NOT attempt
to mount or dismount a tire without the proper
C K tools, training and equipment.
• NEVER rework, heat, weld or braze a wheel rim
with tire mounted.
F b. Wheel Inspection and Replacement

G
B OT0310
WARNING: Damaged, modified,
repaired or mis-matched wheels and tires, or
5.5.5 Tires dirt and rust prevent the tire from seating
properly on the wheel, which could result in an
a. Dismounting Tire from Wheel explosive separation. Such explosions could
result in death or severe personal injury.
WARNING: Risk of death or serious • NEVER rework, heat, weld or braze a
personal injury. Using incorrect tire mounting wheel rim.
methods, or using damaged or dirty
• Clean and inspect the wheel rim before
components could result in an explosive
installing a new tire. Verify that the wheel
separation. When dismounting a tire from a
rim diameter exactly matches the tire
wheel, follow the instructions in the “Wheel
rim diameter molded into the tire.
Dismounting Instruction” box that follows.
• Inspect the inside of the tire for dirt, for-
eign material, loose cords, cuts, pene-
trating objects and other damage. DO
NOT use tires with irreparable damage.
Replace any tire that is worn or cut through the cords.

When replacing a tire, follow the recommendations of the
tire manufacturer.
5.26 Model 8042, 10042, 10054 Legacy Rev. 10/03

c. Tire and Wheel Lubrication 1. Read, understand and follow the above warning
messages.
WARNING: Risk of death or serious 2. Cle]an, inspect and replace the wheel if necessary.
personal injury. Use an approved tire-mounting DO NOT use a damaged or cracked wheel.
lubricant only. NEVER use anti-freeze, 3. Orient the tire in the direction of forward travel required.
silicones or petroleum-based lubricants.
4. Lubricate the inner tire and rim beads with an
approved tire-mounting lubricant only. NEVER use
Prior to mounting the tire on the rim, apply a suitable
anti-freeze, silicones or petroleum-based lubricants.
lubricant to the bead-seat area of the wheel rim and tire
bead. Use a lubricant specified by the wheel and tire 5. Push the inner bead of the tire over and around as
manufacturers. much of the wheel rim as possible. Use tire irons or a
suitable, commercially available pneumatic tire
d. Mounting Tire onto Wheel installation machine to work the bead completely
over the rim in small increments. Be careful not to
WARNING: Risk of death or serious
damage the bead.
personal injury. Using incorrect tire mounting 6. Lubricate the outer tire and rim beads with an
methods, or using damaged or dirty components approved tire-mounting lubricant.
could result in an explosive separation. When 7. Starting opposite the valve hole, use tire irons to
mounting a tire onto a wheel, follow the “Wheel work the outer tire bead over the wheel rim. Work
Mounting Instructions” box below. the bead completely over the rim in small increments
(DO NOT damage the bead).
8. Install a new valve stem into the valve stem hole on
Wheel Mounting Instructions:
the wheel.
• Use the appropriate specialty tools and equip- 9. Center the tire on the wheel. Inflate the tire until it
ment for mounting a tire to a wheel or for dis- fully seats on the wheel rim or to 35 psi (241,1 kPa).
mounting a tire from a wheel, or have a qualified DO NOT exceed 35 psi (241,1 kPa). Use an extension
professional perform the work. DO NOT attempt hose with a clip-on air chuck and pressure gauge to
to mount or dismount a tire without the proper permit the installer to stand at a safe distance away
tools, training and equipment. from the tire. Each tire bead will usually snap or pop
• Clean and inspect the wheel rim before install- into place, indicating that the bead is seated.
ing a new tire. Verify that the wheel rim diameter Note: If either bead should fail to seat at 35 psi (241,1
exactly matches the tire rim diameter molded kPa), the tire may be pinched or another source may be
into the tire. interfering with proper mounting. DO NOT increase
• Inspect the inside of the tire for dirt, foreign inflation pressure to seat the beads. Remove the valve
material, loose cords, cuts, penetrating objects core and completely deflate the tire. Break both beads
and other damage. DO NOT use tires with loose from the rim and inspect the tire, rim and inner
irreparable damage. tube, if applicable. Lubricate the tire bead, install the
• Use an approved tire-mounting lubricant only. valve core and repeat the 35 psi (241,1 kPa) inflation
NEVER use anti-freeze, silicones or petroleum- procedure until the beads seat properly.
based lubricants. 10. After the beads have seated, remove the valve core
• Use safety chains, or place the wheel and tire and fully deflate the tire, but DO NOT break the bead
assembly in a safety cage when deflating a tire or separate the tire from the wheel. Re-install the valve
or when inflating a newly mounted tire. core and inflate the tire to 70 psi (438 kPa) (8042), or
60 psi (414 kPa) (10042/10054).
• Inflate the tire to the cold-operating pressure
recommended by the tire manufacturer.
Model 8042, 10042, 10054 Legacy Rev. 10/03 5.27

e. Tire Speed and Road Surface Limitations Tires should not be stored outside or in direct sunlight. If
there is no other alternative, tires stored outside must be
The tires on this vehicle are designed for low-speed
covered or otherwise protected from sunlight, wind and
operations not to exceed 25 mph (40 km/hr). If the vehicle
rain. Use an unbroken, opaque covering to help protect
is towed at high speeds, high temperatures may develop
tires stored outdoors.
under the tread bars, causing a shifting of the tread bars
and a weakening of the tire material and cord fabric. Store tires away from electric motors, generators, arc
There may be no visible evidence of this type of damage, welders, etc., as these generate ozone, which attacks
but later, a failure can occur. If tires are to operate for any rubber and causes crazing and weather checking.
length of time on a paved road, highway or other hard Exposure to weather will also cause cracking or crazing
surface, increase pressure in the tire to the maximum of the rubber as well as deterioration of the tire carcass,
amount recommended by the tire manufacturer to help particularly where rainwater is permitted to accumulate in
reduce the chances of damage, or arrange to have the the tire.
vehicle transported on a flat-bed truck.
When extended vehicle storage is anticipated, the vehicle
should be placed on suitable supports with the tires
f. Care and Storage of Tires
raised out of ground contact. Inflation pressure in the tire
Store unmounted tires vertically, standing on their tread. should then be reduced to 10 psi (68,9 kPa). Keep the
If stored for an extended period of time, rotate the tires tires out of contact with sunlight, wind and rain as noted
periodically to help reduce stress concentrations in the above.
ground contact area of the tread. Tires should not be If it is not possible to raise the vehicle, increase tire
stored flat or stacked vertically (“stove piped”) as they will inflation pressure by 25 percent. Move the vehicle
become flattened and distorted, making mounting periodically to change the location of stress
difficult, particularly for tubeless tires. concentrations in the tire ground contact area.
Store mounted tires as noted above, but reduce the
inflation pressure to 10 psi (68,9 kPa).
Store tires indoors in a cool, dark, dry area away from
drafts. Heat and light can cause oxidation on the tire
surface, which leads to decomposition (“crazing”) and
weather checking. NEVER store tires on oily surfaces or
in contact with oil, grease, petroleum-based substances,
anti-freeze or solvents. Tires should not be stored near
volatile substances. Tires absorb volatile substances,
which damage and weaken the tire.
5.28 Model 8042, 10042, 10054 Legacy Rev. 10/03

5.6 BRAKES
5.6.1 Brake Disk Inspection. CAUTION: DO NOT exceed 650 psi (45
bar) when pressurizing the park brake. Apply-
Check the brake disks for wear every ing too much pressure may damage the brake
1,000 hours of operation or yearly.
1000 seals.
If the brake disks require service due to
OH2690 wear, the axle should be checked, 3. Pressurize the parking brake with the pressurizing
serviced and repaired only by unit. Close the needle valve on the pressurizing unit.
experienced service technicians who are aware of all 4. Working through the level plug hole (2), carefully use
safety instructions and particular component features. a screwdriver to spread the brake disks apart.
a. Front Axle IMPORTANT: DO NOT damage the surfaces of the

brake disks when spreading the brake disks.
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. Attach a remote portable hydraulic pressurizing unit MT2850
to the breather port (1) on the axle. 2
5. Using a feeler gauge, check the gap (3) between the
brake disks (4). 8042 Only, if the gap is greater than
0.22" (5,6 mm), replace the brake disks. 10042 &
1 10054 Only, if the gap is greater than 0.26"
(6,75 mm), replace the brake disks.
MH4340
Note: DO NOT Turn the key switch to the ON. DO NOT

Release the parking brake switch. Oil pressure will be
lost and Parking Brake will be engaged.
3 4
MT2840
Model 8042, 10042, 10054 Legacy Rev. 10/03 5.29

Note: If the brake disks are worn beyond their tolerance, 8. Reassemble the level plugs using new o-rings.
the brake disk must be replaced on both sides of the axle 9. Re-install the axle fill plug (1) into axle housing.
at the same time.
10. Remove the remote portable hydraulic pressurizing
6. Repeat steps 4 and 5 for the other side of the axle. unit on from the port (3).
7. Fill the axle with Universal Tractor Fluid through the
axle fill hole (1) until the oil level is even with both
axle level holes (2).
See chart of approved fluids. The axle capacity is 1.7 3
qt (1,6 Liters) for the front axle. Fill axle slowly, the oil
has to run across the differential. Allow time for the oil
to run across the differential. Axle level is correct
when oil is up to both level plugs.
MH4340
2 MU0580
Approved Universal Tractor Fluid

John Deere JDM J20C (HY-GARD)
Ford/New Holland ESN-M2C134-D

(HYDRAULIC OIL 134)
Massey-Ferguson M-1141 (PERMANTRAN III)

Chevron CHEVRON 1000 THF
5.30 Model 8042, 10042, 10054 Legacy Rev. 10/03

b. Rear Axle 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.
WARNING: BLOCK ALL FOUR
4. Repeat steps 2 and 3 for the other side of the axle.
WHEELS. Failure to do so could result in
death or serious injury from vehicle roll-away 5. Fill the axle with Universal Tractor Fluid through the
axle fill hole (7) until the oil level is even with both
1. Block all four wheels to help prevent the vehicle axle level holes (8).
from moving after the parking brake is disabled.
See chart of approved fluids. The axle capacity is
2. Working through the level plug hole (4), carefully use 1.3 qt (1,2 Liters) for the rear axle. Fill axle slowly, the
a screwdriver to spread the brake disks apart. oil has to run across the differential. Allow time for the
IMPORTANT: DO NOT damage the surfaces of the oil to run across the differential. Axle level is correct
brake disks when spreading the brake disks. when oil is up to both level plugs.
MT2850
4
3. Using a feeler gauge, check the gap (5) between the
brake disks (6). If the gap is greater than 0.167"
(4,25 mm), replace the brake disks. 8 MU0580
Approved Universal Tractor Fluid
John Deere JDM J20C (HY-GARD)
Ford/New Holland ESN-M2C134-D

(HYDRAULIC OIL 134)
Massey-Ferguson M-1141 (PERMANTRAN III)
Chevron CHEVRON 1000 THF
6. Reassemble the level plugs using new o-rings.

7. Re-install the axle fill plug (7) into axle housing.
5 6
MT2840
Model 8042, 10042, 10054 Legacy Rev. 10/03 5.31

5.32 Model 8042, 10042, 10054 Legacy Rev. 10/03

Section 6
Transmission: ZF 4 WG-98 TC
Contents

6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . 6.2
6.2 Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.3 Transmission Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.4 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.5 Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
6.5.1 Transmission General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
6.5.2 Transmission Performance Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 6.4
6.5.3 Transmission Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
6.5.4 Transmission-Related Fuse/Relay Ratings . . . . . . . . . . . . . . . . . . . . . . . . 6.4
6.6 Transmission Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
6.6.1 Maintenance Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
6.6.2 Transmission Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
6.7 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
6.7.1 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
6.7.2 Transmission Inspection and Internal Repair . . . . . . . . . . . . . . . . . . . . . . 6.10
6.7.3 Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
6.7.4 After Transmission Service or Replacement . . . . . . . . . . . . . . . . . . . . . . . 6.13
6.8 Towing a Disabled Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
6.9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
6.9.1 Transmission Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
Model 8042, 10042, 10054 Legacy Rev. 10/03 6.1

6.1 TRANSMISSION ASSEMBLY

locations of the major assemblies of the transmission.
The following illustration identifies the components that
are referred to throughout this section.
8042 S/N 13198 thru 18990 Radiator/Oil

10042 S/N 13198 thru 19030 Cooler
10054 S/N 13198 thru 19079
Outlet (Cooler)
Torque Hose
Converter
Housing
Oil Cooler Inlet (Cooler)
Hose
Inlet (Cooler)
Hose
Dipstick and Fill

Valve Block (Con-
trol Circuit 1)
Oil Filter Outlet (Cooler)

Hose
Valve Block
Radiator
(Control Circuit 2)
Output Shaft
8042 S/N 18991 & After

10042 S/N 19031 & After
10054 S/N 19080 & After
Vehicle Frame
(Reference)
MH4480
6.2 Model 8042, 10042, 10054 Legacy Rev. 10/03

The transmission gear (“speed”) select lever, an electric

WARNING: DO NOT service the vehicle shift control, is located on the left side of the steering
without following all safety precautions as column in the operator’s cab. Movement of the gear
outlined in Section 1, “Safety Practices,” of this select lever energizes the selected transmission shift
manual. Failure to follow the safety practices solenoid valves, which, in turn, direct the transmission
may result in death or serious injury. fluid under pressure to the selected forward or reverse
valve and to the designated range (gear or “speed”)
6.2 TRANSMISSION DESCRIPTION clutch. Several factors, including terrain, loading, engine
rpm, axle/wheel-end gearing and the selected
Instructions in this section pertain mainly to general transmission gear, determine actual vehicle speed.
specifications, towing, maintenance information, and To engage the clutch, the gear select lever is placed in
transmission removal and installation procedures. Internal the desired direction (forward or reverse) and range (gear
transmission service instructions and detailed specifications or “speed”) position. The gear select lever movement
are provided in the ZF 4 WG-98 TC Transmission Repair energizes the selected direction and range (gear)
Manual, P/N 8990455 (ZF P/N 5871 135 002). solenoids, allowing transmission fluid under pressure to
The ZF 4 WG-98 TC Transmission used in this vehicle is flow through tubes and passages to the selected clutch
a four-speed configuration. The “intermediate drop” shafts. Oil sealing rings are located on the clutch shaft;
designation refers to the relative top-to-bottom length of the these rings direct oil under pressure through a drilled
transmission case, chosen for its compatibility with passageway in the shaft to a desired clutch. Hydraulic
vehicle chassis and operating requirements. Intermediate pressure forces the piston and discs against the back-up
drop does not refer to an operational rpm shift or drop. plate. Discs, with edge tangs, clamp against toothed
discs on the inner diameter, enabling the hub and the
6.3 TRANSMISSION OPERATION clutch shaft to lock together and drive as a unit, providing
output power.
The transmission is mounted to the frame by front and
rear mounting brackets and rubber isolator pads. Power 6.4 TRANSMISSION SERIAL NUMBER
from the engine is transmitted to the transmission by
means of a drive shaft, bolted to the engine flywheel and The transmission serial number plate (1) is located on the
a torque converter at the transmission input. The pump side (front) of the transmission at the bottom right,
transmission in turn transmits power to the drive shafts, toward the vehicle frame. Information specified on the
driving the front and rear axles. serial number plate includes the transmission model
The torque converter consists of three main components: number, the transmission serial number and other data.
the impeller (driver), stator and turbine (driven) in an oil- Information on the serial number plate is required in
filled, enclosed housing. As the torque converter is driven correspondence regarding the transmission.
by the engine flywheel, the impeller (pump) wheel rotates,
forcing oil through the stator, which is held stationary by
the stator shaft bolted to the transmission housing. This
directs the moving oil onto the vanes of the turbine
(driven) wheel, causing the turbine wheel to rotate. The
turbine wheel is connected to the transmission input
shaft, and transfers power to the transmission. Oil from
the turbine wheel is then returned to the impeller wheel to
repeat the process. This process results in an increase in
the torque available at the transmission input shaft.
The transmission and torque converter are powered by
their own internal hydraulic (“transmission fluid”) system,
separate from the vehicle hydraulic system. Pressurized 1
oil for the valve control circuits and torque converter is
supplied by a pump located at the rear of the transmission. MA8940
The pump is driven by the central shaft, which in turn is
connected to the impeller of the torque converter. The
vehicle is equipped with an external oil cooler to cool the
transmission oil.
Model 8042, 10042, 10054 Legacy Rev. 10/03 6.3
6.5 TRANSMISSION SPECIFICATIONS 6.6 TRANSMISSION MAINTENANCE
6.5.1 Transmission General Specifications 6.6.1 Maintenance Introduction

General transmission specifications are found in Section 2,
“General Information and Specifications.” Transmission fluid WARNING: To help avoid severe burns,
information is found in Section 2.6.3, “Transmission.” DO NOT attempt this procedure when the
engine, cooling, and hydraulic systems are hot.
6.5.2 Transmission Performance Wait until they have cooled before proceeding.
Specifications • Follow the manufacturer’s instructions
Performance criteria is based on full throttle engine to avoid health hazards when using
speed unless otherwise specified or not applicable. solvents and caustic cleaners.
Travel Speed (standard tires, no load) • Exercise extreme care when using a
steam cleaner to help avoid burns.
First gear .......................................... 3.5 mph (5,6 km/hr)
Second gear ........................................ 6 mph (9,7 km/hr) IMPORTANT: These instructions cover only the routine
maintenance of the transmission. Refer to the
Third gear .......................................... 14 mph (23 km/hr) ZF 4 WG-98 TC Transmission Repair Manual, P/N
Fourth gear ......................................... 20 mph (32 km/hr) 8990455 (ZF P/N 5871 135 002), for information on
transmission internal component replacement.
6.5.3 Transmission Lubrication Refer to the ZF 4 WG-98 TC Transmission Technical Data
and Maintenance Manual, P/N 8990449 (ZF P/N
a. Transmission Fluid
5872 134 002), for information on transmission diagnosis
Complete transmission fluid information is found in and internal schematics.
Section 2.6.3, “Transmission.” Cleanliness is of extreme importance. Before attempting
any repairs, thoroughly clean the exterior of the
b. Transmission Fluid (Oil) Capacity transmission to help prevent dirt from entering while
Capacity w/ filter change .......................3 gal (11,4 liters) performing maintenance checks and procedures.
Filter....................................................... 1.5 qt (1,4 liters) Section 6.6.2, “Transmission Maintenance Schedule,”
provides a suggested maintenance schedule with
6.5.4 Transmission-Related Fuse/Relay references to pertinent procedures and instructions in this
Ratings manual. To help prevent transmission problems before
they occur, follow the maintenance schedule.
Instrument Cluster ............................................... 10 amp
Note: Lubrication (1) and Maintenance chart (2) decals
Neutral Start Relay .................................................... 12V are located inside the engine compartment access door.
Transmission ...................................................... 7.5 amp These decals contain a general maintenance schedule
that should be followed to maintain the vehicle in good
operating condition. Refer to Section 2, “General
Information and Specifications.” The same schedule
information is presented in the appropriate owners/
operators manual, with a detailed account of how to
perform the procedures.
6.4 Model 8042, 10042, 10054 Legacy Rev. 10/03

CAUTION: DO NOT exceed 165 psi

(39.6 bar) when back flushing the oil cooler.
Applying too much pressure may damage the
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.
IMPORTANT: DO NOT use flushing compounds for
1 2 OH19702
cleaning purposes.
8042 S/N 13198 thru 18990

6.6.2 Transmission Maintenance Schedule 10042 S/N 13198 thru 19030
3
Complete transmission maintenance information is 10054 S/N 13198 thru 19079
located in the appropriate owners/operators manual.
• At ten hour intervals, check the transmission oil 4
level. Refer to the appropriate owners/operators
manual.
• When the vehicle completes its first 50 hours of
use, change the transmission filter. Change the
filter only; DO NOT change the transmission oil
at the first 50 hour maintenance level. Refer to
5
the appropriate owners/operators manual.
• At 1,000 hour intervals, change the transmission
oil and filter. Refer to the appropriate owners/
operators manual.
Front
MA8951
Periodically, depending on operating conditions and
other factors, back flush the transmission oil cooler (3),
which is located in or behind the radiator. ALWAYS back
flush the transmission oil cooler after removing the 8042 S/N 18991 & After
transmission for repair or replacement. 10042 S/N 19031 & After
The transmission oil cooler outlet hose (4), routed to the 10054 S/N 19080 & After 3
lower oil cooler fitting, is located on the top of the
transmission. The transmission oil cooler inlet hose (5),
routed to the upper oil cooler fitting, is located on the top 4
of the transmission. (Refer to Section 7A.6.3, “Radiator/
Oil Cooler and Coolant Heater Replacement,” and
Section 7B.6.4, “Radiator/Hydraulic and Transmission
Cooler Replacement.”
5
MH4490
Model 8042, 10042, 10054 Legacy Rev. 10/03 6.5

6.7 TRANSMISSION REPLACEMENT 5. Drain the hydraulic oil reservoir. (Refer to the
appropriate owners/operators manual for information
Note: Contact the JLG Service Department at concerning the hydraulic oil and filter change.)
1-877-554-5438 or 1-717-485-6657, if internal 6. Disconnect the battery negative (-) cable or cables (1)
transmission repair is required during the warranty at the battery negative (-) terminal, to prevent the
period. engine from starting accidentally.
IMPORTANT: To help ensure safety and optimum
performance, replace the transmission if it is damaged.
Refer to the appropriate parts manual for ordering
information. 1
Cleanliness is of extreme importance. Before attempting
to remove the transmission, thoroughly clean the exterior
of the transmission to help prevent dirt from entering
during the replacement process. Avoid spraying water or
cleaning solution onto or near the transmission shift
solenoids and other electrical components.
6.7.1 Transmission Removal
WARNING: Risk of severe personal

injury. NEVER lift a transmission alone; enlist
the help of at least one assistant or use a
suitable hoist or overhead crane and sling.
1. Park the vehicle on a firm, level surface, fully retract 1

the boom, raise the boom, place the travel select MH4510
lock lever in the NEUTRAL LOCK position, engage
the parking brake switch and shut the engine OFF. 7. Remove six hex nuts, six lockwashers and six flat
2. Place an Accident Prevention Tag on both the transmission covers to the frame. Remove the
ignition key switch and steering wheel, stating that covers.
the vehicle should not be operated. Refer to Section
1.5, “Accident Prevention Tags.”
3 2
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
2
~
serious injury.
3. Temporarily block up or support the boom.
WARNING:
4
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 engine, OH2371
transmission and hydraulic fluid to cool.
8. Thoroughly clean the transmission and surrounding
area, including all hoses and fittings, before
proceeding.
6.6 Model 8042, 10042, 10054 Legacy Rev. 10/03

9. Place a suitable receptacle under the transmission 6

drain plug (5). Remove the transmission drain plug, 12
and allow the transmission oil to drain into the 10
9
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
7
facility. Clean and reinstall the transmission drain 11
plug.
MH3390
Figure 6-1 Transmission Wiring

Harness Connector Location
5
17. Remove the capscrew (13) securing the lifting ring
OH2380
(14) to the transmission housing. Once the lifting ring
has been removed, reinstall the capscrew into the
11. Remove the engine-to-transmission drive shaft. hole.
Refer to Section 5.4.3, b. “Engine-to-Transmission
18. Move the lifting ring (14) to the holes (15) used to
Drive Shaft.”
secure the black wire (10) and clamp (12). Secure
12. Remove the transmission-to-axle drive shafts. Refer the lifting ring using the capscrews (9 and 11), and
to Section 5.4.3, a. “Transmission-to-Axle Drive tighten securely.
Shafts.”
13. Remove the hydraulic pump. Refer to Section 8.11.2, 15
a. “Pump Removal.” 14
14. Label and disconnect the transmission temperature
switch connector (6) and shift solenoid wiring
harness connectors (7 and 8).
15. Remove the capscrew (9) securing the black wire
(10) to the transmission housing, and disconnect the
wire. DO NOT reinstall the capscrew at this time.
16. Remove the capscrew (11) securing the clamp (12)
and wiring harness to the transmission housing, and
move the wiring harness safely out of the way. DO
NOT reinstall the capscrew at this time.
13 MH3400
Model 8042, 10042, 10054 Legacy Rev. 10/03 6.7

19. Label, disconnect and cap the transmission oil 21. Connect a lifting strap or chain to the lifting eye (3) at
cooler inlet (1) and outlet (2) hoses at the the top of the transmission, and to a suitable hoist or
transmission. The transmission oil cooler outlet overhead crane. Operate the hoist or crane to
hose, routed to the lower radiator fitting, is located remove slack from the chain, but DO NOT raise the
on the top of the transmission. The transmission oil transmission at this time.
cooler inlet hose, routed to the upper radiator fitting, 22. Place blocks under the transmission to help support
is located on top of the transmission. it during removal.
20. Wipe up any spilled hydraulic and transmission oil. 23. Remove the four capscrews (4) and four
lockwashers (5) securing the front transmission
8042 S/N 13198 thru 18990 2 mount (6) to the transmission.
10042 S/N 13198 thru 19030 24. Remove the two capscrews (7), two hex locknuts (8)
10054 S/N 13198 thru 19079 and two rebound washers (9). Remove the front
1 transmission mount (6) from the vehicle.
25. Remove the four capscrews (10) and four
lockwashers (11) securing the rear transmission
mount (12) to the transmission.
26. Remove the two capscrews (13), two hex locknuts
(14) and two rebound washers (15). Remove the
rear transmission mount (12) from the vehicle.
27. Inspect the rubber mounts (16). Replace the mounts
if damaged.
WARNING: Risk of personal injury. The

transmission may move while hoisting it out of
the chassis. Carefully move the transmission
and adjust the sling as needed. Keep fingers,
MA8990
hands, legs and other body parts clear of the
transmission.
8042 S/N 18991 & After 28. Carefully remove the transmission from the vehicle.
10042 S/N 19031 & After 2 Avoid causing damage to the transmission or
10054 S/N 19080 & After surrounding parts.
29. Lift the transmission clear of the vehicle, and lower it
onto suitable supports or secure it to a stand built
especially for transmission or engine service. Secure
the transmission so that it will not move or fall.
1
MH4500
6.8 Model 8042, 10042, 10054 Legacy Rev. 10/03

3 13 13
11
12 10
11
16
6
5 7
16
4 5
4
5
15
9
14
8
MH3380
Model 8042, 10042, 10054 Legacy Rev. 10/03 6.9

30. Remove any external transmission components as 6.7.3 Transmission Installation

required, including the transmission temperature
switch (1), and inlet (2) and outlet (3) cooler hose
fittings. Cover all transmission openings.
WARNING: Risk of severe personal
injury. NEVER lift a transmission alone; enlist
31. Remove the transmission oil filter (4) and dispose of the help of at least one assistant or use a
properly. Clean the filter mounting surface. Cover or suitable hoist or overhead crane and sling.
cap the oil filter mount.
3
WARNING: The transmission must be
1 properly installed using fasteners of the correct
2 size and grade, and torqued to their specified
values.
1. Install two rubber mounts (5) and the rear

transmission mount (6) in the vehicle frame. Secure
the mount with two capscrews (7), two rebound
washers (8) and two locknuts (9).
4 2. Use a hoist or overhead crane and sling attached to
the lifting eye (10) at the top of the transmission.
Raise and position the transmission within the
chassis.
3. Attach the transmission to the rear mounting bracket
(6) with four capscrews (11) and four lockwashers
(12). Torque the capscrews to 148 lb-ft (200 Nm).
MA8970
4. Install the two front rubber mounts (13) and the front
transmission mounting bracket (14) on the
The transmission is now ready for inspection and/or transmission with four capscrews (15) and four
further service. Refer to the ZF 4 WG-98 TC lockwashers (16). Torque the capscrews to 148 lb-ft
Transmission Repair Manual, P/N 8990455 (ZF P/N 5871 (200 Nm).
135 002) for information on transmission diagnosis, and 5. Attach the front mounting bracket (14) to the frame
internal component repair or replacement. with two capscrews (17), two hex locknuts (18) and
two rebound washers (19).
6.7.2 Transmission Inspection and Internal 6. Remove the hoist or overhead crane and sling.
Repair
Refer to the ZF 4 WG-98 TC Transmission Repair Manual,
P/N 8990455 (ZF P/N 5871 135 002) for information on
internal component repair or replacement. Refer to the
ZF 4 WG-98 TC Transmission Technical Data Manual and
Maintenance Manual, P/N 8990449 (ZF part number
5872 134 002) for information on transmission diagnosis
and internal schematics.
If replacing the entire transmission, transfer the
transmission temperature switch to the replacement
transmission. The gear shift solenoids are included with a
new transmission.
6.10 Model 8042, 10042, 10054 Legacy Rev. 10/03

10 7
12
6 11
12
17
14
16 17
15 13
16
15 16
8
19
9
18
MH3380
Model 8042, 10042, 10054 Legacy Rev. 10/03 6.11

Note: The lifting ring must be repositioned, to allow the 10. Attach the black wire (8) to the transmission housing
covers to be installed. with a capscrew (9) removed in Step 7.
7. Remove the two capscrews (1) securing the lifting 11. Secure the wiring harness to the transmission
ring (2) to the transmission housing. Save the housing using the clip (10) and capscrew (11)
capscrews for later use. removed in Step 7.
8. Remove the capscrew (3), and secure the lifting ring 12. Connect the transmission oil cooler inlet (12) and
(2) in the storage position (4) on the transmission outlet (13) hoses at the transmission.
housing as shown.
8042 S/N 13198 thru 18990
4 2 10042 S/N 13198 thru 19030
10054 S/N 13198 thru 19079 13
12
3 1 MH3410
MA8990
9. Connect the transmission temperature switch

connector (5) and shift solenoid wiring harness 8042 S/N 18991 & After
connectors (6 and 7). 10042 S/N 19031 & After 13
10054 S/N 19080 & After
5
10
8
9
12
6
11
7 MH4500
MH3390
6.12 Model 8042, 10042, 10054 Legacy Rev. 10/03

13. Install the hydraulic pump. Refer to Section 8.11.2, h. 6.7.4 After Transmission Service or
“Pump Installation.” Replacement
14. Install the engine-to-transmission drive shaft. (Refer Refer to the ZF 4 WG-98 TC Transmission Repair Manual,
to Section 5.4.7, b. “Engine-to-Transmission Drive P/N 8990455 (ZF P/N 5871 135 002) for information on
Shaft.” servicing the transmission after overhaul or repair. In
15. Install the transmission-to-axle drive shafts. Refer to general:
Section 5.4.7, a. “Transmission-to-Axle Drive Shafts.” 1. Check the transmission oil level and add oil as
16. Clean the transmission oil filter mounting surface. required.
17. Apply a thin film of clean Universal Tractor Fluid to 2. Install a new transmission filter.
the new transmission filter gasket. Install the new 3. Check the torque on the drive shaft yoke capscrews.
filter and torque to 20-25 lb-ft (27-34 Nm).
4. Wear suitable eye protection. When an overhauled
18. Transmission oil may be added through the dipstick or repaired transmission is installed, thoroughly
tube. Remove the dipstick and add approximately clean the oil cooler lines to and from the transmission.
3 gallons (11,4 liters) of Universal Tractor Fluid.
5. Drain and flush the entire system.
Check the oil level by taking intermittent dipstick
readings as outlined in the appropriate owners/ 6. Disconnect and clean all transmission cooler hoses.
operators manual. DO NOT overfill. Reinstall the When possible, remove transmission lines from the
dipstick when finished. vehicle for cleaning.
19. Install the upper (14) and lower (15) transmission 7. Thoroughly clean transmission filter screens and
covers, and secure to the frame with six flat washers, cases, and replace transmission filter elements.
six lockwashers and six hex nuts (16).
. CAUTION: DO NOT exceed 165 psi
(11,4 bar) when back flushing the oil cooler.
14 16 Applying too much pressure may damage the
~ 8. Back flush the transmission oil cooler portion of the

radiator or the oil cooler (located behind the radiator)
with oil and compressed air until all foreign material
16 is removed. Flushing in the direction of normal oil
~
flow does not adequately clean the cooler. If needed,

remove the radiator or oil cooler from the vehicle.
15 IMPORTANT: DO NOT use flushing compounds for
cleaning purposes.
OH2371
20. Connect the battery negative (-) cable at the battery.
Model 8042, 10042, 10054 Legacy Rev. 10/03 6.13

9. Reassemble all components and fill the transmission 6.8 TOWING A DISABLED VEHICLE
with clean, fresh Universal Tractor Fluid through the
dipstick tube opening (1). Remove the dipstick and Towing a disabled vehicle should only be attempted as a
fill with approximately 3 gallons (11,4 liters) of last resort, after exhausting all other options. Make every
Universal Tractor Fluid. Check the level by taking effort to repair the vehicle, and move it under its own
intermittent dipstick readings as outlined in the power, before using the emergency towing procedures
appropriate owners/operators manual. DO NOT outlined in the appropriate owners/operators manual.
overfill. Reinstall the dipstick when finished. IMPORTANT: After the vehicle has been towed to a
secure location, reactivate the parking brake. Carefully
1 follow the procedures from start to finish. Consult your
local Sky Trak distributor or the JLG Service
Department at 1-877-554-5438 or 1-717-485-6657, if
you are unsure about any part of the procedure, or for
specific instructions concerning your particular situation.
OH23622
10. Run the engine for two minutes at idle to help prime the
torque converter and the transmission oil lines.
11. Recheck the level of the fluid in the transmission with
the engine running at idle.
12. Add Universal Tractor Fluid as necessary to bring
the fluid level up until it reaches the FULL mark on
the dipstick. Recheck the oil level when it reaches
operating temperature (180-200° F or 83-94° C).
13. Recheck all drain plugs, lines, connections, etc., for
leaks, and tighten where necessary.
6.14 Model 8042, 10042, 10054 Legacy Rev. 10/03

6.9 TROUBLESHOOTING Detailed transmission service instructions (covering repair,

disassembly, reassembly and adjustment information) are
This section provides an easy reference guide covering provided in the ZF 4 WG-98 TC Transmission Repair
the most common problems that may occur during Manual, P/N 8990455 (ZF P/N 5871 135 002).
operation of the transmission. The transmission should be checked, serviced and
Note: Contact the JLG Service Department at repaired only by experienced service technicians who are
1-877-554-5438 or 1-717-485-6657, if internal aware of all safety instructions and particular component
transmission repair is required during the warranty features.
period.
6.9.1 Transmission Troubleshooting

1. Transmission will not engage 1. Oil level too high or low. 1. Fill transmission to correct level
or will not shift properly. with Universal Tractor Fluid.
(Refer to the appropriate
2. Travel select lever not 2. Refer to Section 9.14.7, a.
functioning properly and/or a “Travel Select Lever and Wiring
fault in the wiring harness. Harness Testing.”
3. Transmission valve body 3. Refer to Section 9.14.7, b.
solenoids not functioning “Upper and Lower Transmission
properly. Valve Body Solenoid Testing.”
4. Pilot-operated shift valves not 4. Clean the valve spool and
operating properly. housing. Replace return spring
as needed.
5. Pump output pressure low. 5. Refer to Section 6.9.1,
“Transmission Troubleshooting,”
Problem 2. “Low or no pump
flow or pressure.”
6. Clutch piston o-rings damaged. 6. Replace o-rings.
7. Clutch discs worn or damaged. 7. Replace clutch discs.
8. Coupling shafts or gear teeth 8. Replace couplings.
damaged.
2. Low or no pump flow or 1. Low oil level. 1. Fill transmission to correct level
pressure. with Universal Tractor Fluid.
(Refer to the appropriate
2. Transmission filled with incorrect 2. Drain transmission and fill to
oil, or oil contaminated. correct level with Universal
Tractor Fluid. (Refer to the
manual.)
3. Pump suction pipe screen 3. Clean, repair and/or replace
clogged. suction pipe.
4. Central shaft damaged. 4. Replace central shaft.
5. Pump worn or damaged. 5. Repair or replace pump
assembly.
Model 8042, 10042, 10054 Legacy Rev. 10/03 6.15

6.9.1 Transmission Troubleshooting (Continued)

3. Low clutch pressure. 1. Incorrect oil level. 1. Fill transmission to correct level
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 3. Replace coupling and/or o-rings.
piston o-rings.
4. Pressure reducing valve stuck 4. Clean the valve spool and
open. housing.
4. Lack of power. 1. Park or service brake dragging. 1. Refer to Section 8.8, “Hydraulic
Circuits and Troubleshooting.”
2. Low engine rpm causes 2. Adjust the engine rpm to
converter stall. specifications. Refer to
Cummins Service Manual.
3. Pump output pressure is low. 3. Refer to Section 6.9.1,
Problem 2. “Low or no pump
flow or pressure.”
4. Clutch discs worn or damaged. 4. Replace clutch discs.
5. Transmission overheating. 5. Refer to Section 6.9.1,
Problem 5. “Transmission
overheating (oil above 248° F
[120° C]).”
5. Transmission overheating 1. Low oil level. 1. Fill transmission to correct level

(oil above 248° F [120° C]). with Universal Tractor Fluid.
Refer to the appropriate owners/
operators manual.
2. Clogged radiator. 2. Remove debris from the
radiator.
oil, or oil contaminated. correct level with Universal
Tractor Fluid. Refer to the
manual.
4. Excessive “roading.” 4. Stop and idle the engine.
5. Restriction in oil cooler hoses. 5. Replace cooler hoses.
6. Pump worn or damaged. 6. Repair or replace pump
assembly.
7. Engine thermostat stuck. 7. Replace engine thermostat.
Refer to Section 7B.6.2, b.
“Thermostat Installation.”
6.16 Model 8042, 10042, 10054 Legacy Rev. 10/03

6.9.1 Transmission Troubleshooting (Continued)

6. Grinding or “clunking” noise 1. Oil level too low. 1. Fill oil to correct level. Refer to
from transmission. appropriate owners/operators
manual.
oil. correct level with Universal
Tractor Fluid. Refer to the
manual.
3. Incorrect clutch engagement. 3. Refer to Section 9.14.7,
“Transmission Solenoid Valves.”
4. Internal damage. 4. Repair or replace parts as
needed.
5. Broken diaphragm (flex plate). 5. Replace diaphragm (flex plate).
Refer to Section 6.7.1,
“Transmission Removal.”
6. Loose diaphragm (flex plate) 6. Tighten capscrews.
mounting capscrews.
7. Oil leaking from transmission. 1. Oil leaking from vent (high oil 1. Remove drain plug and drain oil
level). as needed, until oil is at correct
level. Refer to the appropriate
owners/operators manual).
Replace o-rings as needed and
tighten plugs to 96 lb-ft (130 Nm).
2. Drain plug loose and/or o-rings 2. Replace o-rings as needed and
damaged or missing. tighten plug to 26 lb-ft (35 Nm).
3. Hose fittings loose. 3. Tighten fittings.
4. Oil leaking at valve bodies 4. Replace gaskets and/or tighten
(possible valve body gaskets capscrews to 7 lb-ft (9,5 Nm).
damaged or missing and/or
mounting capscrews not tight).
5. Housing capscrews loose. 5. Tighten capscrews to 34 lb-ft
(46 Nm).
6. Oil leaking at pump (possible 6. Replace o-rings and/or tighten
pump-to-housing o-rings capscrews to 85 lb-ft (115 Nm).
missing or damaged, and/or
pump mounting capscrews not
tight).
7. Oil leaking at converter bell 7. Replace converter and/or input
(possible converter leak and/or shaft seal.
input shaft seal damage).
8. Oil leaking at output shaft 8. Replace output shaft seal.
(output shaft seal damaged).
9. Housing damaged. 9. Replace housing as needed.
Model 8042, 10042, 10054 Legacy Rev. 10/03 6.17

6.18 Model 8042, 10042, 10054 Legacy Rev. 10/03

Section 7A
Engine: Cummins 4BT3.9 and 4BTA3.9
Contents

7A.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.4
7A.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.4
7A.1.2 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.4
7A.2 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.6
7A.3 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.8
7A.4 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.8
7A.5 Standard Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.8
7.5.1 Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.8
7A.5.2 Gaskets and O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.8
7A.5.3 Capscrews, Nuts and Metric Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.8
7A.6 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.9
7A.6.1 Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.9
7A.6.2 Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.9
7A.6.3 Radiator/Oil Cooler and Coolant Heater Replacement . . . . . . . . . . . . . . . 7A.11
7A.6.4 Engine Block Heater Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.16
7A.7 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.17
7A.8 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.18
7A.8.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.18
7A.8.2 Fuel/Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.20
7A.8.3 Fuel Level Sender and Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.24
7A.8.4 Fuel Lift Pump Inspection and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.24
7A.8.5 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.24
7A.8.6 Venting Air from the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.24
7A.8.7 Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.24
7A.8.8 After Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.26
7A.9 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.26
7A.9.1 Exhaust System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.27
7A.9.2 Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.28
7A.10 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.28
7A.10.1 Air Cleaner Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.28
7A.10.2 Air Cleaner Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.29
7A.11 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.29
7A.11.1 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.29
7A.11.2 Engine Disassembly, Inspection and Service . . . . . . . . . . . . . . . . . . . . . . 7A.32
7A.11.3 Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.33
Model 8042, 10042, 10054 Legacy Rev. 10/03 7A.1

7A.12 Engine Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.38

7A.12.1 Split Taper Bushing Coupler and Drive Shaft Removal. . . . . . . . . . . . . . . 7A.38
7A.12.2 Coupler and Drive Shaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.39
7A.12.3 Coupler and Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.40
7A.13 Engine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.42
7A.14 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A.43
7A.2 Model 8042, 10042, 10054 Legacy Rev. 10/03


7A.1 INTRODUCTION A gradual running-in (break-in) of a new engine is not

necessary. Full load can be applied to a new engine as
soon as the engine is put into service and the coolant
7A.1.1 Disclaimer and Scope temperature is at least 140° F (60° C). Extended light-
These instructions are written for worldwide use. In load operation during the early life of the engine is not
territories where legal requirements govern engine smoke recommended. DO NOT run the engine at high, no-load
emission, noise, safety factors, etc., apply all instructions, speeds. DO NOT apply an overload to the engine.
data and dimensions provided herein in such a way that
after maintenance, service and repair of the engine, 7A.1.2 Component Terminology
engine operation does not violate local regulations.
IMPORTANT: These instructions cover only the routine information presented in this section, it is necessary that
maintenance, removal, installation and troubleshooting the operator/mechanic be familiar with the names and
of the engine. Refer to the local Cummins Engine locations of the engine components. The following
Distributor and the applicable Cummins engine service illustration identifies the components that are referred to
manual for assistance with comprehensive engine throughout this section.
diagnosis, repair and component replacement.
Note: The 8042 model unit has the 4BT3.9 Cummins
engine installed. The 10042 and 10054 models have the
4BTA3.9 engine installed. The “A” designation represents
the After Cooler found on the 10042 and 10054 models.
For additional information on the After Cooler, refer to
the appropriate Cummins engine manual.

12V Starter
Air Cleaner
Alternator
Assembly
Engine Oil Engine

Filter
Fuel Filter
Engine
Suction Block
Fan Heater Left Side
Right Side
Engine Mount
Engine Mount
Fan Belt
Upper
Radiator
Radiator Hose
Shroud
Lower
Radiator Hose
Radiator Cap
Isolator
Radiator Muffler Mount
Bracket
Isolator
Mount
Rear
Frame Engine
Mount Mount
Isolator
Mount
Exhaust
Rebound
Pipe
Washer
Coolant Bracket
Overflow
Tank
Hydraulic Oil
Cooler
Transmission
Oil Connector
MH4000

7A.2 SAFETY INFORMATION Cleaning
General Vehicle Operation WARNING: When using steam cleaners

and pressure washers, wear protective
WARNING: Before attempting to start
glasses, gloves and clothing to help prevent
personal injury.
the engine and/or operate the vehicle, read the
owners/operators manual.
• Before operating the engine and/or the WARNING: NEVER use gasoline or
vehicle, install any engine guards that other flammable materials for cleaning parts.
were removed, and clear all personnel Use only approved cleaning solvents.
from the immediate area.
• Check that the brakes are fully functional. Engine Coolant (anti-freeze/anti-boil over)
WARNING:
• DO NOT exceed the stability limits of
the vehicle. DO NOT remove the
radiator cap while the engine and coolant are
• Allow only ONE person to have control
hot. Hot coolant under pressure is dangerous
of the engine and the vehicle.
and can injure the eyes and cause severe burns.
• Cooling system corrosion inhibitors
Preparation
contain alkali (chemicals that break
WARNING:
down organic substances such as skin
Wear protective glasses and and eye tissue), DO NOT swallow.
protective shoes. Avoid prolonged or repeated contact
• Verify that the work area is capable of with corrosion inhibitors. In case of skin
supporting the weight of the vehicle contact, immediately wash affected
and the torque created by any sus- area with soap and water. In case of
pended load. contact with eyes, immediately flood
eyes with large amounts of water for a
• DO NOT work on an engine or a vehicle
minimum of 15 minutes. Obtain medi-
that is supported ONLY by a hoist or lift
cal assistance immediately. Keep cor-
jacks. Use blocks or suitable stands.
rosion inhibitors out of the reach of
children.
Engine Operation
• DO NOT use salt water or other corro-
WARNING:
sive liquid in the cooling system.
Operate the engine in a
well-ventilated area only. Assure that engine
operation will not produce a concentration of
toxic emissions.
• DO NOT operate the engine in the
presence of a fuel spill or gas leak.
Such combustible vapors, when drawn
into the engine, can cause engine
over-acceleration, explosion, fire and
extensive personal injury and property
damage. Before operating in any haz-
ardous environment, consult a recog-
nized authority (such as the engine
distributor) on engine operation in haz-
ardous environments.
• DO NOT smoke or operate the engine
during refueling.

Rotating Parts and Fan Blades Engine Repair
WARNING: Keep away from parts which WARNING: Before beginning any
rotate; the fan blades can appear invisible adjustments or repairs, place accident
when the fan is rotating. prevention tags in the operator’s compartment
DO NOT pull or pry on the fan blades. This and on the controls, and disconnect the battery
practice will cause fan failure. Use only approved negative cable.
methods and tools for manually rotating the • DO NOT operate, clean, lubricate or
engine. adjust the engine without proper training.
• NEVER attempt to perform an adjust-
Battery ment or repair that is not understood.
• Before servicing, relieve pressure in
WARNING: Keep sparks and fires away fuel, oil, coolant and hydraulic lines.
from batteries. Batteries produce hydrogen Obtain medical assistance immediately
gas, which can explode and cause severe if a high-pressure jet of fuel, oil, coolant
personal injury and property damage. or hydraulic fluid strikes the skin.
Battery fluid can burn the skin and injure the • DO NOT permit loose clothing, hair,
eyes. If you come in contact with battery acid, etc., near moving parts.
flush the affected area with large amounts of • Keep away from parts which rotate; fan
water and obtain medical assistance immediately. blades can appear invisible when the
fan is rotating.
Engine Oil • To help prevent burns, avoid contact
with components that remain hot after
WARNING: Engine oil can cause skin power is turned off or disconnected.
disorders and other personal injury. Avoid • Some of the gaskets on the engine
prolonged or repeated contact with both new contain asbestos. Breathing asbestos
and used engine oil. dust is dangerous to health and may
cause severe bodily harm. Avoid creat-
Diesel Fuel ing dust and follow local directives for
handling and disposing of materials
WARNING: Diesel fuel can cause skin that contain asbestos.
irritation. Use gloves or protective hand lotion
when working on the fuel system. Parts
WARNING: When replacement is

necessary, ALWAYS use factory-approved
fasteners and parts.

7A.3 ENGINE SERIAL NUMBER DO NOT steam clean the following parts:
• Electrical Components
The Cummins 4BT3.9 or 4BTA3.9 serial number (1) Is
stamped on the front of the engine block, near the fan • Wiring
pulley. Information contained in the serial number is • Injectors
required in correspondence with the engine • Fuel Pump
manufacturer.
• Belts and Hoses
• Bearings
Front of
vehicle During reassembly and inspection, thoroughly clean all
parts, and, where present, remove burrs and scales.
7A.5.2 Gaskets and O-rings

NEVER reuse a gasket or o-ring. Use new gaskets and o-
rings. Thoroughly clean sealing surfaces before installing
a new gasket or o-ring. ALWAYS install new flat-faced o-
rings when servicing hydraulic fittings.
1
Cover any open ports of high-precision components
(such as fuel system equipment) exposed by removal or
disassembly to help prevent the entry of foreign material.
MS1152
7A.5.3 Capscrews, Nuts and Metric Parts
Supply the engine serial number and/or data tag When replacing capscrews, ALWAYS use a capscrew of
information when communicating about an engine or the same size and strength (Grade) as the capscrew
engine components. being replaced. Incorrect capscrews can result in engine
damage. Return capscrews removed from the engine to
7A.4 SPECIFICATIONS AND their original locations.
MAINTENANCE INFORMATION Always replace used elastic locknuts with new elastic
locknuts.
For engine, coolant and oil specifications, and
maintenance information, refer to Section 2, “General The Cummins 4BT3.9 and 4BTA3.9 engines use parts
Information and Specifications.” that are of metric dimensions. Metric capscrews are
described, in millimeters, in terms of major thread
Note: Detailed Cummins engine service instructions diameter, distance between threads and overall length.
(covering disassembly, inspection, internal repair,
assembly, adjustment and troubleshooting information) Metric capscrew dimensions:
are provided in the appropriate Cummins engine service M8 x 1,25 - 25
manual.
Length, in millimeters
7A.5 STANDARD PRACTICES Distance between threads, in millimeters
Major thread diameter, in millimeters
7.5.1 Cleanliness Verify that the correct type of part is used at all times.
Cleanliness is very important during engine repair.
Contamination of the engine during repair will reduce the
life of an engine. Thoroughly clean the engine and engine
compartment area before attempting to service or repair
the engine.

7A.6 ENGINE COOLING SYSTEM a. Thermostat Removal

1. Level the vehicle, ground the attachment, place the
The engine cooling system is a closed, pressurized
travel select lever in NEUTRAL (N), engage the
system that consists of coolant passages in the engine,
neutral lock lever, engage the parking brake switch
plus the oil cooler, thermostat, water pump, coolant
and shut off the engine.
heater, hoses, radiator and radiator overflow bottle. The
engine is cooled by the circulation of coolant through 2. Remove the ignition key. Secure accident prevention
passages in the cylinder block, engine head and radiator. tags to the steering wheel and ignition key switch.
Circulation is by thermo-siphon action, assisted by an Refer to Section 1.5, “Accident Prevention Tags.”
impeller-type water pump, driven by a fan belt from the
crankshaft pulley. WARNING: DO NOT attempt this
The water pump bearings are prepacked with a special procedure when the engine is hot. Wait for the
grease and DO NOT require service. Replace a faulty engine, muffler and tailpipes to cool down
water pump. General engine cooling specifications and before proceeding. Failure to do so could result
maintenance procedures are listed in Section 2, “General in severe burns.
Information and Specifications.”
3. Unlock, unlatch and open the side and rear engine
doors. Allow the engine to cool before proceeding.
7A.6.1 Radiator Pressure Cap Draining the cooling system while the engine is hot
The cooling system is designed to use a radiator can cause cracks in the engine block.
pressure cap to help prevent the coolant from boiling. In 4. Disconnect the negative (-) battery cable (2).
addition, the pressure helps to eliminate the formation of
steam pockets within the engine and ensures coolant
circulation throughout all coolant passageways of the
engine. For a 210° F (99° C) system, use a 13 psi
(90 kPa) radiator cap. An incorrect or malfunctioning cap
can result in the loss of coolant and a hot-running engine.
7A.6.2 Thermostat Replacement

Before considering thermostat replacement, check the
coolant level, fan belt tension and instrument cluster
temperature indicator.
• If the engine seems to take a long time to warm 2
up, the thermostat may be stuck in the open posi-
tion and requires replacement.
• If the engine runs hot, check the temperature of
MH4010
the upper radiator hose.
• If the hose is not hot, the thermostat may be
stuck in the closed position.
• If the engine has overheated, performance may
suffer, indicating other damage including a leak-
ing cylinder head gasket, cracked cylinder head
or block, and/or other internal engine damage.

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 4
cap. Place a funnel at the base of the radiator to
channel the drained coolant into a container. Open 3
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
MT1840
8. Loosen the lower alternator bracket capscrew (6) on

the bottom of the alternator (7). Remove the upper
alternator mounting capscrew (8), and lower the
2 alternator.
MH4230
6. This engine is equipped with an automatic belt

tensioner pulley (3). Insert a 1/2" drive ratchet into 7
the square hole (4) in the tensioner housing, and
remove the tension from fan belt (5).
7. While lifting the automatic belt tensioner pulley (3) 6
away from the belt, remove the fan drive belt (5).
MA61902
9. Remove the three capscrews (9) securing the

thermostat housing (10) to the engine.

14
11
10 15
13
12
9
16
13 MS1160
MH4010
10. Remove the thermostat housing (10), old gasket

(11), thermostat (12), thermostat seal (13) and 7A.6.3 Radiator/Oil Cooler and Coolant
engine lift bracket (14). Clean all gasket surfaces Heater Replacement
(15). DO NOT let any debris into the thermostat Before considering radiator or oil cooler replacement for
opening. other than obvious damage, conduct a cooling system
IMPORTANT: ALWAYS use the correct thermostat and pressure test check the coolant specific gravity, coolant
install a new gasket. NEVER operate the engine without level, fan belt tension and dash panel temperature
a thermostat, or engine damage will result. indicator.
• If the engine runs hot, check the temperature of
b. Thermostat Installation the upper radiator hose.
Note: Ensure that notched edge (arrow) of thermostat • If the hose is not hot, the thermostat may be
seal (13) is facing thermostat. stuck in the closed position.
1. Install the engine lift bracket (14), thermostat seal • If the engine has overheated, performance may
(13), thermostat (12) gasket (11) and thermostat suffer, indicating other damage including a leaking
housing (10). Secure with the three capscrews (9) cylinder head gasket, cracked cylinder head or
removed earlier. Torque to 18 lb-ft (24 Nm). block, and/or other internal engine damage.
2. Raise the alternator (7), and install the upper
a. Oil Cooler and Radiator Removal
alternator mounting capscrew (8) and alternator
lower capscrew 6). Torque to 32 lb-ft (43 Nm). Note: ALWAYS replace elastic locknuts with new elastic
3. Insert a 1/2" drive ratchet or breaker bar into the into locknuts to help ensure proper fastening.
the square hole (4) in the automatic belt tensioner 1. Level the vehicle, ground the attachment, place the
housing and lift the automatic tensioner travel select lever in NEUTRAL (N), and engage the
pulley (3). With the automatic tensioner pulley lifted neutral lock lever, engage the parking brake switch
out of the way, install the fan drive belt (5). and shut off the engine.
4. Connect the negative (-) battery cable (16). 2. Remove the ignition key. Secure accident prevention
5. Open the radiator cap (1), and fill the radiator tags to the steering wheel and ignition key switch.
completely with a 50/50 mixture of ethylene glycol Refer to Section 1.5, “Accident Prevention Tags.”
and water. Replace and tighten the radiator cap. Add
coolant to the overflow bottle until the bottle is 1/4 to WARNING: DO NOT attempt this
1/2 full. This overfilling will compensate for any air procedure when the engine is hot. Wait for the
trapped in the cooling system. engine, muffler, and tailpipes to cool down
6. Run the engine to operating temperature. Visually before proceeding. Failure to do so could result
check for leaks with the engine running. Check the in severe burns.
coolant level in the overflow bottle and fill, or drain,
as necessary.
Draining the cooling system while the engine is hot
can cause cracks in the engine block.

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 7
10
hold-down rods (5) and hold-down bracket (6).
Remove battery from vehicle. Store battery in a cool,
dry area. 9
5 4
1 6 3 2
MH4010
WARNING:
MH4230
Hot coolant can cause

radiator cap while the engine is hot. The cooling
system is under pressure. Wear protective
clothing and safety glasses.
radiator petcock (8) and allow the coolant to drain
6. Slowly turn the radiator cap (7) to the first stop and into the funnel. Transfer the coolant into a properly
allow any pressure to escape. Remove the radiator labeled container. Dispose of properly if coolant
cap. needs to be replaced. Close the radiator petcock.
7. Place a suitable container beneath the radiator 9. Loosen the radiator side clamp (9) on the radiator
petcock (8). input (upper) hose (10). 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.

10. Loosen clamp (11) on the radiator return (lower) 12. Disconnect and cap the inlet (15) and outlet (16)
hose (12). Work the hose off the radiator. Position fittings from the oil cooler (17).
the hose out of the way to allow radiator removal, or
remove the hose from the engine. Inspect the hose,
and replace if necessary.
13
19
14
15 16
17
11 18 MH4030
12 13. At the rear of the oil cooler, remove the six

capscrews (18 and 19), lockwashers and flat
washers. Remove oil cooler.
MH4040
11. Disconnect and cap the transmission inlet (13) and

outlet (14) hoses. Place a suitable container below
the fittings to catch any oil that may drain from the
radiator.

14. Working above the radiator (1), remove capscrews 15. At the sides of the radiator, remove the
(2), plain washers (3) and lockwashers (4) securing capscrews (6), radiator mount bushings (7), flat
the radiator at the upper mounting tabs to the washers (8 and 10), spacers (11) and elastic
radiator shroud (5). The radiator shroud contains locknuts (12) securing the radiator side mounting
weld nuts that retain the capscrews. tabs to the radiator mount weldments.
16. Working below the radiator, remove the elastic
locknuts (13) and rebound washers (14). Lift the
radiator and remove the isolator mounts (15) from
between the radiator (1) and frame mounts (16).
Carefully remove the radiator from the vehicle.
17. At the radiator overflow tank (17), remove the elastic
locknuts (18), flat washers (19) and hose support
(20). Remove the radiator overflow tank.
b. Oil Cooler and Radiator Installation

1. Install the radiator overflow tank (17), hose
support (20), flat washer (19) and new elastic
locknuts (18).
2. Install the isolator mounts (15) to the bottom of the
radiator (1). Insert radiator through the vehicle frame
mounts (16) and install the rebound washers (14)
and new elastic locknuts (13).
5 3. At the sides of the radiator, install capscrews (6) with
2 radiator mount bushings (7) and flat washers (8)
3 through the radiator mount tab (21). Install flat
1 4 washers (10) and spacers (11) between radiator
mount tabs (21) and mount weldments (9) Install
new elastic locknuts (12) on the back side of the
weldments (9).
4. Working above the radiator (1), install capscrews (2),
15 21 plain washers (3) and lockwashers (4) to secure the
9 12 radiator at the upper mounting tabs to the radiator
16
11 shroud (5). The radiator shroud contains weldnuts
19 that retain the capscrews.
10
14
18
13 17
8
20
6 7
MH4220

5. Place the oil cooler (22) into the vehicle, and install 9. At the upper radiator hose (31), and with the clamp
the capscrews (23 and 24), lockwashers and flat (32) installed over the hose, work the hose onto the
washers. radiator, and tighten the clamp.
33
37
31
32
24
35
22 26
25
23 MH4030
6. Uncap and connect inlet (25) and outlet (26) fittings

to the oil cooler (22).
7. At the lower radiator return hose (27), and with the
clamp (28) installed over the hose, work the hose 34
onto the radiator, and tighten the clamp. 36
MH4230
10. Install the radiator overflow tube at the radiator cap

connection (33) and at the overflow bottle (36) tube
29 connection (34).
11. Open the radiator cap (37) and fill the radiator (35)
completely with a 50/50 mixture of ethylene glycol
and water. Replace and tighten the radiator cap. Add
coolant to the overflow bottle (36) until the bottle is
1/4 to 1/2 full. This overfilling will compensate for any
air trapped in the cooling system.
30
28
27
MH4040
8. Uncap and connect transmission inlet (29) and outlet

(30) hoses to the radiator.

12. Install the battery (1), hold-down bracket (2), threaded 4. Disconnect the negative (-) battery cable (8) from the
hold-down rods (3) and hold-down nuts (4). battery (1).
13. Connect the positive (+) battery cable (5) and
negative (-) battery cable (6) to the battery (1). WARNING: Hot coolant can cause
5. Place a suitable container beneath the radiator

petcock (7). Slowly turn the radiator cap (9) to the
first stop, and allow any pressure to escape. Remove
the radiator cap (9).
3 4
9
6 2 1 5
MH4010
14. Run the engine to operating temperature. Visually

check for leaks with the engine running. Check the
as necessary.
7A.6.4 Engine Block Heater Replacement

7
a. Engine Block Heater Removal
travel select lever in NEUTRAL (N) and engage the
neutral lock lever; engage the parking brake switch
2. Remove the ignition key. Secure accident prevention 8
tags to the steering wheel and ignition key switch.
Refer to Section 1.5, “Accident Prevention Tags.”
WARNING: DO NOT attempt this

MH4230
procedure when the engine is hot. Wait for the 6. Open the radiator petcock (7), and allow the coolant
engine, muffler and tailpipes to cool down to drain into the funnel. Transfer the coolant into a
before proceeding. Failure to do so could result properly labeled container. Dispose of properly if
in severe burns. coolant needs to be replaced. Close the radiator
petcock.
3. Unlock, unlatch and open the engine cover. Allow
the engine to cool before proceeding. Draining the
cooling system while the engine is hot can cause
cracks in the engine block.

7. Remove plastic retainer (10) from around coolant b. Engine Block Heater Installation
heater element (11) and 110 volt cord (12). Using a
1. Apply Teflon tape to coolant heater element threads
29-mm socket, remove heating element from engine
(11), and install element using a 29-mm socket. DO
block.
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. Connect the negative (-) battery cable (6) to the
battery (1).
3. Fill the cooling system. Run the engine to operating
temperature. Visually check for leaks with the engine
running. Check the coolant level in the overflow
bottle (8) and fill, or drain, as necessary.
7A.7 ENGINE ELECTRICAL SYSTEM

The engine electrical system, including the starter,
alternator and primary wiring, is described in Section 9,
11 “Electrical System.”
10
12
MT0870

7A.8 FUEL SYSTEM IMPORTANT: Due to the precise tolerances of diesel

injection systems, keep the fuel clean, and free of dirt
The fuel system includes a fuel tank (1), fuel level sender and water. Dirt and water in the fuel system can cause
with gasket (2), instrument cluster gauge (not shown), severe damage to both the injection pump and the
fuel strainer (3), fuel lift pump (4), fuel filter (5), fuel supply injection nozzles. Use ASTM #2 diesel fuel with a
hose (6) and fuel return line (7). minimum Cetane rating of 40. #2 diesel fuel gives the
The threaded fuel filler (8) has a fuel cap (9) and permits best economy and performance under most operating
entry of diesel fuel into the tank. conditions. Fuels with Cetane numbers higher than 40
may be needed in high altitudes or extremely low
The fuel level sender (2) and instrument cluster gauge ambient temperatures to help prevent misfiring and
are described in Section 9.14.15, “Fuel Level Indicator excessive smoking.
and Fuel Level Sender.”
Inform the owner/operator of the vehicle to use #2 diesel
A fuel supply hose (6) carries fuel from the tank (1) to the fuel, unless ambient temperatures are below 32° F (0° C).
fuel lift pump (4) and then under pressure to the fuel filter When temperatures are below 32° F (0° C), a blend of #1
(5). Filtered fuel is directed to the fuel injection pump and diesel and #2 diesel fuels (known as “winterized”
to the individual fuel injectors. Surplus fuel at the fuel #2 diesel) may be used.
injector pump is returned to the tank via the fuel return
line (7). Note: #1 diesel fuel may be used, however, fuel
economy will be reduced.
7A.8.1 Diesel Fuel
Fuel represents a major portion of vehicle operating costs WARNING: DO NOT mix gasoline or
and therefore must be used efficiently. ALWAYS use a alcohol with diesel fuel. The mixture can cause
premium brand of high-quality, clean diesel fuel. Low an explosion.
cost, inferior fuel can lead to poor performance and
Use a low-sulfur content fuel with a cloud point (the
expensive engine repair.
temperature at which wax crystals form in diesel fuel) at
Note: Use only diesel fuel designed for diesel engines. least 10° below the lowest expected fuel temperature.
Some heating fuels contain harmful chemicals that can The viscosity of the fuel must be kept above 1.3
seriously affect engine efficiency and performance. centistrokes to provide adequate fuel system lubrication.
Note: When using diesel fuel with a sulfur content below
1.3 percent, the filter change interval must be reduced by
75 hours. The use of fuel with a sulfur content above
1.3 percent is not recommended.

6
2
9 4
5
3
7
PH28502

7A.8.2 Fuel/Hydraulic Oil Tank 5. Remove fuel tank drain plug (2), and drain fuel into
an approved and suitable container. Dispose of fuel
Note: The fuel/hydraulic oil tank is part of a one piece unit
properly.
divided into a two compartment (tank) unit. It is located on
the right side of the vehicle, across from the operator’s 6. Remove hydraulic oil tank drain plug (3), and drain
cab. If it is determined that either the fuel or hydraulic oil tank hydraulic oil into an approved and suitable container.
must be removed, both the fuel and hydraulic oil must be Dispose of oil properly.
drained before tank removal. Always dispose of hydraulic 7. Disconnect the hydraulic oil temperature sensor
oil or fuel properly. connector (4), from the engine harness connector,
and remove from tank (5).
8. Loosen the clamps (6) and disconnect the fuel
WARNING: Explosion and fire hazard. supply hose (7) and return line hose (8) from tank.
Cap or safely cover the fuel/hydraulic oil tank 9. Remove the fuel line fittings (9) from tank.
fittings before removing tank.
10. Loosen clamp (10) and disconnect the lower
hydraulic oil strainer hose (11) from hydraulic fuel
strainer (12). Cap hose.
a. Fuel/Hydraulic Oil Tank Removal
11. Remove the hydraulic fuel strainer (12) from tank (5).
12. Disconnect and cap the hydraulic return hose (13)
and remove lower tank fitting (14).
can cause cracks in the engine block. 13. Remove capscrews securing the hydraulic fluid level
sight-glass (15) from tank.
2. Disconnect the negative (-) battery cable (1).
14. Disconnect upper hydraulic hoses (16 and 17) from
the tee fittng (18) and cap hoses.
15. Remove the tee fittng (18) from tank.
16. Disconnect fuel level sender electrical connectors
(19) from the fuel level sender (21).
17. Remove screws (20) securing fuel sender (21) to the
tank. Remove fuel sender from tank.
18. Remove nuts (22) securing the hydraulic oil filter
head (23) to the tank. Remove filter (24) and gasket
(25) from tank.
1 19. Remove plug (26) from top of tank.
20. Remove nuts (27) securing hydraulic oil filler neck
components (28) and remove filler neck
components.
MH4010
21. Remove nuts (29) securing fuel filler neck
3. Remove the fuel/hydraulic oil tank top cover from tank. components (30) and remove filler neck
Refer to Section 4.7, “Access Panels and Covers.” components.
4. Remove the two frame top covers from above the frame. 22. Position and connect a suitable chain support to tank
Refer to Section 4.7, “Access Panels and Covers.” lifting point (31) and take up slack in the chain.
Note: If replacing the tank, remove all internal and 23. While supporting the tank, remove nuts (32) and
external components from the old tank, and retain for lockwashers (33 securing the tank to vehicle frame.
use on the replacement tank. Pull tank away from the tank carriage bolts (34), and
remove tank. Retain hardware for reuse.
Note: Have a dry chemical (Class B) fire extinguisher
near the work area.

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

b. Disassembly e. Inspection
DANGER:
Note: If a leak is suspected between the fuel and hydraulic
NEVER weld in, on, near or oil tank, contact JLG Service Department at:
around the fuel/hydraulic oil reservoir. Fuel and Domestic: 1-877-554-5438
hydraulic fluid and fumes can cause the reservoir International: 1-717-485-6657
to explode. This can result in death or serious
personal injury. 1. Inspect the fuel/hydraulic oil tank thoroughly for any
cracks, slices, leaks or other damage.
The fuel/hydraulic oil reservoir is a one-piece unit and 2. With the fuel/hydraulic oil tank removed from the
cannot be disassembled. The fuel level indicator and vehicle, plug all openings except one elbow fitting.
hydraulic filters can be removed and reused on the new Install the elbow fitting, and apply approximately
replacement reservoir. Dispose of the old reservoir 1-1.5 psi (7-10 kPa) of air pressure through the
according to local regulations concerning hazardous elbow. Check the tank for leaks by applying a soap
materials disposal. solution to the exterior and look for bubbles to
appear at the cracked or damaged area.
c. Cleaning and Drying
f. Assembly
If contaminated fuel, hydraulic oil or foreign material is in
the tank, the tank can usually be cleaned. The fuel/hydraulic oil reservoir is a one piece-unit and
cannot be disassembled. The fuel level indicator and
d. If a leak is suspected between the fuel and hydraulic oil hydraulic filters can be removed and reused on the new
tank, contact JLG Service Department at: replacement tank. Dispose of the old tank according to
Domestic: 1-877-554-5438 local regulations concerning hazardous materials disposal
International: 1-717-485-6657 regulations.
To clean the fuel/hydraulic oil tank: g. Fuel/Hydraulic Oil Tank Installation

1. Have a dry chemical (Class B) fire extinguisher near 1. Attach the tank (1) to a suitable lifting device at the
the work area. lift point (2).
2. Place the tank carriage bolts (3) into the slotted
WARNING: NEVER drain or store fuel in holes in frame.
an open container due to the possibility of
3. Position the tank (1) and insert carriage bolts (3)
explosion or fire. Discard the fuel in an approved
through tank attachment holes. Install lock-
manner.
washers (4) and finger tighten nuts (5) onto carriage
2. Depending on which side of the tank is contaminated bolts. Slide tank and carriage bolts toward the front
(fuel or hydraulic oil), remove the fuel or oil tank of vehicle, until carriage bolts are bottomed out into
drain plug, and safely drain any fuel or hydraulic oil the slotted frame holes.
into a suitable container. Dispose of fuel or hydraulic 4. Install plugs (6, 7 and 8) using new o-ring seals.
oil properly. 5. Install the hydraulic oil temperature sensor (9) in the
3. Clean the fuel/hydraulic oil tank with a high-pressure tank and connect to the engine harness connector.
washer, or flush the tank with hot water for five 6. Install the fuel line fittings (10) to the tank.
minutes and drain the water. Dispose of
contaminated water properly. 7. Install the fuel supply (11) and return line (12) hoses
to the fuel tank. Secure with clamps (13).
4. For the fuel tank side, add a diesel fuel emulsifying
agent to the tank. Refer to the manufacturer’s 8. Install the hydraulic fuel strainer (14) in the tank.
instructions for the correct emulsifying agent-to- 9. Connect the lower hydraulic oil strainer hose (15) to
water mixture ratio. Refill the tank with water, and the strainer (14) and secure using clamp (16).
agitate the mixture for 10 minutes. Drain the tank 10. Install lower tank fitting (17) and connect hydraulic
completely. Dispose of contaminated water properly. return hose fitting (18).
5. Refill the fuel tank with water until it overflows. 11. Install the hydraulic fluid level sight-glass (19) using
Completely flush the tank with water. Empty the fuel special designed and drilled capscrews and gaskets.
tank, and allow it to dry completely.
12. Connect the tee fitting (20) to the tank.

27
23 25 29
24
30 31 26
33
32 28
6 19
2 22
20
21
5 18
7
14
4
17
10
9
3 13
11
15
16
8 12
MH4270
13. Connect upper hydraulic hoses (21 and 22) to the 19. Fill fuel tank and hydraulic tank according to
tee fitting. specifications. Refer to Section 2.6, “Fluids,
14. Attach fuel level sender harness connectors (23) to Lubricants and Capacities.”
the sending unit (24). 20. Check fuel and hydraulic oil tanks for leaks.
15. Install the fuel sender with new gasket (24) into the 21. Connect the negative (-) battery cable (34).
fuel tank and secure with screws (25). DO NOT
overtighten.
16. Install hydraulic oil filter (26) onto the hydraulic oil
filter head (27). Replace gasket (28) onto tank and
install filter head (with filter attached), and secure
using new elastic locknuts (29). 34
MH4010
17. Install hydraulic filler neck components (30) and
secure using new elastic locknuts (31).
18. Install fuel filler neck components (32) and secure
using new elastic locknuts (33).

7A.8.3 Fuel Level Sender and Gauge b. Cleaning and Drying

The fuel level sender and gauge assembly is described in Clean the exterior of the pump with mineral spirits, and
Section 7A.8.3, “Fuel Level Sender and Gauge.” blow dry with compressed air.
Note: Parts replacement is not practical. The fuel lift
7A.8.4 Fuel Lift Pump Inspection and Testing pump is serviced as an entire assembly.
1. Inspect the camshaft lever and return spring for
excessive wear. c. Fuel Lift Pump Installation
2. To test the diaphragm, remove the fuel inlet line (1) 1. Clean the mounting surface on the cylinder block.
from the fuel lift pump (2). Block the fuel inlet with a
2. Install the fuel lift pump (2) with a new gasket. Install and
finger and operate the hand plunger (3). A properly
torque the capscrews (5) to 18 lb-ft (24 Nm).
operating pump will provide suction that will remain
until the finger is removed from the inlet. 3. Connect the fuel line (1). Vent air from fuel system.
Refer to appropriate Owners/Operators Manual.
4. Connect the negative (-) battery cable (6).
4
7A.8.5 Fuel Filter
Refer to the appropriate Owners/Operators Manual for
your vehicle for the correct fuel filter (4) removal procedure.
7A.8.6 Venting Air from the Fuel System

your vehicle for the correct fuel system venting procedure.
7A.8.7 Fuel Injectors

1 The engine uses Bosch 17-mm, closed nozzle, hole-type
5 MT2530 injectors. The injectors have different part numbers for
2 3
different engine ratings. The last four digits of the Cummins
part number (stamped on the bottom portion of the
a. Fuel Lift Pump Removal injector) identify the injector.
1. Disconnect the negative (-) battery cable (6) from the IMPORTANT: Use only the specified injector for the engine.
battery. Damage to the engine can occur if incorrect injectors are
used.
During the injection cycle, high pressure from the
injection pump rises to the operating (or “pop”) pressure,
which causes the needle valve in the injector to lift. Fuel
is then injected into the cylinder. A shimmed spring is
used to force the needle valve closed as the injection
pressure drops below the pop pressure to seal off the
nozzle after injection.
6
Failure of the needle valve to lift and to close at the
MH4010 correct time, or a needle valve that is stuck open, can
cause the engine to misfire and produce low power. Fuel
2. Clean debris from around the fuel lift pump (2). leaking from the open nozzle can cause a fuel knock,
poor performance, smoke, poor fuel economy and rough
3. Disconnect the fuel inlet line (1).
running.
4. Remove the capscrews (5), gasket and fuel lift
pump (2).

a. Locating Faulty Fuel Injectors 4. Operate the starter to turn the engine over until fuel
sprays from the nozzle. Examine the shape of the
A faulty fuel injector can cause:
spray. If the spray is unduly “wet” or “streaky”, or
• Misfiring obviously sprays to one side, or if the nozzle
• Knocking “dribbles” fuel, it may only be necessary to probe the
• Overheating nozzle holes to remove blockage.
• Loss of power
IMPORTANT: DO NOT attempt to adjust injection
• Smoky (black) exhaust
pressure without a testing pump and pressure gauge. It
• Increased fuel consumption
is not possible to accurately adjust the setting of fuel
The particular faulty fuel injector(s) may be determined by injectors without the proper equipment.
releasing the pipe union nut on each fuel injector in turn,
A perfect fuel injector, when tested by pumping fuel through
with the engine running at a fast “tick-over.” If, after
it in the open air, gives a short “pinging” sound as the fuel
slackening a pipe union nut, the engine revolutions
emerges from the holes. After the fuel injector has been
remain constant, a faulty fuel injector has been identified.
in service for some time, the pinging changes to a
To test a fuel injector: crackling sound. It is not until the fuel injector sounds
1. Remove the fuel injector (7) from the cylinder head. “dead” that its condition is likely to affect the running of the
Refer to Section 7A.8.7, b. “Injector Replacement.” engine.
b. Injector Replacement
Preparatory steps:
7 1. Thoroughly clean around the injector(s).
2. Disconnect the high-pressure fuel lines (8).
3. Disconnect the fuel drain manifold (9).
MA1960
2. Invert the fuel injector, with the nozzle facing out,

then retighten the unions.
3. Loosen the unions of the other fuel injector pipes (to
help avoid the possibility of the engine starting).
WARNING: Diesel fuel under pressure

can penetrate the skin and cause serious
personal injury. Slowly loosen fittings, and allow
release of residual pressure before removing.
MT3160

IMPORTANT: The injector must not rotate in the bore of

the cylinder head, or damage to the cylinder head will 6
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.
4. Use a 16-mm wrench to prevent the injector body (1) 7
from turning. Loosen the hold-down nut (2) with a
24-mm box wrench.
2
1
MT3160
5
15. Install the high-pressure fuel lines (6) and torque to
18 lb-ft (24 Nm).
3
MA1960 16. Run the engine and check for fuel and air leakage.
17. Bleed the fuel system in accordance with the
5. Clean the injector nozzle bore.
instructions found in the appropriate owners/
6. Remove the injector hold-down nut from the injector operators manual.
body.
7. Apply a light coat of anti-seize compound to the new 7A.8.8 After Fuel System Service
injector surface. Avoid getting anti-seize compound 1. Drain and flush the fuel tank if it was contaminated.
into the fuel drain hole.
2. Vent air from the fuel system in accordance with the
8. Install the hold-down nut on the injector body. instructions found in the appropriate owners/
9. Install a new o-ring into the recessed groove in the operators manual.
top of the hold-down nut. Make sure the o-ring is not 3. Fill the fuel tank with fresh, clean diesel fuel as required.
cut or twisted during installation.
10. Apply a light coat of anti-seize compound to the 7A.9 ENGINE EXHAUST SYSTEM
threads of the injector hold-down nut.
11. Assemble the injector and new copper washer (3).
Use only ONE copper washer. A light coat of clean
WARNING: Exhaust fumes contain
carbon monoxide, a colorless, odorless gas
15W40 engine oil placed between the washer and which is fatal when inhaled in a confined area.
the injector will help keep the washer from falling Avoid breathing exhaust fumes, and prevent
during installation. engine operation from becoming a cause of
12. Install the injector with the protrusion (4) on the side toxic emissions. Exhaust system components
of the nozzle fitting into the notch (5) in the head. reach high temperatures and can cause
13. Tighten the hold-down nut (2) and torque to 44 lb-ft severe burns. DO NOT come into contact with
(60 Nm). hot exhaust system components.
14. Install the fuel drain manifold (7) and torque to 6 lb-ft (8 The exhaust system is supported by the engine and the
Nm). vehicle frame, and helps minimize the transfer of noise

and vibration into the operator’s cab. The tail pipe directs 4. Disconnect the negative (-) battery cable (8).
exhaust fumes to the right side of the vehicle, away from
the cab.
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.
When replacing the muffler, also replace the tail pipe.
Before assembling components, use exhaust system 8
sealer at all slip joint connections.
MH4010
When installing exhaust system components, allow
sufficient clearance between the components and other
vehicle pipes, hoses and wiring that could be adversely
affected by excessive heat. 5. Disconnect and remove the V-band clamp (9) from
When installing an exhaust system, provide for parts the exhaust pipe (10).
expansion when the system is hot. 6. Disconnect and remove the clamp (11) attaching the
Whenever performing service on the vehicle, check the muffler (12) to the exhaust pipe (10) and remove the
condition of the exhaust system. Check the entire exhaust exhaust pipe.
system for broken, damaged, missing or improperly 7. Disconnect and remove the clamp (14) supporting
aligned parts, open seams, holes, loose connections and the tail pipe (15), from the tail pipe support bracket
other deterioration which could permit exhaust fumes to (16).
seep into the operator’s cab. Correct any damaged areas 8. Disconnect and remove the clamp (13) attaching the
immediately. tail pipe (15) to the muffler (12) and remove the tail
pipe.
7A.9.1 Exhaust System Removal
9. Disconnect and remove the front and rear band
1. Level the vehicle, ground the attachment, place the clamps (17 and 18), and remove the muffler (12).
18
2. Remove the ignition key. Secure accident prevention
Rear of vehicle
9
WARNING: To avoid severe burns, DO 16
NOT attempt to remove the engine when the 15
engine, cooling system and hydraulic system 12
10 11
are hot. Wait until all parts and systems are
17 13
3. Unlock, unlatch and open the engine doors. Allow

the engine to cool before proceeding. 14
PH28302

7A.9.2 Exhaust System Installation 7A.10 AIR CLEANER ASSEMBLY

Note: Keep all clamps loosened until entire exhaust
If a replacement engine is being installed into the vehicle,
system is in place.
the air cleaner assembly must be transferred to the new
engine.
2 The air cleaner assembly should be transferred to the
Rear of vehicle replacement engine after the used engine is removed
4 from the vehicle.
9
8 CAUTION: NEVER run the engine with
only the inner safety element installed.
5
3 IMPORTANT: Before transferring the air cleaner
10 11
6 assembly to the new engine, remove the elements and
1 clean the inside and outside of the air cleaner canister.
Replace the outer primary and inner safety elements.
7 Refer to the appropriate Owners/Operators Manual for
PH28302 your vehicle for the correct element change procedure.
1. Install the front and rear band clamps (1 and 2) Note: ALWAYS replace elastic locknuts with new elastic
around the muffler (3) and install the muffler to the locknuts to help ensure proper fastening.
muffler support bracket (4).
7A.10.1 Air Cleaner Assembly Removal
2. Install the tail pipe (5) to the muffler (3) and secure
with a clamp (6). 1. Remove the T-bolt band clamps (13 and 14) securing
the air intake hose (15) to the air cleaner assembly
3. Secure the tail pipe (5) with the clamp (7) to the tail
(16) and engine intake.
pipe support bracket (8).
4. Install the V-band clamp (9) to the exhaust pipe (10).
5. Install the clamp (11) securing the muffler (3) to the
exhaust pipe (5).
19
6. Tighten all clamps.
20
18
17 14
16
13
15
12
MH4010
MH4090
8. Start engine and check for exhaust leaks at all

exhaust connections. Adjust or repair as needed.

2. Remove the engine harness clamp (20), and move 2. Secure accident prevention tags to the steering
harness away from air cleaner assembly (16). wheel and ignition key switch. Refer to Section 1.5,
3. Remove the two capscrews (17) and lockwashers “Accident Prevention Tags.”
(18) securing the air cleaner mounting bracket (19) 3. Open the side and rear access doors, and allow the
to the engine. Remove the air cleaner assembly. engine, cooling system and hydraulic system to cool.
4. Remove the engine exhaust. Refer to Section
7A.10.2 Air Cleaner Assembly Installation 7A.9.1, “Exhaust System Removal.”
Note: Apply Loctite® 242 threadlock to the capscrew Note: ALWAYS replace elastic locknuts with new elastic
threads before installation. locknuts to help ensure proper fastening.
1. With the air cleaner assembly attached, install the air 5. Remove the radiator overflow tube (21), overflow
cleaner mounting bracket (19) using capscrews (17) tank (22), hose support (23), flat washer (24) and
and lockwashers (18). elastic locknuts (25).
2. Place the loosened T-bolt clamps (13 and 14) over
the air intake hose (15), and install hose on the air
cleaner assembly (16) and engine intake. Tighten
T-bolt clamps.
3. Install the engine harness clamp (20) and harness to
the air cleaner mounting bracket (19).
7A.11 ENGINE REPLACEMENT
7A.11.1 Engine Removal
WARNING: To avoid severe burns, DO

NOT attempt to remove the engine when the 21
engine, cooling system and hydraulic system
24
are hot. Wait until all parts and systems are 22
23 25
Note: The radiator and oil cooler must be removed from
the vehicle before engine removal. Refer to Section
7A.6.3, a. “Oil Cooler and Radiator Removal.” Several
additional components must be removed before engine
removal. They will be addressed in the following procedures. MH4200

travel select lever in NEUTRAL (N), engage the

6. Label and disconnect the alternator ground wire (1),

D+ (2) and B+ (3) harness wire leads.
4
7
5
RE
D
2W 5
3
BL
K
1
G
6
38 ORG
B+
D+ 8
6 YEL
D- 2
9 MA8420
11. Label and disconnect the back-up alarm harness

connector (10) from the back-up alarm (11).
10 11
MA8400
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. Remove the red, positive (+) battery cable (6) from the
upper solenoid stud.
9. Label and disconnect the blue/orange wire (7) from
the starter solenoid housing stud.
10. Remove, the lower 12-point starter bolt (8) securing
the starter to the flywheel housing. Remove the
negative (-) ground cable (9) from the 12-point
starter mounting bolt. Reinstall the 12-point starter MH4030
bolt into the lower starter bolt position.

12. Remove fasteners and back-up alarm.

Note: The engine harness is routed and attached to the 16. Remove the drive shaft assembly (10) from engine.
engine using hold-down clamps and plastic wire ties at
various places on the engine. Before removing engine,
12 To 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. 11
13. Label and disconnect the engine coolant temperature
switch lead (7) and oil pressure switch lead (8). 13
Refer to Section 9.14.12, “Engine Coolant High
10
Temperature Sender,” and Section 9.14.11, “Engine
Low Oil Pressure Sender.”
14. Disconnect the fuel shut-off solenoid harness
connector (9).
To Transmission MA8900
9 17. Disconnect the fuel inlet line (14) at the fuel lift
pump. Install a plug in the end of fuel inlet line.
15
16
8 7
19
18
17
14
MT2530
18. Disconnect the fuel return line (15) from the injector
pump (16).
19. Mark the location of the throttle cable (17) at the
throttle cable mount clamp (18). Remove clamp.
20. Disconnect the throttle cable (17) at the engine
throttle lever (19).
MH5580

securing the flange yoke (13) to the engine.

Note: Always discard used elastic locknuts and install 23. At the exhaust pipe bracket (12), remove the
new elastic locknuts. capscrews (13) and lockwashers (14). Remove
21. At the front right engine mount (1) remove the elastic exhaust pipe bracket.
locknut (2), rebound washer (3), engine isolator (4) 24. Position a fork truck behind the vehicle, and drive
and capscrew (5). Repeat for the front left engine forward, placing the forks underneath the rear engine
mount (6). mount (15) and front engine mount brackets (1 and 6).
Slightly lift the engine, and slowly back engine out of the
vehicle. Have an assistant ensure that the engine
clears all frame components during removal.
16
25. Place engine on a flat, level surface.
26. If replacing the engine, attach a lifting chain to the
front (16) and rear (17) engine lift brackets, and lift
6 engine clear of the ground.
27. Remove the right (1), and left (6) front engine
17 mounting brackets, and muffler bracket (18).
5
28. Remove the rear engine mount bracket (15) from the
engine.
7A.11.2 Engine Disassembly, Inspection and

18 1 19 Service
8 Engine disassembly, internal inspection, service, repair
4 and assembly procedures are covered in the Cummins
3
4BT3.9 or 4BTA3.9 service manual. Several special engine
15 service tools are required to properly service the Cummins
2
engine. Contact the local Cummins parts distributor for
7 12 further information.
9 Note: If the engine is being replaced, there may be external

10 components that will be required to be transferred from the
14 13 original engine to the replacement engine depending upon
11 who you purchase the new engine from and the
MH4060
configuration of your replacement engine. Refer to the
appropriate Cummins user manual for detailed procedures
that cover the transfer of original engine components to the
22. At the rear engine mount (7), remove the elastic replacement engine.
locknut (8), engine isolator (9), rebound washer (10)
and capscrew (11).

7A.11.3 Engine Installation Note: Always replace used elastic locknuts with new
elastic locknuts.
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
Note: Refer to Section 2.3, “Torques,” for specific
new elastic locknuts (24).
fastener torque specifications.
1. If replacing the engine, attach a lifting chain to the front
(16) and rear (17) engine lift brackets, and lift engine
clear of the ground.
Note: Apply Loctite® 242 threadlock to the engine mount
bracket capscrew threads before installation.
1. Inspect the rear engine mounting bracket isolator
(9). Replace isolator if cracked or worn.
2. If previously removed, install the rear (15) engine
mount bracket to the engine.
3. Install the muffler bracket (18), right (1), and left (6)
front engine mounting brackets to the engine.
4. Place engine on a flat, level surface.
5. Position a fork truck behind the engine, and drive 20
forward, placing the forks underneath the rear
engine mount (15) and front right (1) and left (6)
engine mount brackets. Lift the engine and slowly 21 23
drive it into the back of the vehicle. Have an assistant
ensure that the engine clears all frame, hose and 22
24
harness components during engine installation.
Position engine brackets over rear and front frame
mounts (19).
6. At the rear engine mount (7), install the capscrew
(11), rebound washer (10), engine isolator (9) and MH4200
new elastic locknut (8).

7. Install the right side exhaust pipe mount bracket
(12), capscrews (13) and lockwashers (14) to the
rear engine mount (7).

9. Secure the throttle cable clevis (1) to the engine

11 To Engine
throttle lever (2), located just above the starter.
10. Install the throttle cable mount clamp (3) over the
throttle cable (4).
10
11. Connect the fuel inlet line (5) to the fuel lift pump (6).
12
8
7
IMPORTANT: Yokes at both ends of the drive shaft must

2
Note: If installing a new drive shaft unit, special attention
1 need not be applied to installation. New drive shaft units
are balanced at the factory.
6 3 14. At the drive shaft (9), install the capscrews (10) and
lockwashers (11), securing the flange yoke (12) to
4
the engine. Torque to 105 ±10 lb-ft (142 ±14 Nm).
5
MT2530
Note: The engine harness is routed and attached at
various places on the engine using hold-down clamps
12. Connect the fuel return line (7) to the fuel injector and plastic wire ties. Before installing engine and with
pump (8). the help of an observer, ensure that engine clears the
harness during installation.
13. Raise the drive shaft assembly (9) into position. The
slip-yoke end of the drive shaft mounts toward the 15. Connect the engine coolant temperature switch lead
engine. If reinstalling a drive shaft previously (13) and oil pressure switch lead (14). Refer to
removed, align the flange yokes according to the Section 9.14.12, “Engine Coolant High Temperature
alignment marks made during removal. Sender,” and Section 9.14.11, “Engine Low Oil
Pressure Sender.”
16. Connect the fuel shut-off solenoid harness
connector (15) to the fuel shut-off solenoid.

5
15 16
18
RE
D
2W
BL
K
38 ORG
B+
D+
6 YEL
14 13 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. DO
NOT connect the negative (-) lead at this time.
20. Install the blue/orange wire (25) to the solenoid
mounting stud (26). Install a lockwasher and nut to
the stud. Torque to 3.4 lb-ft (4,6 Nm).
MH5580
23
17. Connect the alternator ground wire (16), D+ (17) and 25
B+ (18) harness wire leads. 19
21
22
24
26
20
MA8420
21. Install Starter and Connect Wires to the Starter.

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 6
1
8 4 3 7
MH4010
30. Check that all hydraulic system, electrical system,

cooling system, fuel system, and exhaust system
connections are correct and connected tightly.
31. From within the cab, lightly depress the throttle pedal
(9) to full-throttle position. As needed, adjust the
limit-stop screw (10) until it touches the pedal. Tighten
the locknut (11) to 120-125 lb-in (13,6-14,1 Nm).
MH4030
9
26. Install the engine exhaust. Refer to Section 7A.9.2,

“Exhaust System Installation.” 10
27. Install the rear engine access door with the help of at
least one assistant. Refer to Section 4.4.6, “Door 11
and Latches.”
28. Install the battery (3), hold-down bracket (4), two
threaded hold-down rods (5) and hold-down nuts (6).
29. Connect the positive (+) and negative (-) battery
cables (7 and 8).
MA01912

Note: Have an assistant stand by with a Class B fire 34. Allow the engine to cool. Check the radiator coolant
extinguisher. Start and idle the engine. level, and top off with a 50/50 mixture of ethylene
glycol and water. Replace the radiator cap.
32. Fill the overflow tank (12), 1/4 to 1/2 full with a 50/50
mixture of ethylene glycol and water. Replace and 35. Check for leaks from the engine, main hydraulic pump
tighten overflow tank cap (13). and lines, transmission, hydraulic reservoir and fuel
tank. Check the levels of all fluids and lubricants. Fill
33. Run engine to normal operating temperature then shut
as required.
off the engine. While the engine is cooling, check for
leaks. IMPORTANT: During the full throttle check:
• DO NOT steer or apply any pressure to the steer-
ing wheel.
• Keep the transmission in NEUTRAL (N).
36. Obtain and connect an appropriate engine analyzer
or tachometer. Check the engine rpm at full throttle.
If the rpm is not 2600-2800 rpm, readjust the throttle
limit-stop screw at the throttle pedal within the cab.
boom functions through their entire range of motion
several times. Check the hydraulic oil level.
38. Check for proper operation of all components.
39. Turn the engine OFF.
12
13
MH4020

7A.12 ENGINE COUPLER 5. Remove the capscrews and lockwashers (7) holding
the access cover plate (8) to the bell housing of
Note: Before beginning, verify your current coupler type. engine. Discard the capscrews and lockwashers. Let
If you have a hexagonal access cover plate (2), use the the cover plate rest on the tube of the drive shaft (9).
“Split Taper Bushing instructions for removal. Installation
instructions remain the same for all applications.
7
7A.12.1 Split Taper Bushing Coupler and Drive
Shaft Removal
neutral lock lever, engage the parking brake switch 9
3. Disconnect the negative (-) battery cable (1).
8 SH1060
6. Remove the capscrews (10) holding the split taper

bushing (11) to the coupler. After the capscrews are
removed, thread two of the capscrews into the two
threaded holes (12) in the flange of the bushing.
Turn these two capscrews evenly into the bushing
flange to force the bushing out of the coupler.
Remove the bushing with the drive shaft attached
from the vehicle and discard. Discard the cover
plate.
1
11
MH4010
10
4. Remove the drive shaft (3) from between the engine

and the transmission. At the transmission end of the
drive shaft, remove the capscrews (4) and straps (5)
holding the drive shaft to the transmission yoke (6).
Discard both straps and capscrews.
12
SH1080
7. Remove the access hole cover (13) from the back of

3 the bell housing on the right side of the engine. This
is to access the capscrews (14) holding the coupler
6
(15) to the flywheel. Save the cover and hardware for
reassembly.
4
2
5 SH1070

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
14 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
13 to the frame. Watch the fan-to-radiator clearance as you
are lifting the engine. If necessary, turn the fan slightly,
16 by hand, to gain additional clearance.
22
15 SH1090
17
20
8. Remove the capscrews and nuts (14) holding the
coupler (15) to the flywheel. Turn the engine by 21
hand, using the fan belt, until the capscrews line up 18 24
with the access hole (13). Discard the capscrews 23
19
and nuts. After all the capscrews are removed, SH3050
remove the coupler from the flywheel and discard
the coupler. 3. Remove the capscrews and lockwashers (23)
Note: It will be easier to remove the coupler from the left securing the outer half of the coupler (24).
side of the engine.
9. At this time use a suitable cleaner/solvent and
thoroughly clean the mounting lip of the flywheel.
Wipe any debris from the inside of the bell housing.
Use the cleaner to clean the threaded holes (16)
around the flange of the bell housing.
7A.12.2 Coupler and Drive Shaft Removal 25

1. Shut off the engine, shift the transmission into
NEUTRAL, apply the parking brake and remove the
ignition key.
Note: Rotating the fan belt by hand, gives greater
access to removing the drive shaft mounting
capscrews (17).
SH4000
1. Remove the capscrews (18) and straps (19) that
secure the drive shaft (20) to the transmission yoke
(21). Discard both straps and capscrews.
2. Remove the capscrews and lockwashers (17)
securing the drive shaft (20) to the coupling flange
(22).

4. Remove the capscrews (1) securing the small

access cover (2).
1
5
2
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.
3. Insert one capscrew into the access hole (2) on the
rear right side of the bell housing and through the
SH3060 flywheel and coupler. Assemble a new elastic
locknut onto the capscrew. DO NOT fully tighten at
this time.
5. Remove the capscrews and locknuts (3) securing 4. Turn the flywheel 180° and insert another capscrew
the coupler (4) to the flywheel. Turn the engine by and assemble with another new elastic locknut.
hand, using the fan belt, until the capscrews line up DO NOT fully tighten until all of the capscrews and
with the access hole (2). locknuts are in place.
5. After all the capscrews are in place, check to be sure
6. At this time, use a suitable cleaner/solvent and the coupler is resting squarely in the indentation of
thoroughly clean the mounting lip of the flywheel. the flywheel (6). Torque all the capscrews to 37 lb-ft
Wipe any debris from the inside of the bell housing. (48 Nm).
7A.12.3 Coupler and Drive Shaft Installation

1. Use cleaner to clean the backside of the coupler,
where it comes in contact with the flywheel.
Note: The new coupler weighs approximately
56 lbs (25,4 kg) and requires two people, one on each
side, to install.
SH1100
6. Install the small access cover plate (2), to the right

side of the engine and tighten the hardware securely.

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. Install the access cover plate (9) over the drive
shaft (7) (both supplied in the kit) and assemble the
drive shaft flange (10) to the coupler (8) using new 17
Grade 8 capscrews and lockwashers (11). Torque to
48 lb-ft (65 Nm).
18
11 10 19 SH4000
9
10. Thoroughly clean the transmission yoke (14) and
secure in place with new straps (15) and
7 capscrews (16). Torque to 55-60 lb-ft (75-81 Nm).
14 8
11. After the drive shaft is in place, grease both u-joints
12 and the slip joint using multi-purpose grease (MPG).
16
15 13 SH3090
8. Install the access cover plate (9) to the engine bell

housing (12) with capscrews and lockwashers (13)
Torque to 37 lb-ft (48 Nm).
locknuts to help ensure proper fastening. MH4010
9. If engine mounts (17) were previously removed or

loosened, carefully lower the engine down onto the
front engine mounts. Reassemble the rebound
washer (18) and secure in place with a new elastic
locknut (19). Torque to 60 lb-ft (81 Nm). Repeat this
procedure for the engine mount on the other side.

7A.13 ENGINE STORAGE 7. Run the engine for a short period to distribute
lubricating oil and coolant throughout the engine.
If the engine is properly protected and stored according 8. Clean out the engine breather pipe (where fitted)
to the following recommendations, no corrosion damage and seal the end of the pipe.
will normally occur. Cummins Engine Company, Inc. and
JLG are not responsible for any damage that occurs in 9. Remove the fuel injectors and spray clean engine
relation to a service storage period. lubricating oil into cylinder bores. Divide four ounces
(118,3 ml) of lubricating oil evenly between the four
Use the following procedures immediately upon removing cylinders.
engine from service if it is being stored for an extended
period of time. 10. Remove the air filter and any pipe installed between
the air filter and the induction manifold. Seal the
1. Clean the outside of the engine. manifold with waterproof tape.
2. When using a preservative fuel, drain the fuel 11. Remove the exhaust pipe. Seal the manifold with
system and fill with the preservative fuel. When not waterproof tape.
using preservative fuel, keep the fuel system
charged with regular fuel, which, along with the fuel 12. Disconnect the battery and store it safely, in a fully
filter, will have to be drained and discarded at the charged condition. Before the battery is put into
end of the storage period. storage, give the battery terminals a protection
against corrosion with a light coating of dielectric
3. Run the engine to operating temperature. Correct grease or petroleum jelly.
any fuel, fluid, oil or air leaks. Stop the engine, and
drain the oil. 13. Seal the vent pipe of the fuel tank or the fuel filler
cap with waterproof tape.
4. Replace the oil filter.
14. Remove and store the fan drive belt.
5. Fill the crankcase (sump) to the FULL mark on the
dipstick with new, clean oil or with an approved Note: Before starting the engine after storage, operate
preservative fluid. If a preservative fluid is used, it the starter motor with one of the fuel shut-off solenoid
must be drained and replaced with regular wires disconnected for 15 seconds or until the dash
lubricating oil before the engine is returned to panel low oil pressure warning indicator goes out. This
service. will allow oil to be circulated throughout the engine to
prevent damage to internal components.
6. Drain the cooling system. To provide protection
against corrosion, fill the cooling system with a
coolant containing a corrosion inhibitor. If frost
protection is needed, use the appropriate mixture of
anti-freeze and water. If frost protection is not
required, use an appropriate mixture of water with an
approved corrosion mixture.

7A.14 TROUBLESHOOTING
Trouble Possible Causes (see key, below)

Low Cranking Power 1, 2, 3, 4
Will Not Start 5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 31, 32, 33
Difficult Starting 5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 29, 31, 32, 33, 61, 63
Lack of Power 8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 31, 32, 33, 61, 63
Misfiring 8, 9, 10, 12, 13, 14, 16, 18, 19, 20, 25, 26, 28, 29, 30, 32
Excessive Fuel Consumption 11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33, 63
Black Exhaust 11, 13, 14, 16, 18, 19, 20, 22, 24, 25, 27, 28, 29, 31, 32, 33, 61, 63
Blue/White Exhaust 4, 16, 18, 19, 20, 25, 27, 31, 33, 34, 35, 45, 56, 62
Low Oil Pressure 4, 36, 37, 38, 39, 40, 42, 43, 44, 58
Knocking 9, 14, 16, 18, 19, 22, 26, 28, 29, 31, 33, 35, 36, 45, 46, 59
Erratic Running 7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 23, 26, 28, 29, 30, 33, 35, 45, 59
Vibration 13, 14, 20, 23, 25, 26, 29, 30, 33, 45, 47, 48, 49
High Oil Pressure 4, 38, 41
Overheating 11, 13, 14, 16, 18, 19, 24, 25, 45, 50, 51, 52, 53, 54, 57
Excessive Crankcase Pressure 25, 31, 33, 34, 45, 55, 60
Poor Compression 11, 19, 25, 28, 29, 31, 32, 33, 34, 46, 59
Starts and Stops 10, 11, 12
Key to Possible Causes
1. Battery charge low 21. Blocked fuel tank vent 43. Faulty suction pipe
2. Bad electrical connection 22. Incorrect grade of fuel 44. Restricted oil filter
3. Faulty starter motor 23. Sticking throttle or 45. Piston seizure/pick up
4. Incorrect grade of restricted movement 46. Incorrect piston height
lubricating oil 24. Exhaust pipe restriction 47. Damaged fan
5. Low cranking speed 25. Leaking cylinder head gasket 48. Faulty engine mounting
6. Fuel tank empty 26. Overheating 49. Incorrectly aligned flywheel
7. Faulty stop control operation 27. Cold running housing or incorrectly aligned
8. Fuel inlet restricted 28. Incorrect tappet adjustment flywheel
9. Faulty fuel lift pump 29. Sticking valves 50. Faulty thermostat
10. Clogged fuel filter 30. Incorrect high pressure pipes 51. Restriction in water jacket
11. Restricted air cleaner 31. Worn cylinder bores 52. Loose fan belt
12. Air in fuel system 32. Pitted valves and seats 53. Restricted radiator
13. Faulty fuel injection pump 33. Broken, worn or sticking 54. Faulty water pump
14. Faulty fuel injectors or piston ring(s) 55. Restricted breather pipe
incorrect type 34. Worn valve stems and guides 56. Damaged valve stem oil
15. Incorrect use of cold start 35. Restricted air cleaner deflectors (if fitted)
equipment 36. Worn or damaged bearings 57. Coolant level too low
16. Faulty cold start equipment 37. Insufficient oil in sump 58. Blocked sump strainer
17. Broken fuel injection 38. Inaccurate gauge 59. Broken valve spring
pump drive 39. Oil pump worn 60. Exhauster or vacuum pipe leak
18. Incorrect fuel pump timing 40. Pressure relief valve sticking open 61. Turbo impeller damaged or dirty
19. Incorrect valve timing 41. Pressure relief valve sticking closed 62. Turbo lubricating oil seal leak
20. Poor compression 42. Broken relief valve spring 63. Induction system leaks


Section 7B
Engine: Cummins QSB4.5T
Contents

7B.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.4
7B.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.4
7B.1.2 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.4
7B.2 Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.6
7B.3 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.8
7B.4 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.8
7B.5 Standard Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.8
7B.5.1 Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.8
7B.5.2 Gaskets and O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.8
7B.5.3 Capscrews, Nuts and Metric Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.8
7B.6 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.9
7B.6.1 Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.9
7B.6.2 Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.9
7B.6.3 Drain and Flush Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.11
7B.6.4 Radiator/Hydraulic and Transmission Cooler Replacement . . . . . . . . . . . 7B.13
7B.6.5 Block Heater Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.19
7B.7 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.20
7B.8 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.22
7B.8.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.22
7B.8.2 Fuel/Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.24
7B.8.3 Fuel Level Sender and Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.28
7B.8.4 Fuel Lift Pump Inspection and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.28
7B.8.5 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.28
7B.8.6 Venting Air from the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.28
7B.8.7 Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.28
7B.8.8 After Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.30
7B.9 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.31
7B.9.1 Exhaust System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.31
7B.9.2 Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.32
7B.10 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.32
7B.10.1 Air Cleaner Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.32
7B.10.2 Air Cleaner Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.33
Model 8042, 10042, 10054 Legacy Rev. 10/03 7B.1

7B.11 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.33

7B.11.1 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.33
7B.11.2 Engine Disassembly, Inspection and Service . . . . . . . . . . . . . . . . . . . . . . 7B.37
7B.11.3 Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.38
7B.12 Engine Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.42
7B.12.1 Coupler and Drive Shaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.42
7B.12.2 Coupler and Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.43
7B.13 Engine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.45
7B.14 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B.46
7B.2 Model 8042, 10042, 10054 Legacy Rev. 10/03


7B.1 INTRODUCTION A gradual running-in (break-in) of a new engine is not

necessary. Full load can be applied to a new engine as
soon as the engine is put into service and the coolant
7B.1.1 Disclaimer and Scope temperature is at least 140° F (60° C). Extended light-
These instructions are written for worldwide use. In load operation during the early life of the engine is not
territories where legal requirements govern engine smoke recommended. DO NOT run the engine at high, no-load
emission, noise, safety factors, etc., apply all instructions, speeds. DO NOT apply an overload to the engine.
data and dimensions provided herein in such a way that
after maintenance, service and repair of the engine, 7B.1.2 Component Terminology
engine operation does not violate local regulations.
IMPORTANT: These instructions cover only the routine information presented in this section, it is necessary that
maintenance, removal, installation and troubleshooting the operator/mechanic be familiar with the names and
of the engine. Refer to the local Cummins Engine locations of the engine components. The following
Distributor and the applicable Cummins engine service illustration identifies the components that are referred to
manual for assistance with comprehensive engine throughout this section.
diagnosis, repair and component replacement.

12V Starter
Air Cleaner
Assembly
Engine Oil
Filter
Fuel Filter
Engine
Alternator Block
Heater Left Side
Engine Mount
Hydraulic Oil Right Side
Suction
Engine Cooler Engine Mount
Fan
Fan Belt Muffler
Bracket
Upper
Radiator
Hose
Radiator Cap
Radiator
Rear
Engine Isolator
Transmission Mount Mount
Oil Cooler
Isolator
Mount
Frame Exhaust
Assembly Rebound Pipe
Washer Bracket
Lower
Radiator
Hose Fan Shroud
Isolator
Mount
Spacer
Coolant
Overflow
Tank
MH4570

7B.2 SAFETY INFORMATION Engine Operation
General Vehicle Operation WARNING: Never use Ether on Engines

equipped with Cold Start Grid Heaters. Use of
WARNING: Before attempting to start
starting fluid, which contains Ether, can cause
an explosion.
the engine and/or operate the vehicle, read the
Owners/Operators Manual.
• Before operating the engine and/or the WARNING: Operate the engine in a
vehicle, install any engine guards that well-ventilated area only. Assure that engine
were removed and clear all personnel operation will not produce a concentration of
from the immediate area. toxic emissions.
• Check that the brakes are fully • DO NOT operate the engine in the
functional. presence of a fuel spill or gas leak.
Such combustible vapors, when drawn
• DO NOT exceed the stability limits of into the engine, can cause engine over-
the vehicle. acceleration, explosion, fire and
• Allow only ONE person to have control extensive personal injury and property
of the engine and the vehicle. damage. Before operating in any
hazardous environment, consult a
Preparation recognized authority (such as the
engine distributor) on engine operation
WARNING: Wear protective glasses and

in hazardous environments.
• DO NOT smoke or operate the engine
protective shoes.
during refueling.
• Verify that the work area is capable of
supporting the weight of the vehicle
and the torque created by any Cleaning
suspended load.
• DO NOT work on an engine or a WARNING: When using steam cleaners
vehicle that is supported ONLY by a and pressure washers, wear protective
hoist or lift jacks. Use blocks or suitable glasses, gloves and clothing to help prevent
stands. personal injury.
CAUTION: When doing welding WARNING: NEVER use gasoline or

anywhere on the vehicle, disconnect the wire other flammable materials for cleaning parts.
harness (1 and 2) from the Engine Control Use only approved cleaning solvents.
Module (ECM) (3) on the engine.
Rotating Parts and Fan Blades
WARNING: Keep away from parts which

rotate; the fan blades can appear invisible
when the fan is rotating.
DO NOT pull or pry on the fan blades. This
practice will cause fan failure. Use only
1 approved methods and tools for manually
2 rotating the engine.
3
MH4540

Engine Coolant (anti-freeze/anti-boil over) Engine Oil
WARNING: DO NOT remove the WARNING: Engine oil can cause skin
radiator cap while the engine and coolant are disorders and other personal injury. Avoid
hot. Hot coolant under pressure is dangerous prolonged or repeated contact with both new
and can injure the eyes and cause severe and used engine oil.
burns.
• Cooling system corrosion inhibitors Diesel Fuel
contain alkali (chemicals that break
down organic substances such as skin
and eye tissue), DO NOT swallow. WARNING: Diesel fuel can cause skin
Avoid prolonged or repeated contact irritation. Use gloves or protective hand lotion
with corrosion inhibitors. In case of skin when working on the fuel system.
contact, immediately wash affected
area with soap and water. In case of Engine Repair
contact with eyes, immediately flood
eyes with large amounts of water for a
minimum of 15 minutes. Obtain
medical assistance immediately. Keep
WARNING: Before beginning any
adjustments or repairs, place accident
corrosion inhibitors out of the reach of prevention tags in the operator’s compartment
children. and on the controls, and disconnect the battery
• DO NOT use salt water or other negative cable.
corrosive liquid in the cooling system. • DO NOT operate, clean, lubricate or
adjust the engine without proper
Battery training.
• NEVER attempt to perform an
WARNING: Keep sparks and fires away

adjustment or repair that is not
understood.
from batteries. Batteries produce hydrogen
gas, which can explode and cause severe • Before servicing, relieve pressure in
personal injury and property damage. fuel, oil, coolant and hydraulic lines.
Obtain medical assistance immediately
Battery fluid can burn the skin and injure the if a high-pressure jet of fuel, oil, coolant
eyes. If you come in contact with battery acid, or hydraulic fluid strikes the skin.
flush the affected area with large amounts of
water and obtain medical assistance • DO NOT permit loose clothing, hair,
immediately. etc., near moving parts.
• Keep away from parts which rotate; fan
blades can appear invisible when the
fan is rotating.
• To help prevent burns, avoid contact
with components that remain hot after
power is turned off or disconnected.
Parts
WARNING: When replacement is

necessary, ALWAYS use factory-approved
fasteners and parts.

7B.3 ENGINE SERIAL NUMBER DO NOT steam clean the following parts:
• Electrical Components
The serial number (1) Is stamped on the front of the
engine block, near the fan pulley. Information contained • Wiring
in the serial number is required in correspondence with • Injectors
the engine manufacturer. • Fuel Pump
• Belts and Hoses
• Bearings
During reassembly and inspection, thoroughly clean all
parts, and, where present, remove burrs and scales.
Front of 7B.5.2 Gaskets and O-rings

vehicle
NEVER reuse a gasket or o-ring. Use new gaskets and o-
rings. Thoroughly clean sealing surfaces before installing
a new gasket or o-ring. ALWAYS install new flat-faced o-
rings when servicing hydraulic fittings.
Cover any open ports of high-precision components
(such as fuel system equipment) exposed by removal or
disassembly to help prevent the entry of foreign material.
7B.5.3 Capscrews, Nuts and Metric Parts

When replacing capscrews, ALWAYS use a capscrew of
MH4530
the same size and strength (Grade) as the capscrew
1 being replaced. Incorrect capscrews can result in engine
damage. Return capscrews removed from the engine to
Supply the engine serial number and/or data tag their original locations.
information when communicating about an engine or
Always replace used elastic locknuts with new elastic
engine components.
locknuts.
7B.4 SPECIFICATIONS AND The Cummins QSB4.5T engines use parts that are of
MAINTENANCE INFORMATION metric dimensions. Metric capscrews are described, in
millimeters, in terms of major thread diameter, distance
For engine, coolant and oil specifications, and between threads and overall length.
maintenance information, refer to Section 2, “General Metric capscrew dimensions:
M8 x 1,25 - 25
Note: Detailed Cummins engine service instructions Length, in millimeters
(covering disassembly, inspection, internal repair,
assembly, adjustment and troubleshooting information) Distance between threads, in millimeters
are provided in the appropriate Cummins engine service Major thread diameter, in millimeters
manual.
Verify that the correct type of part is used at all times.
7B.5 STANDARD PRACTICES
7B.5.1 Cleanliness
Cleanliness is very important during engine repair.
Contamination of the engine during repair will reduce the
life of an engine. Thoroughly clean the engine and engine
compartment area before attempting to service or repair
the engine.

7B.6 ENGINE COOLING SYSTEM a. Thermostat Removal

The engine cooling system is a closed, pressurized
vehicle, ground the attachment, place the travel
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
the engine OFF.
passages in the cylinder block, engine head and radiator.
Circulation is by thermo-siphon action, assisted by an 2. Place an Accident Prevention Tag on both the
impeller-type water pump, driven by a fan belt from the ignition key switch and steering wheel, stating that
crankshaft pulley. the vehicle should not be operated. Refer to Section
1.5, “Accident Prevention Tags.”
The water pump bearings are pre packed with a special
grease and DO NOT require service. Replace a faulty 3. Disconnect the negative (-) battery cables (2) from
water pump. General engine cooling specifications and the batteries.
maintenance procedures are listed in Section 2, “General
7B.6.1 Radiator Pressure Cap

The cooling system is designed to use a radiator
pressure cap to help prevent the coolant from boiling. In
addition, the pressure helps to eliminate the formation of
steam pockets within the engine and ensures coolant
circulation throughout all coolant passageways of the
engine. For a 210° F (99° C) system, use a 13 psi
(90 kPa) radiator cap. An incorrect or malfunctioning cap
can result in the loss of coolant and a hot-running engine. 2
7B.6.2 Thermostat Replacement

Before considering thermostat replacement, check the MH4440
coolant level, fan belt tension and instrument cluster

temperature indicator.
• If the engine seems to take a long time to warm
up, the thermostat may be stuck in the open
position and requires replacement.
procedure when the engine is hot. Wait for the
• If the engine runs hot, check the temperature of engine, muffler and tailpipes to cool down
the upper radiator hose. before proceeding. Failure to do so could result
• If the hose is not hot, the thermostat may be in severe burns.
• If the engine has overheated, performance may doors. Allow the engine to cool before proceeding.
suffer, indicating other damage including a Draining the cooling system while the engine is hot
leaking cylinder head gasket, cracked cylinder can cause cracks in the engine block.
head or block, and/or other internal engine
damage.

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. Loosen the lower alternator bracket capscrew (6) on

the bottom of the alternator (7). Remove the upper
alternator mounting capscrew (8), and lower the
alternator.
8 6
MH4580
6. This engine is equipped with an automatic belt

tensioner pulley (3). Insert a 1/2" drive ratchet into
the square hole (4) in the tensioner housing, and
remove the tension from fan belt (5). 7
7. While lifting the automatic belt tensioner pulley (3)
away from the belt, remove the fan drive belt (5). MH4550
9. Remove the capscrews (9) securing the thermostat

housing (10) to the engine.

7B.6.3 Drain and Flush Radiator

14
11
10 15 vehicle, ground the attachment, place the travel
13 select lever in the (N) NEUTRAL position, place the
12 neutral lock lever in the (N) NEUTRAL LOCK
9 the engine OFF.
13 the vehicle should not be operated. (Refer to Section
MS1160
WARNING:
10. Remove the thermostat housing (10), old gasket
(11), thermostat (12), thermostat seal (13) and DO NOT attempt this
engine lift bracket (14). Clean all gasket surfaces procedure when the engine is hot. Wait for the
(15). DO NOT let any debris into the thermostat engine, muffler, and tailpipes to cool down
opening. before proceeding. Failure to do so could result
in severe burns.
IMPORTANT: ALWAYS use the correct thermostat and
install a new gasket. NEVER operate the engine without 3. Disconnect the battery negative (-) ground cables
a thermostat, or engine damage will result. (16) at the battery negative (-) terminal.
b. Thermostat Installation
Note: Ensure that notched edge (arrow) of thermostat
seal (13) is facing thermostat.
1. Install the engine lift bracket (14), thermostat seal
(13), thermostat (12) gasket (11) and thermostat
housing (10). Secure with the capscrews (9)
removed earlier. Torque to 18 lb-ft (24 Nm).
2. Raise the alternator (7), and install the upper
alternator mounting capscrew (8) and alternator
lower capscrew (6). Torque to 32 lb-ft (43 Nm). 16
3. Insert a 1/2" drive ratchet or breaker bar into the into
the square hole (4) in the automatic belt tensioner
housing and lift the automatic tensioner pulley (3). MH4440
With the automatic tensioner pulley lifted out of the

way, install the fan drive belt (5).
4. Connect the negative (-) battery cables (16) to the
batteries.
5. Refer to Section 7B.6.3, “Drain and Flush Radiator.”

WARNING: Never remove the radiator

cap while the engine is hot. The cooling 6
system is under pressure. Hot coolant can
cause severe burns or eye injury. Wear
protective clothing and safety glasses.
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. Place a funnel (4) under the
drain tube (2) and loosen the drain petcock (3).
6. Drain the coolant into a suitable container.
1 5
MH4700
8. Flush the system with clean water and allow to drain

again. Upon completion, replace the hose onto the
the radiator fill neck (5) and tighten the drain
petcock (3).
9. Transfer the coolant to a container with a cover, and
label as “Used Antifreeze.” Dispose of the used
coolant at an approved recycling facility.
batteries.
11. Turn the ignition to RUN and turn the heat control
knob to the HOT position to open the heat valve.
12. Fill the radiator completely with a 50/50 mixture of
ethylene glycol and water.
13. Replace the radiator cap (1). Add coolant to the
3 2 overflow bottle until the bottle is1/2 to 3/4 full. This
“overfilling” will compensate for any air in the cooling
system.
4 MH4690 14. Clean any dirt or debris from the radiator fins and
core.
7. Drain the contents of the overflow bottle (6) by 15. Start the engine and allow to idle for 30 seconds.
removing the hose (5) from the radiator fill neck. Use Bring engine speed up to 1500 rpm for about one
the hose to drain the coolant into a suitable minute; inspect for leaks.
container. 16. Allow the engine to cool.
Note: On vehicles equipped with a cab heater option, a 17. The overflow bottle should be 1/4 to 1/2 full. If not, fill
shut off valve is installed at the engine inlet. Disconnect to this level with a 50/50 mixture of ethylene glycol
hose from shut off valve to drain heater. and water.
18. Close and latch the engine door.

7B.6.4 Radiator/Hydraulic and Transmission

Cooler Replacement WARNING: DO NOT attempt this
Before considering radiator or oil cooler replacement for
engine, muffler, and tailpipes to cool down
other than obvious damage, conduct a cooling system
before proceeding. Failure to do so could result
pressure test check the coolant specific gravity, coolant
in severe burns.
level, fan belt tension and dash panel temperature
indicator. 5. Unlock, unlatch and open the side and rear engine
• If the engine runs hot, check the temperature of doors. Allow the engine to cool before proceeding.
the upper radiator hose. 6. Draining the cooling system while the engine is hot
• If the hose is not hot, the thermostat may be can cause cracks in the engine block.
• If the engine has overheated, performance may
suffer, indicating other damage including a leaking
cylinder head gasket, cracked cylinder head or
block, and/or other internal engine damage.
a. Oil Coolers and Radiator Removal
1. Level the vehicle, ground the attachment, place the 7. Slowly turn the radiator cap (1) to the first stop and
travel select lever in NEUTRAL (N), and engage the allow any pressure to escape. Remove the radiator
neutral lock lever, engage the parking brake switch cap.
and shut off the engine. 8. Locate the drain tube (2) and petcock (3) on the right
2. Remove the ignition key. Secure accident prevention side of the radiator. Place a funnel (4) under the
tags to the steering wheel and ignition key switch. drain tube (2) and loosen the drain petcock (3).
(Refer to Section 1.5, “Accident Prevention Tags.”) Transfer the coolant into a properly labeled container.
3. Disconnect the battery negative (-) ground cables (7) Dispose of properly if coolant needs to be replaced.
and positive (+) cables (8) from the batteries (12). Close the radiator drain plug.
4. Remove the battery hold-down nuts (9), threaded
hold-down rods (10), and hold-down bracket (11).
Remove batteries (12) from the vehicle. Store
batteries in a cool dry area.
7 7
8 11 10 8
12 12
MH4210

9. Loosen the radiator side clamp (1) on the radiator 11. Disconnect and cap the inlet (8) and outlet (9) fittings
input (upper) hose (2). Work the hose off the from the transmission oil cooler.
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 8
(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.
2 3
MH4800
9
MH4770
10. Disconnect and cap the hydraulic oil cooler inlet (6)
and outlet (7) hoses. Place a suitable container
below the fittings to catch any oil that may drain from
the radiator.
6
7
MH4790


12. Working at the back of vehicle, remove the b. Oil Coolers and Radiator Installation
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 1. Install the radiator overflow tank (31) by connecting
the frame assembly (7). the hose (32) to the radiator (11) filler neck, and
13. Remove the fan shroud (8), fan shroud spacer (9), installing the locknuts (33), washers (34) and hose
hydraulic oil cooler (10), frame assembly (7) and clip (35).
radiator (11) as a unit, by removing capscrews 2. Assemble the radiator (11) to the frame assembly (7)
(12 and 13), washers (14 and 15), isolators (16) and by installing capscrews (27), washers (28), isolators
locknuts (17). (29) and frame brackets (30).
14. Disassemble the fan shroud (8) from the fan shroud 3. Assemble the hydraulic oil cooler (10) to the frame
spacer (9), by removing capscrews (18 and 19), assembly (7) by installing capscrews (25) and
lockwasher (20) and washers (21 and 22). washers (26).
15. Disassemble the fan shroud spacer (9) from the 4. Assemble the fan shroud spacer (9), to the frame
frame assembly (7), by removing capscrews (23) assembly (7) by installing capscrews (23) and
and washers (24). washers (24).
16. Disassemble the hydraulic oil cooler (10) from the 5. Assemble the fan shroud (8) to the fan shroud
frame assembly (7) by removing the capscrews (25) spacer (9), by installing capscrews (18 and 19),
and washers (26). lockwasher (20) and washers (21 and 22).
17. Disassemble the radiator (11) from the frame 6. Install the fan shroud (8), fan shroud spacer (9),
assembly (7) by removing capscrews (27), washers hydraulic oil cooler (10), frame assembly (7) and
(28), isolators (29) and frame brackets (30). radiator (11) as a unit, by installing capscrews
18. Remove the radiator overflow tank (31) by (12 and 13), washers (14 and 15), isolators (16)
disconnecting the hose (32) from the radiator (11) and locknuts (17).
filler neck, and removing the locknuts (33), 7. Working at the back of vehicle, install the capscrews
washers (34) and hose clip (35). (1) and lockwashers (2) that secure 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).

28
30 27
8
9
29 10
24 23 20 18
7
4 21
19
22
11
13 16 25
26
1 3
15 17
14
2 12
14
16
32
17
6 31
5 33
34
MH5000
35

8. At the back of the vehicle, connect the transmission

cooler inlet (1) and outlet (2) hoses. 5
6
7
MH4770
MH4800
2
11. Install the batteries (10), hold-down bracket (11),
threaded hold-down rods (12) and hold-down nuts
9. Connect the hydraulic oil cooler inlet (3) and outlet (13).
(4) hoses.
12. Connect the positive (+) battery cables (14) and
negative (-) battery cables (12) to the batteries (10).
3
4
13
12 12
14 11 12 14
10 7
MH4210
MH4790
13. Run the engine to operating temperature. Visually

check for leaks with the engine running. Check the
10. Install the radiator side clamp (5) on the radiator as necessary.
input (upper) hose (6) at the radiator (7). Install the
clamp (8) on the radiator return (lower) hose (9) at
the radiator.

7B.6.5 Block Heater Replacement

15
neutral lock lever; engage the parking brake switch
(Refer to Section 1.5, “Accident Prevention Tags.”)

engine, muffler and tailpipes to cool down
in severe burns.
3. Unlock, unlatch and open the rear engine door.

Allow the engine to cool before proceeding. Draining
the cooling system while the engine is hot can cause
cracks in the engine block.Disconnect the negative (-) 16
17
battery cables (14) from the batteries (10).
WARNING: Hot coolant can cause 18 MH4690

system is under pressure. Wear protective 7. Remove plastic retainer (19) from around coolant
clothing and safety glasses. heater element (20) and 110 volt cord (21). Remove
heating element from engine block.
4. Slowly turn the radiator cap (15) to the first stop, and
allow any pressure to escape. Remove the radiator
cap.
5. Locate the drain tube (16) and petcock (17) on the
right side of the radiator. Place a funnel (18) under
the drain tube and loosen the drain petcock.
6. Drain the coolant into a suitable container.
19
20
21
MH4710

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
3 7B.7 ENGINE ELECTRICAL SYSTEM

The engine electrical system, including the starter,
1
alternator and primary wiring, is described in Section 9,
“Electrical System.”
2
MH4710

batteries.
MH4440
3. Fill the cooling system. Run the engine to operating

temperature. Visually check for leaks with the engine
running. Check the coolant level in the overflow
bottle (5) and fill, or drain, as necessary.


7B.8 FUEL SYSTEM IMPORTANT: #1 diesel fuel may be used, however, fuel
economy will be reduced.
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
WARNING: DO NOT mix gasoline or
alcohol with diesel fuel. The mixture can cause
hose (6) and fuel return line (7).
an explosion.
The threaded fuel filler (8) has a fuel cap (9) and permits
entry of diesel fuel into the tank. Use a low-sulfur content fuel with a cloud point (the
The fuel level sender (2) and instrument cluster gauge temperature at which wax crystals form in diesel fuel) at
are described in Section 9.14.15, “Fuel Level Indicator least 10° below the lowest expected fuel temperature.
and Fuel Level Sender.” The viscosity of the fuel must be kept above 1.3
centistrokes to provide adequate fuel system lubrication.
A fuel supply hose (6) carries fuel from the tank (1) to the
fuel lift pump (4) and then under pressure to the fuel filter Note: When using diesel fuel with a sulfur content below
(5). Filtered fuel is directed to the fuel injection pump and 1.3 percent, the filter change interval must be reduced by
to the individual fuel injectors. Surplus fuel at the fuel 75 hours. The use of fuel with a sulfur content above
injector pump is returned to the tank via the fuel return 1.3 percent is not recommended.
line (7).
7B.8.1 Diesel Fuel
WARNING: Engine fuel is flammable

and can cause a fire or an explosion. Keep
sparks and open flames away from the vehicle
and DO NOT use smoking materials while
refueling.
Fuel represents a major portion of vehicle operating costs

and therefore must be used efficiently. ALWAYS use a
premium brand of high-quality, clean diesel fuel. Low
cost, inferior fuel can lead to poor performance and
expensive engine repair.
Note: Use only diesel fuel designed for diesel engines.
Some heating fuels contain harmful chemicals that can
seriously affect engine efficiency and performance.
Due to the precise tolerances of diesel injection systems,
keep the fuel clean and free of dirt and water. Dirt and
water in the fuel system can cause severe damage to
both the injection pump and the injection nozzles. The
preferred fuel is ASTM #2 diesel fuel with a minimum
Cetane rating of 40. #2 diesel fuel gives the best fuel
economy and performance under most operating
conditions. Fuels with Cetane ratings higher than 40 may
be needed in higher altitudes or extremely low ambient
temperatures to prevent misfiring and excessive smoke.
• When operating at temperatures above 32° F
(0° C), use standard #2 diesel fuel.
• When operating at temperatures below 32° F
(0° C), use a blend of #1 & #2 diesel fuels,
most commonly known as “winterized” #2
diesel.

6
2
9 4
5
3
7
PH28502

7B.8.2 Fuel/Hydraulic Oil Tank 5. Remove fuel drain plug (2), and drain fuel into an
approved and suitable container. Dispose of fuel
Note: The fuel/hydraulic oil tank is part of a one piece unit
properly.
divided into a two compartment (tank) unit. It is located on
the right side of the vehicle, across from the operator’s 6. Remove hydraulic oil drain plug (3), and drain
cab. If it is determined that either the fuel or hydraulic oil tank hydraulic oil into an approved and suitable container.
must be removed, both the fuel and hydraulic oil must be Dispose of oil properly.
drained before tank removal. Always dispose of hydraulic 7. Disconnect the hydraulic oil temperature sensor
oil or fuel properly. connector (4), from the engine harness connector,
and remove from tank (5).
8. Loosen the clamps (6) and disconnect the fuel
WARNING: Explosion and fire hazard. supply hose (7) and return line hose (8) from tank.
Cap or safely cover the fuel/hydraulic oil tank 9. Remove the fuel line fittings (9) from tank.
fittings before removing tank.
10. Loosen clamp (10) and disconnect the lower
hydraulic oil strainer hose (11) from hydraulic fuel
strainer (12). Cap hose.
a. Fuel/Hydraulic Oil Tank Removal
11. Remove the hydraulic fuel strainer (12) from tank (5).
12. Disconnect and cap the hydraulic return hose (13)
and remove lower tank fitting (14).
can cause cracks in the engine block. 13. Remove capscrews securing the hydraulic fluid level
sight-glass (15) from tank.
2. Disconnect the negative (-) battery cables (1) from the
batteries. 14. Disconnect upper hydraulic hoses (16 and 17) from
the t-fittng (18) and cap hoses.
15. Remove the t-fittng (18) from tank.
16. Disconnect fuel level sender electrical connectors
(19) from the engine harness.
17. Remove screws (20) securing fuel sender (21) to the
tank. Remove fuel sender from tank.
18. Remove elastic nuts (22) securing the hydraulic oil
1
filter (23) to the tank. Remove filter and gasket (24)
from tank.
19. Remove plug (25) from top of tank.
MH4440 20. Remove elastic nuts (26) securing hydraulic oiler
filler neck components (27) and remove
components.
3. Remove the fuel/hydraulic oil tank top cover from tank.
21. Remove elastic nuts (28) securing fuel filler neck
Refer to Section 4.7, “Access Panels and Covers.”
components (29) and remove components.
4. Remove the two frame top covers from above the frame.
22. Position and connect a suitable chain support to tank
Refer to Section 4.7, “Access Panels and Covers.”
lifting point (30) and take up slack in the chain.
Note: If replacing the tank, remove all internal and 23. While supporting the tank, remove hex nuts (31) and
external components from the old tank, and retain for lockwashers (32) securing the tank to vehicle frame.
use on the replacement tank. Pull tank away from the tank carriage bolts (33), and
Note: Have a dry chemical (Class B) fire extinguisher remove tank. Retain hardware for reuse.
near the work area.

20
19 22
21
28 27
26
29 23 15
24 25
30 17
18
16
31
3
32 13
14
9
4
33 6
7
12 11
10
2 8
MH4270

b. Disassembly d. Inspection
Note: If a leak is suspected between the fuel and hydraulic
DANGER: NEVER weld in, on, near or oil tank, contact JLG Service Department at:
around the fuel/hydraulic oil reservoir. Fuel and Domestic: 1-877-554-5438
hydraulic fluid and fumes can cause the reservoir International: 1-717-485-6657
to explode. This can result in death or serious
Note: Inspect the fuel/hydraulic oil tank thoroughly for
personal injury.
any cracks, slices, leaks or other damage.
The fuel/hydraulic oil reservoir is a one-piece unit and With the fuel/hydraulic oil tank removed from the vehicle,
cannot be disassembled. The fuel level indicator and plug all openings except one elbow fitting. Install the
hydraulic filters can be removed and reused on the new elbow fitting, and apply approximately 1-1.5 psi (7-10
replacement reservoir. Dispose of the old reservoir kPa) of air pressure through the elbow. Check the tank for
according to local regulations concerning hazardous leaks by applying a soap solution to the exterior and look
materials disposal. for bubbles to appear at the cracked or damaged area.
c. Cleaning and Drying e. Assembly
If contaminated fuel, hydraulic oil or foreign material is in The fuel/hydraulic oil reservoir is a one piece-unit and
the tank, the tank can usually be cleaned. cannot be disassembled. The fuel level indicator and
hydraulic filters can be removed and reused on the new
Note: If a leak is suspected between the fuel and hydraulic replacement tank. Dispose of the old tank according to
oil tank, contact JLG Service Department at: local regulations concerning hazardous materials disposal
Domestic: 1-877-554-5438 regulations.
International: 1-717-485-6657
f. Fuel/Hydraulic Oil Tank Installation
To clean the fuel/hydraulic oil tank:
1. Attach the tank (1) to a suitable lifting device at the
1. Have a dry chemical (Class B) fire extinguisher near
lift point (2).
the work area
. 2. Place the tank carriage bolts (3) into the slotted
WARNING: NEVER drain or store fuel in
holes in frame.
an open container due to the possibility of 3. Position the tank (1) and insert carriage bolts (3)
explosion or fire. Discard the fuel in an approved through tank attachment holes. Install
manner. lockwashers (4) and finger tighten hex nuts (5) onto
carriage bolts. Slide tank and carriage bolts toward
2. Depending on which side of the tank is contaminated the front of vehicle, until carriage bolts are bottomed
(fuel or hydraulic oil), remove the fuel or oil tank out into the slotted frame holes.
drain plug, and safely drain any fuel or hydraulic oil
4. Install plugs (6, 7 and 8) using new gaskets.
into a suitable container. Dispose of fuel or hydraulic
oil properly. 5. Install the hydraulic oil temperature sensor (9) in the
tank and connect to the engine harness connector.
3. Clean the fuel/hydraulic oil tank with a high-pressure
washer, or flush the tank with hot water for five 6. Install the fuel line fittings (10) in the tank.
minutes and drain the water. Dispose of 7. Install the fuel supply (11) and return line (12) hoses
contaminated water properly. to the fuel tank. Secure with clamps (13).
4. For the fuel tank side, add a diesel fuel emulsifying 8. Install the hydraulic fuel strainer (14) in the tank.
agent to the tank. Refer to the manufacturer’s
9. Connect the lower hydraulic oil strainer hose (15) to
instructions for the correct emulsifying agent-to-
the strainer (14) and secure using clamp (16).
water mixture ratio. Refill the tank with water, and
agitate the mixture for 10 minutes. Drain the tank 10. Install lower tank fitting (17) and connect hydraulic
completely. Dispose of contaminated water properly. return hose fitting (18).
5. Refill the fuel tank with water until it overflows. 11. Install the hydraulic fluid level sight-glass (19) using
Completely flush the tank with water. Empty the fuel special designed and drilled capscrews and gaskets.
tank, and allow it to dry completely. 12. Connect the t-fitting (20) to the tank.

25
23 28
24
29 30 26
32
31 27
6 19
2 22
20
21
5 18
7
14
4
17
10
9
3 13
11
15
16
8 12
MH4270
13. Connect upper hydraulic hoses (21 and 22) to the 19. Fill fuel tank with No. 2 D fuel. Fill the hydraulic tank
t-fitting. with ISO-46 hydraulic oil.
14. Attach fuel level sender harness connectors (23) to 20. Check fuel and hydraulic oil tanks for leaks.
the sending unit (24). 21. Connect the negative (-) battery cables (33) to the
15. Install the fuel sender with new gasket (24) into the batteries.
fuel tank and secure with screws (25). DO NOT
overtighten.
16. Install hydraulic oil filter (26) and gasket (27) and
secure using new elastic nuts (28).
17. Install hydraulic filler neck components (29) and
secure using new elastic locknuts (30). 33
18. Install fuel filler neck components (31) and secure
MH4440
using new elastic locknuts (32).

7B.8.3 Fuel Level Sender and Gauge b. Cleaning and Drying

The fuel level sender and gauge assembly is described in Clean the exterior of the pump with mineral spirits, and
Section 9.14.15, “Fuel Level Indicator and Fuel Level blow dry with compressed air.
Sender.”
Note: Parts replacement is not practical. The fuel lift
pump is serviced as an entire assembly.
7B.8.4 Fuel Lift Pump Inspection and Testing
1. To test the diaphragm, remove the fuel inlet line (1) c. Fuel Lift Pump Installation
from the fuel lift pump (2). Block the fuel inlet with a
1. Clean the mounting surface on the cylinder block.
finger and operate the hand plunger (3). A properly
operating pump will provide suction that will remain 2. Install the fuel lift pump (2) with a new gasket. Install and
until the finger is removed from the inlet. torque the capscrews (5) to 18 lb-ft (24 Nm).
3. Connect the fuel line (1). Vent air from fuel system.
Refer to appropriate Owners/Operators Manual.
4 4. Connect the negative (-) battery cables (6) to the
batteries.
7B.8.5 Fuel Filter

your vehicle for the correct fuel filter (4) removal procedure.
7B.8.6 Venting Air from the Fuel System

your vehicle for the correct fuel system venting procedure.
7B.8.7 Fuel Injectors

5 2 3 1 MH4660 The engine uses Bosch 17-mm, closed nozzle, hole-type
injectors. The injectors have different part numbers for
different engine ratings. The last four digits of the Cummins
a. Fuel Lift Pump Removal part number (stamped on the bottom portion of the
injector) identify the injector.
batteries. IMPORTANT: Use only the specified injector for the engine.
Damage to the engine can occur if incorrect injectors are
used.
During the injection cycle, high pressure from the
injection pump rises to the operating (or “pop”) pressure,
which causes the needle valve in the injector to lift. Fuel
is then injected into the cylinder. A shimmed spring is
used to force the needle valve closed as the injection
6 pressure drops below the pop pressure to seal off the
nozzle after injection.
Failure of the needle valve to lift and to close at the
MH4440
correct time, or a needle valve that is stuck open, can
cause the engine to misfire and produce low power. Fuel
2. Clean debris from around the fuel lift pump (2).
leaking from the open nozzle can cause a fuel knock,
3. Disconnect the fuel inlet line (1). poor performance, smoke, poor fuel economy and rough
4. Remove the capscrews (5), gasket and fuel lift running.
pump (2).

a. Locating Faulty Fuel Injectors 5. Operate the starter to turn the engine over until fuel
sprays from the nozzle. Examine the shape of the
A faulty fuel injector can cause:
spray. If the spray is unduly “wet” or “streaky,” or
• Misfiring obviously sprays to one side, or if the nozzle
• Knocking “dribbles” fuel, it may only be necessary to probe the
• Overheating nozzle holes to remove blockage.
• Loss of power
IMPORTANT: DO NOT attempt to adjust injection
• Smoky (black) exhaust
pressure without a testing pump and pressure gauge. It
• Increased fuel consumption
is not possible to accurately adjust the setting of fuel
The particular faulty fuel injector(s) may be determined by injectors without the proper equipment.
releasing the pipe union nut on each fuel injector in turn,
A perfect fuel injector, when tested by pumping fuel through
with the engine running at a fast “tick-over.” If, after
it in the open air, gives a short “pinging” sound as the fuel
slackening a pipe union nut, the engine revolutions
emerges from the holes. After the fuel injector has been
remain constant, a faulty fuel injector has been identified.
in service for some time, the pinging changes to a
To test a fuel injector: crackling sound. It is not until the fuel injector sounds
1. Remove the fuel injector (7) from the cylinder head. “dead” that its condition is likely to affect the running of the
engine.
2. Refer to Section 7B.8.7, b. “Injector Replacement.”
b. Injector Replacement
Preparatory steps:
1. Thoroughly clean around the injector(s).
7
2. Disconnect the high-pressure fuel lines (8).
3. Disconnect the fuel drain manifold (9).
MA1960
3. Invert the fuel injector, with the nozzle facing out,

then retighten the unions.
4. Loosen the unions of the other fuel injector pipes (to
help avoid the possibility of the engine starting).
WARNING: Diesel fuel under pressure

can penetrate the skin and cause serious
personal injury. Slowly loosen fittings, and allow
release of residual pressure before removing.
MT3160

IMPORTANT: The injector must not rotate in the bore of

the cylinder head, or damage to the cylinder head will 6
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.
4. Use a 16-mm wrench to prevent the injector body (1) 7
from turning. Loosen the hold-down nut (2) with a
24-mm box wrench.
2
1
MT3160
5
15. Install the high-pressure fuel lines (6) and torque to
18 lb-ft (24 Nm).
3
MA1960 16. Run the engine and check for fuel and air leakage.
17. Bleed the fuel system in accordance with the
5. Clean the injector nozzle bore.
instructions found in the appropriate owners/
6. Remove the injector hold-down nut from the injector operators manual.
body.
7. Apply a light coat of anti-seize compound to the new 7B.8.8 After Fuel System Service
injector surface. Avoid getting anti-seize compound 1. Drain and flush the fuel tank if it was contaminated.
into the fuel drain hole.
2. Vent air from the fuel system in accordance with the
8. Install the hold-down nut on the injector body. instructions found in the appropriate owners/
9. Install a new o-ring into the recessed groove in the operators manual.
top of the hold-down nut. Make sure the o-ring is not 3. Fill the fuel tank with fresh, clean diesel fuel as required.
cut or twisted during installation.
10. Apply a light coat of anti-seize compound to the
threads of the injector hold-down nut.
11. Assemble the injector and new copper washer (3).
Use only ONE copper washer. A light coat of clean
15W40 engine oil placed between the washer and
the injector will help keep the washer from falling
during installation.
12. Install the injector with the protrusion (4) on the side
of the nozzle fitting into the notch (5) in the head.
13. Tighten the hold-down nut (2) and torque to 44 lb-ft
(60 Nm).
14. Install the fuel drain manifold (7) and torque to 6 lb-ft
(8 Nm).

7B.9 ENGINE EXHAUST SYSTEM 7B.9.1 Exhaust System Removal

WARNING: Exhaust fumes contain travel select lever in NEUTRAL (N) and engage the
carbon monoxide, a colorless, odorless gas
which is fatal when inhaled in a confined area. and shut off the engine.
Avoid breathing exhaust fumes, and prevent 2. Remove the ignition key. Secure accident prevention
engine operation from becoming a cause of tags to the steering wheel and ignition key switch.
toxic emissions. Exhaust system components (Refer to Section 1.5, “Accident Prevention Tags.”
reach high temperatures and can cause
severe burns. DO NOT come into contact with
hot exhaust system components.
WARNING: To avoid severe burns, DO
NOT attempt to remove the engine when the
The exhaust system is supported by the engine and the
are hot. Wait until all parts and systems are
vehicle frame, and helps minimize the transfer of noise
and vibration into the operator’s cab. The tail pipe directs
exhaust fumes to the right side of the vehicle, away from 3. Unlock, unlatch and open the engine doors. Allow
the cab. the engine to cool before proceeding.
Annoying rattles and noise vibrations in the exhaust 4. Disconnect the negative (-) battery cables (8) from the
system are usually caused by misalignment of parts. batteries.
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.
When replacing the muffler, also replace the tail pipe.
Before assembling components, use exhaust system
sealer at all slip joint connections.
When installing exhaust system components, allow 8
sufficient clearance between the components and other
vehicle pipes, hoses and wiring that could be adversely
affected by excessive heat. MH4440
When installing an exhaust system, provide for parts

expansion when the system is hot.
Whenever performing service on the vehicle, check the
condition of the exhaust system. Check the entire exhaust
system for broken, damaged, missing or improperly
aligned parts, open seams, holes, loose connections and
other deterioration which could permit exhaust fumes to
seep into the operator’s cab. Correct any damaged areas
immediately.

5. Disconnect and remove the clamp (1) supporting the 5. Tighten all clamps.
tail pipe (2), from the tail pipe support bracket (3). 6. Connect the negative (-) battery cables (10) to the
6. Disconnect and remove the clamp (4) attaching the batteries.
muffler (5) to the muffler mounting bracket (6) and
exhaust pipe (7), and remove the muffler from the
muffler mounting bracket.
8
Rear of vehicle 10
12
MH4440
7
7. Start engine and check for exhaust leaks at all
exhaust connections. Adjust or repair as needed.
3
9
7B.10 AIR CLEANER ASSEMBLY

If a replacement engine is being installed into the vehicle,
2
the air cleaner assembly must be transferred to the new
engine.
6
The air cleaner assembly should be transferred to the
replacement engine after the used engine is removed
1 from the vehicle.
4
5
MH4600
CAUTION: NEVER run the engine with
only the inner safety element installed.
IMPORTANT: Before transferring the air cleaner

7. Disconnect and remove the V-band clamp (8) from
assembly to the new engine, remove the elements and
the exhaust pipe (7) and remove the exhaust pipe.
clean the inside and outside of the air cleaner canister.
8. Disconnect and remove the muffler mounting bracket Replace the outer primary and inner safety elements.
(6) and tail pipe support bracket (3) from the rear Refer to the appropriate Owners/Operators Manual for
engine mount (9). your vehicle for the correct element change procedure.
7B.10.1 Air Cleaner Assembly Removal

7B.9.2 Exhaust System Installation 1. Remove the T-bolt band clamp (11) securing the air
Note: Keep all clamps loosened until entire exhaust scoop (12) to the air cleaner assembly (13).
system is in place.
1. Install the muffler mounting bracket (6) and tail pipe
support bracket (3) to the rear engine mount (9).
2. Install the V-band clamp (8) to the exhaust pipe (7)
3. Secure the tail pipe (2) with the clamp (1) to the tail
pipe support bracket (3).
4. Attach the muffler (5) to the muffler mounting bracket
(6) and exhaust pipe (7) with the clamp (4).

7B.11 ENGINE REPLACEMENT

12
7B.11.1 Engine Removal
13
11 14 WARNING: To avoid severe burns, DO
NOT attempt to remove the engine when the
18 are hot. Wait until all parts and systems are
16 15 cool before proceeding.
14 Note: The radiator and oil cooler must be removed from
17 the vehicle before engine removal. Refer to Section
7B.6.4, a. “Oil Coolers and Radiator Removal.” Several
19 additional components must be removed before engine
removal. They will be addressed in the following procedures.
MH5200 travel select lever in NEUTRAL (N), and engage the
21
20
2. Remove the T-bolt clamps (14) securing the tags to the steering wheel and ignition key switch.
hose (15) to the air cleaner assembly (13). Refer to Section 1.5, “Accident Prevention Tags.”
3. Remove capscrews (16) and lockwashers (17) 3. Disconnect the battery negative (-) ground cables
securing the band (18) to the air cleaner (22) and positive (+) battery cables (23) from the
bracket (19). Remove the air cleaner assembly (13). batteries (24).
4. Remove the capscrews (20) and lockwashers (21), 4. Remove the battery hold-down nuts (25), threaded
securing the air cleaner mounting bracket (19) to the hold-down rods (26), and hold-down bracket (27).
engine. Remove batteries (24) from the vehicle. Store
batteries in a cool dry area.
7B.10.2 Air Cleaner Assembly Installation
Note: Apply Loctite® 242 threadlock (Red) compound to
the capscrew threads before installation.
25
5. Secure the air cleaner mounting bracket (19) to the
engine using capscrews (20) and lockwashers (21).
6. Secure the band (18) to the air cleaner bracket (19).
using capscrews (16) and lockwashers (17).
7. Install the air cleaner assembly (13).
22 22
8. Install the T-bolt clamps (14) to secure the hose (15)
to the air cleaner assembly (13).
9. Install the T-bolt band clamp (11) to secure the air
scoop (12) to the air cleaner assembly (13). 23 27 26 23
24 24
10. Tighten all clamps. MH4210
5. With the help of at least one assistant, remove the

rear engine door. Refer to Section 4.7.1, “Access
Panel and Cover Replacement.”

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

MH5660
installed to ensure correct installation later.
7. Label and disconnect the alternator wires: 9. At the negative starter stud (13), label and
• AG1 and AG2 from G terminal (6) disconnect the negative (-) battery cable (14).
• AB1 and AB2 from B terminal (7) 10. Remove the engine ground buss bar (15) from the
• 38 and 6 from D terminal (8) engine block. Leave the wires (16) connected to the
engine ground buss bar.
11. For jump start protection, a protective plastic
cover (17) is installed around the starter solenoid
terminal and mounting screw. A removable, tethered
cap (18) allows access to the terminal mounting
screw.
19
MH5670
17
6 8 7
8. At the positive starter stud (9), label and disconnect

the positive (+) battery cable (10) and starter positive
buss bar (11). Leave the wires (12) connected to the
starter positive buss bar. 20 18 MU1351

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. Label and remove oil pressure switch lead (21).

18. Label and remove the diagnostic system ground
wire (22) at the buss bar (23).
17
22
23
MH49102
15. Label and disconnect the back-up alarm harness

connector (18) from the back-up alarm (19). Refer to
Section 9.11.2, “Back-up Alarm.”
21 MH5210
19
18
MH5250
16. Label and disconnect the engine coolant temperature

switch lead (20). Refer to Section 9.14.12, “Engine
Coolant High Temperature Sender.”

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).”
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.
securing the flange yoke (12) to the engine.
MS16902
25. Remove the drive shaft assembly (9) from engine.
20. Disconnect the wire harness connectors (2 and 3)
from the Engine Control Module (ECM) (4) at the To Engine
engine. 11
10
12
9
2
3
4
MH4540
21. 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.
22. Disconnect the fuel inlet line (5) at the fuel lift
pump (6). Install a plug in the end of fuel inlet line
and cap the fitting on the lift pump.

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 30
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 21
14) to the air conditioning compressor (15).
31
13 20
15
16
32
23
18
14 19
17
22 27
25 24
MH4760 28
26 29
MH5260
Note: Always discard used elastic locknuts and install
new elastic locknuts. 30. Place engine on a flat, level surface.
26. At the front right engine mount (16) remove the 31. If replacing the engine, attach a lifting chain to the
elastic locknut (17), rebound washer (18), engine front (30) and rear (31) engine lift brackets, and lift
isolator (19) and capscrew (20). Repeat for the front engine clear of the ground.
left engine mount (21).
32. Remove the right (16), and left (21) front engine
27. At the rear engine mount (22), remove the elastic mounting brackets, and muffler bracket (32).
locknut (23), engine isolator (24), rebound washer
(25) and capscrew (26). 7B.11.2 Engine Disassembly, Inspection and
28. At the exhaust pipe bracket (27), remove the Service
capscrews (28) and lockwashers (29). Remove Engine disassembly, internal inspection, service, repair
exhaust pipe bracket. and assembly procedures are covered in the Cummins
29. Position a fork truck behind the vehicle, and drive QSB4.5T service manual. Several special engine service
forward, placing the forks underneath the rear engine tools are required to properly service the Cummins engine.
mount (22) and front engine mount brackets (16 and Contact the local Cummins parts distributor for further
21). Slightly lift the engine, and slowly back engine out information.
of the vehicle. Have an assistant ensure that the Note: If the engine is being replaced, there may be external
engine clears all frame components during removal. components that will be required to be transferred from the
original engine to the replacement engine depending upon
who you purchase the new engine from and the
configuration of your replacement engine. Refer to the
appropriate Cummins user manual for detailed procedures
that cover the transfer of original engine components to the
replacement engine.

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 6
various places on the engine using hold-down clamps
and plastic wire ties. Before installing engine and with 1
15
the help of an observer, ensure that engine clears the
harness during installation.
1. If replacing the engine, attach a lifting chain to the front
(1) and rear (2) engine lift brackets, and lift engine
8
clear of the ground. 5
4
Note: Apply Loctite® 242 threadlock (Red) compound to 11
the engine mount bracket capscrew threads before 17
16
installation.
1. Inspect the rear engine mounting bracket isolator 18
(3). Replace isolator if cracked or worn. 7 12
2. Install the muffler bracket (4), right (5) and left (6)
front engine mounting brackets to the engine. 10 3
3. Place engine on a flat, level surface. 13
9 14
4. Position a fork truck behind the engine, and drive
MH5260
forward, placing the forks underneath the rear
engine mount (7) and front right (5) and left (6)
8. Install the radiator overflow tube (19), and overflow
engine mount brackets. Lift the engine and slowly
tank (20), hose support (21), flat washer (22) and
drive it into the back of the vehicle. Have an assistant
new elastic locknuts (23).
ensure that the engine clears all frame, hose and
harness components during engine installation.
Position engine brackets over rear and front frame
mounts (8).
5. At the rear engine mount (7), install the capscrew
(9), rebound washer (10), engine isolator (3) and
new elastic locknut (11).
6. Install the right side exhaust pipe mount bracket
(12), capscrews (13) and lockwashers (14) to the
rear engine mount (7). 19
7. Secure the front right engine mount (5) using
capscrew (15), engine isolator (16), rebound washer 22
(17), and new elastic locknut (18). Repeat for the 20
front left engine mount (6).
21 23
MH4730

26 To Engine
25
32
27
24
9. Raise the drive shaft assembly (24) into position.

The slip-yoke end of the drive shaft mounts toward
MS16902
the engine. If reinstalling a drive shaft previously
removed, align the flange yokes according to the 14. Connect the wiring harness connectors (33 and 34)
alignment marks made during removal. to the Engine Control Module (ECM) (35) on the
IMPORTANT: Yokes at both ends of the drive shaft must engine.
Note: If installing a new drive shaft unit, special attention
need not be applied to installation. New drive shaft units
are balanced at the factory.
10. At the drive shaft (24), install the capscrews (25) and
lockwashers (26), securing the flange yoke (27) to
the engine. Torque to 105 ±10 lb-ft (142 ±14 Nm).
33
11. Connect the fuel inlet line (28) to the fuel lift pump
(29). 34
12. Connect the fuel return line (30) at the injector pump 35
(31).
MH4540
31
30
28
29 MH4660
13. Connect the fuel shut-off solenoid harness

connector (32) to the fuel shut-off solenoid. Refer to
Section 9.14.2, “Fuel Shut-off Solenoid
(SN 8042, 13198 - 18990, 10042, 13198 - 19030,
10054, 13198 - 19079).”

15. Connect the engine coolant temperature switch lead

(1). 5
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)

3 from the back-up alarm (8).
4 8
2 MH5210
MH5250
18. Install the locknuts and washers (5) that secure the
coldstart grid heater (6) to the frame studs.

20. Insert the fork terminal of the blue wire (8) into the 24. At the positive starter stud (9), connect the positive
protective cover (9) on the starter solenoid terminal. (+) battery cable (10) and starter positive buss
Use a small phillips screwdriver to tighten the bar (11) with the wires (12) still attached to the bar.
screw (10) securely. 25. Label and disconnect the alternator wires:
21. Snap the tethered cap back in place over the screw • AG1 and AG2 from G terminal (6)
in the protective cover.
• AB1 and AB2 from B terminal (7)
• 38 and 6 from D terminal (8)
10
8
9
MU6190
22. On the engine block, connect the engine ground buss

MH5670
bar (15) with the wires (16) still attached to the bar.
23. At the negative starter stud (13), connect the 6 8 7
negative (-) battery cable (14).
26. Install the exhaust system to the engine. Refer to
Section 7B.9.2, “Exhaust System Installation.”
27. Install the air cleaner assembly on the engine. Refer
9 to Section 7B.10.2, “Air Cleaner Assembly
Installation.”
13 28. Install the radiator and oil cooler. Refer to Section

11 7B.6.4, “Radiator/Hydraulic and Transmission Cooler
15 Replacement.”
12
29. Install the rear engine access door with the help of at
least one assistant. Refer to Section 4.7.1, “Access
Panel and Cover Replacement.”
16
10
14
MH5660

30. Install the batteries (1), hold-down bracket (2), 40. Check for proper operation of all components.
threaded hold-down rods (3) and hold-down nuts (4). 41. Turn the engine OFF.
negative (-) battery cables (6) to the batteries (1). 7B.12 ENGINE COUPLER
7B.12.1 Coupler and Drive Shaft Removal

4
travel select lever in NEUTRAL (N), and engage the
6 tags to the steering wheel and ignition key switch.
6
batteries.
5 2 3 5
1 1 MH4210 Note: Rotating the fan belt by hand, gives greater
access to removing the drive shaft mounting
32. Check that all hydraulic system, electrical system, capscrews (7).
cooling system, fuel system, and exhaust system 1. Remove the capscrews (8) and straps (9) that
connections are correct and connected tightly. secure the drive shaft (10) to the transmission yoke
33. Have an assistant stand by with a Class B fire (11). Discard both straps and capscrews.
extinguisher. Start and idle the engine. 2. Remove the capscrews and lockwashers (7)
34. Run engine to normal operating temperature. Visually securing the drive shaft (10) to the coupling flange
check for leaks with the engine running. Check the (12).
coolant level in the overflow bottle and fill or drain as
Note: It may be necessary to loosen/remove the motor
necessary.
mounts (20) on either side of the engine to gain access
35. Shut off the engine to the bottom capscrews (13) on the outer half of the
36. Allow the engine to cool. Check the radiator coolant coupler (14). Place a jack under the bell housing (use a
level and top off with a 50/50 mixture of ethylene wood block to support engine) and carefully lift the
glycol and water.Allow engine until the bottom edge of the bell housing is at the
top edge of the frame member that mounts the rear axle
37. Check for leaks from the engine, main hydraulic pump
to the frame. Watch the fan-to-radiator clearance as you
and lines, transmission, hydraulic reservoir and fuel
are lifting the engine. If necessary, turn the fan slightly,
tank. Check the levels of all fluids and lubricants. Fill
by hand, to gain additional clearance.
as required.
IMPORTANT: During the full throttle check:
12
• DO NOT steer or apply any pressure to the
steering wheel.
7
• Keep the transmission in NEUTRAL (N).
38. Obtain and connect an appropriate engine analyzer 10
or tachometer. Check the engine rpm at full throttle.
If the rpm is not 2550-2650 rpm, readjust the throttle 11
limit-stop screw at the throttle pedal within the cab. 8 14
Refer to Section 4.3.5, c. “Throttle Adjustment.” 13
9 MH5410
boom functions through their entire range of motion 3. Remove the capscrews and lockwashers (13)
several times. Check the hydraulic oil level. securing the outer half of the coupler (14).

4. Remove the capscrews (15) securing the small 7B.12.2 Coupler and Drive Shaft Installation
access cover (16).
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
SH3060
side, to install.
5. Remove the capscrews and locknuts (17) securing locknuts to help ensure proper fastening.
the coupler (18) to the flywheel. Turn the engine by 2. Place the new coupler (21) into the indentation of the
hand, using the fan belt, until the capscrews line up flywheel and use new Grade 8 capscrews and
with the access hole (16). locknuts (22) to secure the coupler to the flywheel.
19
17
18
20
SH1120
6. At this time, use a suitable cleaner/solvent and

thoroughly clean the mounting lip of the flywheel.
Wipe any debris from the inside of the bell housing.

3. Insert one capscrew into the access hole (1) on the 6. Install the small access cover plate (1), to the right
rear right side of the bell housing and through the side of the engine and tighten the hardware securely.
flywheel and coupler. Assemble a new elastic
Note: Before assembling the drive shaft (3) to the
locknut onto the capscrew. DO NOT fully tighten at
coupling (4); be sure the access cover plate (6) is placed
this time.
on the engine-side of the frame member that mounts the
rear axle to the frame.
Note: Apply Loctite® 242 threadlock (Red) compound
to all of the capscrews used during assembly.
1 7. Install the access cover plate (6) over the drive
shaft (3) and assemble the drive shaft flange (7) to
the coupler (4) using new Grade 8 capscrews and
lockwashers (8). Torque to 48 lb-ft (65 Nm).
7 6
5
3
10 4
8
SH3060
12
4. Turn the flywheel 180° and insert another capscrew 9
11 SH3090
and assemble with another new elastic locknut.
DO NOT fully tighten until all of the capscrews and
locknuts are in place.
8. Install the access cover plate (6) to the engine bell
5. After all the capscrews are in place, check to be sure housing (9) with capscrews and lockwashers (10)
the coupler is resting squarely in the indentation of Torque to 37 lb-ft (48 Nm).
the flywheel (2). Torque all the capscrews to 37 lb-ft
(48 Nm). Note: ALWAYS replace elastic locknuts with new elastic
9. If engine mounts (13) were previously removed or
loosened, carefully lower the engine down onto the
front engine mounts. Reassemble the rebound
washer (14) and secure in place with a new elastic
locknut (15). Torque to 60 lb-ft (81 Nm). Repeat this
procedure for the engine mount on the other side.
SH1100

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. When using a preservative fuel, drain the fuel
system and fill with the preservative fuel. When not
using preservative fuel, keep the fuel system
charged with regular fuel, which, along with the fuel
14
filter, will have to be drained and discarded at the
15 end of the storage period.
SH4000
3. Run the engine to operating temperature. Correct
any fuel, fluid, oil or air leaks. Stop the engine, and
10. Thoroughly clean the transmission yoke (12) and drain the oil.
secure in place with new straps (12) and
4. Replace the oil filter.
capscrews (13) from the kit. Torque to 55-60 lb-ft
(75-81 Nm). 5. Fill the crankcase (sump) to the FULL mark on the
dipstick with new, clean oil or with an approved
11. After the drive shaft is in place, grease both u-joints
preservative fluid. If a preservative fluid is used, it
and the slip joint using multi-purpose grease (MPG).
must be drained and replaced with regular
12. Connect the negative (-) battery cables (16) to the lubricating oil before the engine is returned to
batteries. service.
6. Drain the cooling system. To provide protection
against corrosion, fill the cooling system with a
coolant containing a corrosion inhibitor. If frost
protection is needed, use the appropriate mixture of
anti-freeze and water. If frost protection is not
required, use an appropriate mixture of water with an
approved corrosion mixture.
16
12
MH4440

7. Run the engine for a short period to distribute 12. Disconnect the battery and store it safely, in a fully
lubricating oil and coolant throughout the engine. charged condition. Before the battery is put into
8. Clean out the engine breather pipe (where fitted) storage, give the battery terminals a protection
and seal the end of the pipe. against corrosion with a light coating of dielectric
grease or petroleum jelly.
9. Remove the fuel injectors and spray clean engine
lubricating oil into cylinder bores. Divide four ounces 13. Seal the vent pipe of the fuel tank or the fuel filler
(118,3 ml) of lubricating oil evenly between the four cap with waterproof tape.
cylinders. 14. Remove and store the fan drive belt.
10. Remove the air filter and any pipe installed between Note: Before starting the engine after storage, operate
the air filter and the induction manifold. Seal the the starter motor with one of the fuel shut-off solenoid
manifold with waterproof tape. wires disconnected for 15 seconds or until the dash
11. Remove the exhaust pipe. Seal the manifold with panel low oil pressure warning indicator goes out. This
waterproof tape. will allow oil to be circulated throughout the engine to
prevent damage to internal components.
7B.14 TROUBLESHOOTING
Trouble Possible Causes (see key)
Low Cranking Power 1, 2, 3, 4

Will Not Start 5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 31, 32, 33
Difficult Starting 5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 29, 31, 32, 33, 61, 63
Lack of Power 8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 31, 32, 33, 61, 63
Misfiring 8, 9, 10, 12, 13, 14, 16, 18, 19, 20, 25, 26, 28, 29, 30, 32
Excessive Fuel Consumption 11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33, 63
Black Exhaust 11, 13, 14, 16, 18, 19, 20, 22, 24, 25, 27, 28, 29, 31, 32, 33, 61, 63
Blue/White Exhaust 4, 16, 18, 19, 20, 25, 27, 31, 33, 34, 35, 45, 56, 62
Low Oil Pressure 4, 36, 37, 38, 39, 40, 42, 43, 44, 58
Knocking 9, 14, 16, 18, 19, 22, 26, 28, 29, 31, 33, 35, 36, 45, 46, 59
Erratic Running 7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 23, 26, 28, 29, 30, 33, 35, 45, 59
Vibration 13, 14, 20, 23, 25, 26, 29, 30, 33, 45, 47, 48, 49
High Oil Pressure 4, 38, 41
Overheating 11, 13, 14, 16, 18, 19, 24, 25, 45, 50, 51, 52, 53, 54, 57
Excessive Crankcase Pressure 25, 31, 33, 34, 45, 55, 60
Poor Compression 11, 19, 25, 28, 29, 31, 32, 33, 34, 46, 59
Starts and Stops 10, 11, 12
IMPORTANT: These instructions cover only routine

troubleshooting guidelines for the engine. Refer to the
Cummins Engine Distributor and applicable Cummins
Engine Service Manual for assistance in comprehensive
engine diagnosis, repair and component replacement.

Key to Possible Causes
1. Battery charge low 21. Blocked fuel tank vent 43. Faulty suction pipe
2. Bad electrical connection 22. Incorrect grade of fuel 44. Restricted oil filter
3. Faulty starter motor 23. Sticking throttle or 45. Piston seizure/pick up
4. Incorrect grade of restricted movement 46. Incorrect piston height
lubricating oil 24. Exhaust pipe restriction 47. Damaged fan
5. Low cranking speed 25. Leaking cylinder head gasket 48. Faulty engine mounting
6. Fuel tank empty 26. Overheating 49. Incorrectly aligned flywheel
7. Faulty stop control operation 27. Cold running housing or incorrectly aligned
8. Fuel inlet restricted 28. Incorrect tappet adjustment flywheel
9. Faulty fuel lift pump 29. Sticking valves 50. Faulty thermostat
10. Clogged fuel filter 30. Incorrect high pressure pipes 51. Restriction in water jacket
11. Restricted air cleaner 31. Worn cylinder bores 52. Loose fan belt
12. Air in fuel system 32. Pitted valves and seats 53. Restricted radiator
13. Faulty fuel injection pump 33. Broken, worn or sticking 54. Faulty water pump
14. Faulty fuel injectors or piston ring(s) 55. Restricted breather pipe
incorrect type 34. Worn valve stems and guides 56. Damaged valve stem oil
15. Incorrect use of cold start 35. Restricted air cleaner deflectors (if fitted)
equipment 36. Worn or damaged bearings 57. Coolant level too low
16. Faulty cold start equipment 37. Insufficient oil in sump 58. Blocked sump strainer
17. Broken fuel injection 38. Inaccurate gauge 59. Broken valve spring
pump drive 39. Oil pump worn 60. Exhauster or vacuum pipe leak
18. Incorrect fuel pump timing 40. Pressure relief valve sticking open 61. Turbo impeller damaged or dirty
19. Incorrect valve timing 41. Pressure relief valve sticking closed 62. Turbo lubricating oil seal leak
20. Poor compression 42. Broken relief valve spring 63. Induction system leaks


Section 8
Hydraulic System
Contents

8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
8.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
8.4 Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
8.5 Hoses, Tube Lines, Fittings, Etc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
8.5.1 Replacement Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
8.5.2 Hose, Tube, Line and Fitting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
8.6 Hydraulic Pressure Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
8.6.1 Pressure Checks and Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
8.7 Hydraulic System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
8.7.1 8042 Hydraulic Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
8.7.2 10042 Hydraulic Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
8.7.3 10054 Hydraulic Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
8.8 Hydraulic Circuits and Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
8.8.1 Brake Circuit and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18
8.8.2 Boom Extend Circuit and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20
8.8.3 Boom Retract Circuit and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.22
8.8.4 Boom Lift Circuit and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.24
8.8.5 Boom Lower Circuit and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.26
8.8.6 Frame Sway (Left) and Stabilizer Circuit and Troubleshooting . . . . . . . . . . . . . . 8.28
8.8.7 Frame Sway (Right) and Stabilizer Circuit and Troubleshooting . . . . . . . . . . . . . 8.30
8.8.8 Attachment Tilt (Down) and Slave Cylinder Circuit and Troubleshooting . . . . . . 8.32
8.8.9 Attachment Tilt (Up) and Slave Cylinder Circuit and Troubleshooting . . . . . . . . 8.34
8.8.10 Pump and Cooling Circuit and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 8.36
8.8.11 Auxiliary Hydraulics Circuit and Troubleshooting (Male Coupler Pressurized) . . . 8.38
8.8.12 Auxiliary Hydraulics Circuit and Troubleshooting (Female Coupler Pressurized) . . . 8.40
8.8.13 Outrigger Circuit (Up) and Troubleshooting (10042/10054) . . . . . . . . . . . . . . . . 8.42
8.8.14 Outrigger Circuit (Down) and Troubleshooting (10042/10054) . . . . . . . . . . . . . . 8.44
8.8.15 Front-Wheel Steering Circuit (Left Turn) and Troubleshooting . . . . . . . . . . . . . . 8.46
8.8.16 Front-Wheel Steering Circuit (Right Turn) and Troubleshooting . . . . . . . . . . . . . 8.48
8.8.17 Four-Wheel Steering Circuit (Left Turn) and Troubleshooting. . . . . . . . . . . . . . . 8.50
8.8.18 Four-Wheel Steering Circuit (Right Turn) and Troubleshooting . . . . . . . . . . . . . 8.52
8.8.19 Crab Steering Circuit (Left Turn) and Troubleshooting . . . . . . . . . . . . . . . . . . . . 8.54
8.8.20 Crab Steering Circuit (Right Turn) and Troubleshooting . . . . . . . . . . . . . . . . . . . 8.56
8.8.21 Brake Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.58
8.8.22 Boom Extend/Retract Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.60
8.8.23 Boom Lift/Lower Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.60
8.8.24 Frame Sway and Stabilizer Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . 8.61
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.1

Hydraulic System
8.8.25 Attachment Tilt and Slave Circuit Description . . . . . . . . . . . . . . . . . . . . . . 8.62

8.8.26 Pump and Cooling Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.62
8.8.27 Auxiliary Hydraulics Circuit Description. . . . . . . . . . . . . . . . . . . . . . . . . . . 8.62
8.8.28 Outrigger Circuit Description (10042/10054). . . . . . . . . . . . . . . . . . . . . . . 8.63
8.8.29 Steering Circuit Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.64
8.9 Four-Wheel Steer Indexing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.67
8.10 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.68
8.10.1 Hydraulic Reservoir Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.69
8.11 Hydraulic System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.70
8.11.1 Pump Failure Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.70
8.11.2 Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.70
8.12 Valves and Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.76
8.12.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.76
8.12.2 Secondary Function Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.90
8.12.3 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.93
8.12.4 Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.97
8.12.5 Power Steering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.98
8.12.6 Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.100
8.12.7 Outrigger Valve (10042/10054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.102
8.12.8 Outrigger Shuttle Valve (10042/10054) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.105
8.12.9 Extend Lockout Valve (10054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.107
8.13 Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.110
8.13.1 General Cylinder Disassembly Instructions . . . . . . . . . . . . . . . . . . . . . . . 8.110
8.13.2 General Cylinder Cleaning Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . 8.110
8.13.3 General Cylinder Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 8.110
8.13.4 Attachment Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.111
8.13.5 Slave Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.119
8.13.6 Extend/Retract Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.123
8.13.7 Lift/Lower Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.128
8.13.8 Frame Sway Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.136
8.13.9 Stabil-TRAK Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.141
8.13.10 Outrigger Cylinders (10042/10054). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.150
8.13.11 Swing Carriage (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.160
8.13.12 Side Tilt Carriage Cylinder (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.168
8.13.13 Steering Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.175
8.2 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
8.1 HYDRAULIC COMPONENT

TERMINOLOGY
To understand the safety, operation and service
location of the hydraulic components of the vehicle. The
Slave
Lift/Lower Cylinders
Cylinders
Extend/Retract
Cylinder
Attachment Extend Lockout Valve ~
Tilt Cylinder (Model 10054 Only) ~ Oil
~ Cooler
~
Hydraulic
Hydraulic Main
Filter
Reservoir Pump
Steer Select Fill
Valve
~
Cap ~
Frame Sway
Cylinder Stabilizer
Cylinder
Secondary
~
Outriggers on Models Function

Manifold Steering
10042, 10054 Only Cylinder
Steering (Rear)
Unit Brake
~ Valve
Steering Main
Front Cylinder Control
(Front) Valve
~
Outrigger Valve
Outrigger Cylinders (Models 10042, 10054 Only)
(Models 10042, 10054 Only)
MH3440
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.3

Hydraulic System
8.2 SAFETY INFORMATION Whenever you disconnect a hydraulic line, coupler, fitting
or other component, slowly and cautiously loosen the part
WARNING:
involved. A hissing sound or slow seepage of hydraulic
DO NOT service the vehicle fluid may occur in most cases. After the hissing sound
without following all safety precautions as has ceased, continue removing the part. Any escaping oil
outlined in Section 1, “Safety Practices,” of this should be directed into an appropriate container. Cap or
manual. Failure to follow the safety practices otherwise block off the part to prevent further fluid seepage.
WARNING: Before starting the engine,
WARNING: Wait for hydraulic fluid to cool
verify that all hydraulic connections are
properly tightened. Escaping hydraulic fluid
before servicing any hydraulic component. Hot
under pressure can penetrate the skin causing
hydraulic fluid can cause severe burns.
Petroleum-based hydraulic fluids are used in this vehicle. Hydraulic system maintenance will, at times, require that
The temperature of hydraulic fluid increases during the the engine be operated. Always follow safety precautions.
operation of various hydraulic functions. A heated
petroleum-based hydraulic fluid presents a fire hazard, A major cause of hydraulic component failure is
especially when an ignition source is present. Hydraulic contamination. Keeping the hydraulic fluid as clean as
fluid has a flash point that ranges from 300-600° F possible will help avoid downtime and repairs. Sand, grit
(150-318° C) and an auto-ignition temperature of 500-750° F and other contaminants can damage the finely machined
(262-402° C). surfaces within hydraulic components. If operating in an
exceptionally dirty environment, change filters and
Accordingly, periodically inspect all hydraulic system inspect the fluid more often. When servicing the system,
components, hoses, tubes, lines, fittings, etc. Carefully cap or plug hydraulic fittings, hoses and tube assemblies.
examine any deterioration and determine whether any Plug all cylinder ports, valves and the hydraulic reservoir,
further use of the component would constitute a hazard. and pump openings until installation occurs. Protect
If in doubt, replace the component. threads from contamination and damage.
WARNING: Relieve hydraulic pressure Some hydraulic functions are actuated by interfacing with
electrical system components (switches, solenoids and
Escaping hydraulic fluid under pressure can sensors). When the hydraulic system is not functioning
penetrate the skin causing death or serious injury. properly, check the electrical aspect of the malfunctioning
circuit also. Refer to Section 9.7, “Electrical System
Operate the hydraulic controls after the engine has Troubleshooting,” in this manual.
stopped to relieve trapped pressure.
Note: Residual pressure may remain in hydraulic
cylinders, hoses, valve bodies, components, etc. If the
hydraulic lines going to or coming from a component are
taut, slowly and cautiously relieve (“bleed off”) pressure.
8.4 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
8.3 SPECIFICATIONS Contamination

Contamination, or dirt, can be any material other than
Refer to Section 2.5, “Specifications,” for hydraulic
hydraulic fluid that causes harm or decreases the
system specifications.
performance of the system. Contaminants include solids,
liquids and gases. Most contaminants are abrasive in
8.4 HYDRAULIC FLUID nature, causing rapid wear or damage to the system.
General information and specifications pertaining to Excessive heat
hydraulic fluid are found in Section 2.5.8, “Fluid and
Lubricant Capacities.” Excessive heat is a relative thermal condition that affects
fluid viscosity. Extreme operating conditions, such as
Use only clean, filtered fluid in the hydraulic system.
excessive operation, outside air temperature and other
After servicing or replacing a hydraulic system factors including aeration, cavitation, contamination and
component, cycle all vehicle functions several times to over-pressurization can cause fluid and component
remove (purge or “bleed”) air from the hydraulic system. temperatures to go beyond their specified limits.
DO NOT build maximum pressure at the end of stroke by Excessive heat causes oxidation in hydraulic fluid to
continuing to hold the joystick function. occur more rapidly, breaking down its viscosity. A chain
Inspect the hydraulic system and fluid frequently, and reaction then results and can lead to component damage
look for problems or conditions including the following: or failure. The true cause of an excessive heat condition
must be diagnosed and cured, or the problem will recur.
Aeration
Implosion
Aeration is the presence of air bubbles in hydraulic fluid.
Sudden, violent inward collapse of the air (known as An implosion is a sudden, violent inward collapse, and
implosion) can occur when compressed air bubbles are can often cause a vacuum effect. Imploding air bubbles
subjected to system pressure. Aeration can thus lead to within a hydraulic system can cause component damage.
damage and overheating of components.
Over-pressurization
Pump aeration will produce a loud crackling sound, as
though rocks or marbles were being forced through the Over-pressurization is pressure greater than that for
pump. Excessive aeration will give the hydraulic fluid a which a component was engineered to withstand or
cloudy or milky appearance, and cause erratic operation operate under. Over-pressurization can cause equipment
of hydraulic system components. damage. DO NOT attempt to adjust or tamper with
Aeration is caused by air being introduced into the pressure cartridges, settings, etc. unless otherwise
system, possibly through a leaky seal or joint in the pump specified.
or elsewhere in the system. Check for leaky hydraulic
cylinders and threaded fittings by introducing a special Viscosity
dye, visible under fluorescent light, which may be helpful Viscosity is the property of a fluid or semi-fluid that
in determining the source of the leak. enables it to develop and maintain shearing stress
dependent upon flow rate (velocity), and to offer
Cavitation continued resistance to flow. In other words, viscosity is a
Cavitation occurs when hydraulic fluid fails to entirely fill measurement of fluid resistance to flow (internal friction).
an existing space. Cavitation, like aeration, can produce
a loud crackling sound, as though rocks or marbles were
being forced through the system. Cavitation can be due
to a low hydraulic oil level in the reservoir, a restricted
intake line or improperly high fluid viscosity.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.5

Hydraulic System
8.5 HOSES, TUBE LINES, FITTINGS, ETC. 8.5.2 Hose, Tube, Line and Fitting
Replacement
There are numerous hydraulic hoses, tubes, fittings, etc.
Before removing a hydraulic hose or component, always
used on this vehicle. Periodically inspect all of these and
mark or otherwise label the related parts and the exact
carefully examine any signs of wear, abrasion and/or
location of the hose or component to aid in proper
deterioration. Determine whether any further use of the
reinstallation. Hydraulic fluid is a good cleaner and can
component would constitute a hazard. If in doubt, replace
remove most liquid-ink type markings, so make sure the
the component.
mark or label will remain intact. Alternative methods to
using markers include color-coded tie wraps, number-tag
8.5.1 Replacement Considerations sets, alpha-numeric stampings or markings, and suitably
Conditions including, but not limited to, the following are labeled pieces of tape. Select an appropriate marking
sufficient for considering component replacement: method for the conditions and proceed accordingly.
1. Any evidence of hydraulic fluid leakage at the NEVER replace a hydraulic hose or other component
surface of a flexible hose or its junction with the with a part not specifically designed for this vehicle. For
metal and couplings. example, replacing a hydraulic hose rated for use in a
2. Any blistering or abnormal deformation to the outer 3000 psi (207 bar) circuit with a common garden hose
covering of a hydraulic hose. can result in an exploded garden hose, hydraulic fluid
spray and other damage or personal injury. Use only
3. Hydraulic oil leakage at any threaded or clamped factory approved parts for best performance and safety.
joint that cannot be eliminated by normal tightening
or other recommended procedures. Removal and replacement of hoses, tube lines, fittings,
etc. usually involves straightforward procedures. When
4. Evidence of excessive abrasion or scrubbing on the removing a hydraulic hose or other component, be aware
outer surface of a hose, rigid tube, or hydraulic that o-rings are used throughout the hydraulic system.
fitting. Modification must be made to eliminate the ALWAYS replace a used o-ring with a new part.
interference of the elements in contact with one
another, or to otherwise protect the components Check all routing of hoses, wiring and tubing for sharp
from contact with one another. Slightly moving a bends or interference with any rotating members. Install
hose or adjusting a plastic tie wrap may often be all appropriate protective devices such as tie wraps and
that is necessary to eliminate interference; evaluate conduit to help shield hoses from damage. All tube and
each situation and proceed as required by the hose clamps must be tight.
individual circumstances.
8.6 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
8.6 HYDRAULIC PRESSURE DIAGNOSIS Flowmeter Kit

The flowmeter test kit (2) is used to pinpoint hydraulic
JLG Parts Department has two kits available to use for
system faults. It includes a flowmeter with load valve,
hydraulic system maintenance and troubleshooting: the
magnetic base, photo tachometer head and flex arm. The
Sky Trak Pressure Test Kit and the Sky Trak Flowmeter
kit features:
Kit. The kits are contained in a durable polyethylene
carrying case for demanding field service conditions. • Bi-directional for unrestricted connection and
simplified testing
Pressure Test Kit • Internal by-pass to protect system and tester
The hydraulic pressure test kit (1) is used to pressure test from over-pressure
the various hydraulic components in the hydraulic • Measures up to 60 GPM and 6000 psi
system. The kit includes: • 16" x 22" x 7" durable carrying case
• Gauges for testing high and low pressure circuits
• Fittings, couplers and hoses
• Laminates of test diagrams and test procedures
• 13" x 18" x 7" durable carrying case
2
PH14202
Contact JLG Parts Department at 717-485-6472 for

ordering information.
Part Description Approximate Price and
Number Weight Availability
7133413 Hydraulic Pressure Test Kit 16 lbs. Consult Factory
1321107 Hydraulic Flowmeter Kit 28 lbs. Consult Factory
PH14102
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.7

Hydraulic System
8.6.1 Pressure Checks and Adjustments 5. Fully depress the accelerator pedal as required.
Place and hold the joystick in the position needed to
When diagnosing trouble in the hydraulic system, use the
operate the particular vehicle function being
hydraulic testing information in Section 8.7, “Hydraulic
checked. Continue holding the joystick in position
System Testing.”
until pressure readings are taken.
In general, follow the steps below whenever conducting
6. Check the pressure gauge reading. It should read as
pressure checks and performing adjustments:
specified in the Pressure Readings column of the
1. Park the vehicle on a firm, level surface. Engage the charts found in Section 8.7, “Hydraulic System
park brake, place the travel select lever in (N) Testing.” If the reading is not as specified, turn the
NEUTRAL, place the neutral lock lever in the (N) engine OFF and check other components in the
NEUTRAL LOCK position, level the boom and turn system. Verify that all related hydraulic components
the engine OFF. and electrical switches, sensors, solenoids, etc. are
2. Pressure tee fittings are conveniently located in each operating correctly.
hydraulic circuit. Install a pressure gauge capable of 7. As a last resort, adjust the appropriate relief valve, if
measuring at least 10% more pressure than that applicable. Turning the adjustment screw clockwise
which the circuit being checked operates under. will increase the pressure; turning the screw
WARNING:
counterclockwise will decrease the pressure.
Avoid prolonged engine
operation in closed areas with inadequate
ventilation. Failure to properly ventilate exhaust
fumes can result in death or serious injury. ventilation. Failure to properly ventilate exhaust
3. Start the engine. Operate vehicle functions several fumes can result in death or serious injury.
times to allow hydraulic oil to reach operating 8. Start the engine and check the pressure again. Turn
temperature. The hydraulic oil temperature should the engine OFF, operate the auxiliary hydraulic
be between 100-120° F (38-49° C). If a temperature control lever (on units equipped with the optional
gauge or thermometer is unavailable, the hydraulic oil auxiliary hydraulic system), then disconnect or
reservoir should be warm to the touch. remove the pressure gauge from the vehicle.
4. Refer to Section 8.7, “Hydraulic System Testing,” for
testing procedures.
8.8 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.9

Hydraulic System
8.7 HYDRAULIC SYSTEM TESTING
8.7.1 8042 Hydraulic Testing
ATTACHMENT TILT 2a
FRONT AXLE CYLINDER AUXILIARY
9 COUPLERS
FTR FTB
FRAME SWAY
CYLINDER
E R
FRONT STEERING
CYLINDER
3a 2
BRAKE T MAIN CONTROL VALVE
VALVE P 3b 2b
LS
3
8 1
STEER
LFT/LWR
EXT/RET
SHUTTLE T
ATTACH
SELECT
FRAME
SWAY
LS
TILT
VALVE
AUX
P VALVE
PUMP T P
IN
T
RP B A
LT
POWER
STEERING
UNIT
OPERATOR'S CAB
SECONDARY
FUNCTION 5 7 6
MANIFOLD
PBG HYDRAULIC
C
PSG G RESERVOIR
T
PLT
P
PS PB
4 EXTEND/
RETRACT
R E CYLINDER
4 5
LEFT RIGHT
LIFT/LOWER LIFT/LOWER
CYLINDER CYLINDER
STABILIZER R R
CYLINDER
E E
FTR V
G
LEFT R R RIGHT
PT
SLAVE SLAVE
10 CYLINDER E E CYLINDER
REAR STEERING
CYLINDER
REAR AXLE
HYDRAULIC
OIL COOLER
MH3180
8.10 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
Engine Information Equipment Needed to Perform Tests

Idle . . . . . . . . . . . . . . . . . . . . . 1,050 ±50 rpm
Full Speed. . . . . . . . . . . . . . . 2,750 ±100 rpm
from Hydraulic Diagnostic Test Kit
Hydraulic Oil Information Test Location Gauge Fittings
Oil Type - 10W, meet ISO Grade 46 4,000 psi gauge Unit equipped with fittings from
Capacity - Reservoir . . . . . 32.2 gal. (127 liter) 2 3 4 5 (280 bar gauge) factory.
Capacity - System. . . . . . . 57.5 gal. (218 liter) Unit equipped with fittings from
1,000 psi gauge
Note: To adjust relief settings, pressure reducing 6 7 8 10 (70 bar gauge) factory.
settings or standby pressure, turn the
4,000 psi gauge Requires a male or female quick
adjustment screw clockwise to increase 9 disconnect coupler
(280 bar gauge)
pressure or counterclockwise to decrease
pressure.
CAUTION: GAUGE DAMAGE may occur. Malfunctioning hydraulic system circuits
The hydraulic oil temperature for the pump flow
may have excessive pressure and can cause hydraulic pressure spikes. Test circuit
test should be between 100-120° F (38-49° C) with the highest reading pressure gauge first. If this gauge cannot record an
(tank hot to the touch) during testing. accurate pressure reading, use the next lower pressure gauge.
TEST
LOCATION
Hydraulic Pump Flow Test
To check flow readings, a flow meter capable of measuring 60 gpm (3,8 liter/sec) and a load valve capable of
6,000 psi (413,4 bar) will be required (not included with Hydraulic Diagnostic Test Kit).
1
2,000 psi (137,8 bar) load @ Engine Speed of 2,500 ±25 rpm — Flow rate should be 48.9 GPM (3 liter/sec).
TEST ADJUST. COMPONENT PRESSURE

PRESSURE TEST PROCEDURES
LOCATION LOCATION DESCRIPTION READINGS
Pump Standby 550-600 psi Loosen load sense line at location 2b to bleed off pressure, and
Pressure (38-41 bar) then retighten line. With engine at idle and no hydraulic functions
2 2a operated, check pump standby pressure. If pressure is incorrect,
adjust top screw on compensator.
Pump Pressure 3,300 psi With engine at idle, turn steering wheel all the way in one direction.
2 N/A Compensator (228 bar) Hold over relief and check maximum pump pressure. If pressure is
incorrect, consult factory.
Main Control Valve System Relief With engine at FULL throttle, use the boom control lever to fully
3 3a 3,000 ±100 psi retract the boom. Hold over relief and check pressure. If pressure is
(207 ±7 bar) incorrect, adjust or replace cartridge.
Attachment Tilt Relief/ 3,000 ±100 psi CONSULT FACTORY
3 N/A FORWARD or (207 ±7 bar)
REARWARD
Secondary Function Load Sense With engine at idle, load sense is 0 psi.
Manifold 0-3000 psi With engine at idle, use the boom control lever to fully retract the
4 N/A (0-207 bar) boom. Hold over relief and check pressure. Pressure should be
3000 psi (207 bar).
Secondary Function Steering Relief With engine at idle, turn the steering wheel all the way in one
5 4 Manifold 2500 ±100 psi direction. Hold over relief and check pressure. If pressure is
(172 ±7 bar) incorrect, adjust or replace the pressure reducing cartridge.
Secondary Function Park Brake Release With engine at idle and no hydraulic functions operated, disengage the
6 N/A Manifold 550 ±50 psi park brake, check pressure. This is not an adjustment.
(38 ±3,4 bar)
Secondary Function Park Brake Pressure With engine at idle and park brake released, turn the steering wheel all
Manifold 550 ±50 psi the way in one direction. Hold over relief and check pressure. If
7 5 (38 ±3,4 bar) pressure is incorrect, adjust or replace the pressure reducing cartridge
in the secondary function manifold.
Brake Valve 400 psi minimum With engine OFF, pump brake pedal twice. DO NOT overstroke the
8 N/A (Manual Brake (28 bar) brake pedal. If pressure is incorrect, check for external leaks. If no
Pressure) leaks are found, refer to service manual brake system information.
Brake Valve 550 psi minimum With engine at idle, depress and hold brake pedal. DO NOT turn
8 N/A (Service Brake (38 bar) steering wheel. DO NOT overstroke the brake pedal. Check
Pressure) pressure. If pressure is incorrect, consult service manual.
Auxiliary Hydraulics 3000 psi With engine at low idle, move auxiliary control lever left or right. Hold
9 3b (207 bar) auxiliary control lever over relief and check pressure. If pressure is
incorrect, check main relief per 3 .
Stabilizer Cylinder 75-150 psi With the engine at idle, check the pressure on the cylinder.
10 N/A (5,2-10,3 bar)
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.11

Hydraulic System

LEFT RIGHT
OUTRIGGER OUTRIGGER
CYLINDER CYLINDER
E R
R E
ATTACHMENT TILT
FRONT AXLE CYLINDER AUXILIARY 2a
9 COUPLERS
FTR FTB
FRAME SWAY
CYLINDER
E R
FRONT STEERING
CYLINDER
2
BRAKE T
3a MAIN CONTROL VALVE
2b
VALVE P 3b
LS
3
1
8
STEER
LFT/LWR
EXT/RET
SHUTTLE T
SELECT
FRAME
ATTACH
SWAY
LS
VALVE
AUX
TILT
P VALVE
PUMP T P
IN
T
RP B A
LT
POWER
STEERING
UNIT
HYDRAULIC
OPERATOR'S CAB
RESERVOIR
5 7 6
SECONDARY
FUNCTION
MANIFOLD
PBG B1 A2 B2
C A1
PSG G
T
PLT T
P
LS
P
PS PB
4 EXTEND/
RETRACT
CYLINDER OUTRIGGER
R E
VALVE
4 5
LEFT RIGHT
CYLINDER CYLINDER
STABILIZER R R
CYLINDER
E E
FTR V
G
PT LEFT RIGHT
R R
10 SLAVE
CYLINDER E E
SLAVE
CYLINDER
REAR STEERING
CYLINDER
REAR AXLE
HYDRAULIC
OIL COOLER
MH3170
8.12 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System

Idle . . . . . . . . . . . . . . . . . . . . . 1,050 ±50 rpm
Full Speed. . . . . . . . . . . . . . . 2,750 ±100 rpm
Capacity - System. . . . . . . . 64 gal. (242 liter) Unit equipped with fittings from
1,000 psi gauge
(280 bar gauge)
pressure.
TEST
LOCATION
1

REARWARD
Manifold 0-3,000 psi With engine at idle, use the boom control lever to fully retract the
4 N/A (0-207 bar) boom. Hold over relief and check pressure. Pressure should be
3000 psi (207 bar).
5 4 Manifold 2,500 ±100 psi direction and hold while checking pressure. If pressure is incorrect,
(172 ±7 bar) adjust or replace the pressure reducing cartridge.
6 N/A Manifold 550 ±50 psi park brake, check pressure. This is not an adjustment.
(38 ±3,4 bar)
Auxiliary Hydraulics 3,000 psi With engine at low idle, move auxiliary control lever left or right. Hold
10 N/A (5,2-10,3 bar)
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.13

Hydraulic System
LEFT RIGHT
OUTRIGGER OUTRIGGER
CYLINDER CYLINDER
E R
R E
FRONT AXLE
ATTACHMENT TILT
CYLINDER AUXILIARY
2a
9 COUPLERS
FTR FTB
FRAME SWAY
CYLINDER
E R
FRONT STEERING
CYLINDER
2
BRAKE T 3a MAIN CONTROL VALVE
VALVE P 3b 2b
LS
3
1
8
STEER
LFT/LWR
EXT/RET
SHUTTLE T
SELECT
FRAME
ATTACH
SWAY
LS
VALVE
AUX
TILT
P PUMP VALVE
T P
IN
T
RP B A
LT
POWER
STEERING
UNIT
OPERATOR'S CAB HYDRAULIC

RESERVOIR
7
SECONDARY
5 6
FUNCTION
MANIFOLD
PBG B1 A2 B2
C A1
PSG G
T
PLT T
P
LS
P
PS PB
4 EXTEND/
RETRACT
CYLINDER OUTRIGGER
R E
VALVE
4 5
LEFT RIGHT V C
CYLINDER T
CYLINDER
STABILIZER R R
CYLINDER BOOM LOCKOUT
VALVE
E E
FTR V
G
PT LEFT RIGHT
R R
10 SLAVE
CYLINDER E E
SLAVE
CYLINDER
REAR STEERING
CYLINDER
REAR AXLE
HYDRAULIC
OIL COOLER
MH2850
8.14 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System

Idle . . . . . . . . . . . . . . . . . . . . . 1,050 ±50 rpm
Full Speed. . . . . . . . . . . . . . . 2,750 ±100 rpm
Capacity - System. . . . . . . . 64 gal. (242 liter) Unit equipped with fittings from
1,000 psi gauge
(280 bar gauge)
pressure.
TEST
LOCATION
1

REARWARD
4 N/A Manifold 0-3,000 psi With engine at idle, use the boom control lever to fully retract the
(0-207 bar) boom. Hold over relief. Pressure should be 3000 psi (207 bar).
5 4 Manifold 2,500 ±100 psi direction. Hold over relief and check pressure. If pressure is
(172 ±7 bar) incorrect, adjust or replace the pressure reducing cartridge.
6 N/A Manifold 550 ±50 psi park brake and check pressure. This is not an adjustment.
(38 ±3,4 bar)
Auxiliary Hydraulics 3,000 psi With engine at low idle, move auxiliary control lever left or right. Hold
10 N/A (5,2-10,3 bar)
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.15

Hydraulic System
8.16 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
8.8 HYDRAULIC CIRCUITS AND 3. Check for air in the hydraulic system. Erratic machine
TROUBLESHOOTING performance and/or spongy cylinder operation are
signs of air in the hydraulic system.
This section covers the hydraulic circuits and includes a
circuit drawing, troubleshooting chart, and description of WARNING: Wait for hydraulic fluid to cool
the circuit for each function. before servicing any hydraulic component. Hot
Typically, the circuit drawings illustrate the flow of oil for hydraulic fluid can cause severe burns.
the hydraulic function being shown.
The troubleshooting charts cover some common WARNING: Relieve hydraulic pressure
problems that can occur during the operation of the before servicing any hydraulic component.
hydraulic system. Electrical and hydraulic functions are Escaping hydraulic fluid under pressure can
often related. Verify that the electrical components of the penetrate the skin causing death or serious
circuit are functioning properly whenever troubleshooting injury. When checking for air in the hydraulic
the hydraulic circuit. system, wear safety glasses and gloves to help
Always check the following before beginning to provide protection from spraying hydraulic oil.
troubleshoot a circuit that is not functioning correctly. If air in the hydraulic system is suspected, you will
1. Check the hydraulic oil level in the reservoir. Oil level hear air leakage when hydraulic fittings are loosened
should be to the middle of the sight glass with all and see air bubbles in the hydraulic fluid.
cylinders retracted. Loose fittings, faulty o-rings or seals, trapped oil,
2. Check hoses, tubes, fittings and other hydraulic leaks, system opened for service, etc., can cause air
components for leaks, bends, kinks, interference, etc. in the system. Determine what is causing air to enter
the system and correct it. Bleed air from the system.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.17

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
P MAIN CONTROL VALVE

LS
RETURN
FILTER
LFT/LWR
EXT/RET
T
TO POWER
FRAME
ATTACH
SWAY
AUX
TILT
P
STEERING
UNIT
IN
T
SHUTTLE
VALVE
SECONDARY HYDRAULIC RESERVOIR PUMP
FUNCTION
MANIFOLD
PBG
C
PSG G
PLT T
P
PS PB
Pressure
Return
Suction
Load Sense
REAR AXLE
HYDRAULIC
OIL COOLER
MH3450
8.18 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
Before troubleshooting any If service brakes are not

Not
hydraulic circuit, ALWAYS holding, check the pressure OK
Replace brake valve.
at the brake valve.
begin by checking the
following: If OK
1. Hydraulic oil level in the Not

Check pressure at front axle. Replace brake valve.
reservoir OK
2. All hoses, tubes, fittings
If OK
for leaks, kinks,
interference, etc. Check front and rear brake Not
Refer to the appropriate
3. Air in the lines OK Legacy Owners/Operators
discs for wear.
Manual.
If OK
NOTE: Refer to Section 5.3.8, “ZF

Check the brakes for Not Axle Repair Manuals,” for
When checking pressures in OK proper ZF Axle Repair
mechanical failure.
circuits, refer to Section 8.7, Manual for further
“Hydraulic System Testing,” for information.
correct pressure readings.
If park brake fails to hold,
check the “PBG” port on
the secondary function
manifold. Should read
0 psi.
If park brake fails to
Not Adjust/repair/replace
release, check the “PBG” OK pressure reducing valve.
port on the secondary
function manifold. Should
read 550 psi (38 bar).
Check pressure reducing
valve on secondary
function manifold.
If OK
Check solenoid valves on the Not Refer to Section 9.14,

secondary function manifold. OK “Switches and Solenoids.”
If OK
Check solenoid valve Not Install seal kit/replace

cartridges. OK solenoid valve cartridges.
If OK
Within the front axle:

Refer to Section 5.3.8, “ZF
If not holding, check the park
Not Axle Repair Manuals,” for
brake springs. OK proper ZF Axle Repair
If not releasing, check the Manual for further
piston seals. information.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.19

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.)
MAIN CONTROL VALVE
RETURN
LFT/LWR
EXT/RET
T
FRAME FILTER
ATTACH
SWAY
AUX
TILT
P
IN
T
HYDRAULIC RESERVOIR PUMP
10054 ONLY
EXTEND V
LOCKOUT T
VALVE
C
R E
EXTEND/
RETRACT
CYLINDER Pressure
Return
HYDRAULIC
Suction
OIL COOLER Load Sense
MH3500
8.20 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
Before troubleshooting any If the extend/retract cylinder Repair/replace cable

does not extend, check Not connections. Ensure extend/
hydraulic circuit, ALWAYS
cable connections at main OK retract section of main control
begin by checking the control valve. valve is functioning.
following:
If OK
1. Hydraulic oil level in the
reservoir
On 10054 only, check the Not
2. All hoses, tubes, fittings solenoid valve on the extend Replace solenoid valve.
OK
for leaks, kinks, lockout valve.
interference, etc. If OK
3. Air in the lines
On 10054 only, check the Not Replace the extend lockout
extend lockout valve. OK valve.
NOTE:
If OK
When checking pressures in
circuits, refer to Section 8.7,
“Hydraulic System Testing,” for Check main relief pressure on Not Adjust/repair/replace relief
correct pressure readings. main control valve. OK valve on main control valve.
If OK
NOTE: Check the counterbalance

Not Replace counterbalance
Refer to Section 2.5.4, valve on the extend/retract OK valve.
“Performance Specifications,” for cylinder.
approximate cylinder cycle
times. The operation of the If OK
system function should
approximate the times listed.
Check packing on Not Repair/replace
extend/retract cylinder. OK extend/retract cylinder.
If OK
Not
Check pump flow. OK
Repair/replace pump.
If the extend/retract cylinder

drifts or reacts slowly, check Replace counterbalance and/
Not
counterbalance and pilot- OK
or pilot-operated check valves
operated check valves on the on the extend/retract cylinder.
extend/retract cylinder.
If OK
Check the extend/retract Not Repair/replace

cylinder packing. OK extend/retract cylinder.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.21

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.)
MAIN CONTROL VALVE
RETURN
LFT/LWR
EXT/RET
T
FILTER
FRAME
ATTACH
SWAY
AUX
TILT
P
IN
T
10054 ONLY
EXTEND V
LOCKOUT T
VALVE
C
R E
EXTEND/
RETRACT
CYLINDER Pressure
Return
HYDRAULIC
Suction
MH3530
8.22 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
Before troubleshooting any If the extend/retract cylinder Repair/replace cable

does not retract, check Not connections. Ensure extend/
hydraulic circuit, ALWAYS
cable connections at main OK retract section of main control
begin by checking the control valve. valve is functioning.
following:
If OK
reservoir
On 10054 only, check the Not
2. All hoses, tubes, fittings solenoid valve on the extend OK Replace solenoid valve.
for leaks, kinks, lockout valve.
interference, etc. If OK
3. Air in the lines
On 10054 only, check the Not Replace the extend lockout
extend lockout valve. OK valve.
NOTE:
If OK
“Hydraulic System Testing,” for Check main relief pressure on Not Adjust/repair/replace relief
correct pressure readings. main control valve. OK valve on main control valve.
If OK
NOTE: Check the pilot-operated

Not Replace the pilot-operated
Refer to Section 2.5.4, check valve on the extend/ OK check valve.
“Performance Specifications,” for retract cylinder.
times. The operation of the If OK
approximate the times listed. Check packing on Repair/replace
Not
extend/retract cylinder. OK extend/retract cylinder.
If OK
Not
Check pump flow. OK Repair/replace pump.
If the extend/retract cylinder

drifts or reacts slowly, check Replace counterbalance and/
Not
operated check valves on the on the extend/retract cylinder.
extend/retract cylinder.
If OK
Check the extend/retract Not Repair/replace

cylinder packing. OK extend/retract cylinder.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.23

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.)
MAIN CONTROL VALVE
LFT/LWR
RETURN
T EXT/RET FILTER
FRAME
ATTACH
SWAY
AUX
TILT
P
IN
T
R R
E E
LEFT RIGHT
CYLINDER CYLINDER Pressure
Return
HYDRAULIC
Suction
MH3540
8.24 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
Before troubleshooting any If the lift/lower cylinders do Repair/replace cable

hydraulic circuit, ALWAYS not raise, check the cable Not connections. Ensure lift/lower
connections at the main OK section of main control valve is
begin by checking the control valve. functioning.
following:
1. Hydraulic oil level in the If OK
reservoir
for leaks, kinks, Check main relief pressure on Not Adjust/repair/replace relief
interference, etc. main control valve. OK valve on main control valve.
3. Air in the lines If OK
Check the counterbalance Replace counterbalance

Not
NOTE: valve on the lift/lower OK valve.
When checking pressures in cylinders.
If OK
“Hydraulic System Testing,” for
lift/lower cylinder(s). OK lift/lower cylinder(s).
NOTE:
Refer to Section 2.5.4, If OK
“Performance Specifications,” for
approximate cylinder cycle Not
times. The operation of the Check pump flow. OK
If the lift/lower cylinders drift

or react slowly, check Replace counterbalance and/
Not
operated check valves on the on the lift/lower cylinders.
lift/lower cylinders.
If OK
Check the packing on the lift/ Not Repair/replace

lower cylinders. OK lift/lower cylinders.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.25

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.)
MAIN CONTROL VALVE
RETURN
LFT/LWR
EXT/RET
T FILTER
FRAME
ATTACH
SWAY
AUX
TILT
P
IN
T
R R
E E
LEFT RIGHT
CYLINDER CYLINDER Pressure
Return
HYDRAULIC
Suction
MH3550
8.26 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
Before troubleshooting any If the lift/lower cylinders do Repair/replace cable

hydraulic circuit, ALWAYS not lower, check the cable Not connections. Ensure lift/lower
connections at the main OK section of main control valve is
begin by checking the control valve. functioning.
following:
If OK
reservoir
for leaks, kinks, Check main relief pressure on Not Adjust/repair/replace relief
interference, etc. main control valve. OK valve on main control valve.
3. Air in the lines
If OK
Check the pilot-operated

NOTE: Not Replace the pilot-operated
check valve on the lift/lower OK check valve.
When checking pressures in cylinder(s).
“Hydraulic System Testing,” for If OK

lift/lower cylinder(s). OK lift/lower cylinder(s).
NOTE:
Not
times. The operation of the Check pump flow. OK
If the lift/lower cylinder drifts

or reacts slowly, check Replace counterbalance and/
Not
operated check valves on the on the lift/lower cylinders.
lift/lower cylinders.
If OK
Check the packing on the Not Repair/replace

lift/lower cylinders. OK lift/lower cylinders.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.27

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.)
Ø .041 Ø .048
FRAME FTR FTB

CHECK CHECK
SWAY VALVE VALVE
FITTING FITTING
CYLINDER
Orifice, Part Of
Check Valve Fitting
RETURN
LFT/LWR
EXT/RET
T
FILTER
FRAME
ATTACH
SWAY
AUX
TILT
P
IN
T
MAIN CONTROL
VALVE HYDRAULIC RESERVOIR PUMP
PBG
C
PSG G SECONDARY
T
P
PLT FUNCTION
MANIFOLD
PS PB
FTR
V
STABILIZER
CYLINDER
T
P
Pressure
Return
Suction
HYDRAULIC
OIL COOLER
Load Sense
MH3561
8.28 Model 8042, 10042, 10054 Legacy Rev. 10/03

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: NOTE:
When checking pressures in Refer to Section 2.5.4, “Performance
circuits, refer to Section 8.7, Specifications,” for approximate cylinder cycle
“Hydraulic System Testing,” for times. The operation of the system function
correct pressure readings. should approximate the times listed.
With the boom below 40°, if

the frame sway cylinder will Repair/replace cable
not sway left, drifts or reacts Not connections. Ensure frame
slowly, check cable OK sway section of main control
connections at the main valve is functioning.
control valve.
If OK
Check the pilot-operated check Not Replace check valves on

valves on frame sway cylinder. OK frame sway cylinder.
If OK
Check frame sway Not Repair/replace frame

cylinder packing. OK sway cylinder.
Refer to Section 10.12, “Stabil-TRAK™ Hydraulic Circuit

Operation and Troubleshooting,” for further information on
troubleshooting the frame sway and stabilizer circuits.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.29

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.)
Ø .041 Ø .048
FRAME FTR FTB CHECK

CHECK
VALVE
SWAY VALVE
FITTING FITTING
CYLINDER
Orifice, Part Of
Check Valve Fitting
RETURN
LFT/LWR
EXT/RET
T
FILTER
FRAME
ATTACH
SWAY
AUX
TILT
P
IN
T
MAIN CONTROL
VALVE HYDRAULIC RESERVOIR PUMP
PBG
C
PSG G SECONDARY
T
P
PLT FUNCTION
MANIFOLD
PS PB
FTR
V
STABILIZER
CYLINDER
T
P
Pressure
Return
Suction
HYDRAULIC
OIL COOLER
Load Sense
MH3571
8.30 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
3. Air in the lines
NOTE: NOTE:
When checking pressures in Refer to Section 2.5.4, “Performance
circuits, refer to Section 8.7, Specifications,” for approximate cylinder cycle
“Hydraulic System Testing,” for times. The operation of the system function
correct pressure readings. should approximate the times listed.
With the boom below 40°, if

the frame sway cylinder will Repair/replace cable
not sway right, drifts or Not connections. Ensure frame
reacts slowly, check cable OK sway section of main control
connections at the main valve is functioning.
control valve.
If OK
Check the pilot-operated check Not Replace check valves on

valves on frame sway cylinder. OK frame sway cylinder.
If OK
Check frame sway Not Repair/replace frame

cylinder packing. OK sway cylinder.
Refer to Section 10.12, “Stabil-TRAK™ Hydraulic Circuit

Operation and Troubleshooting,” for further information on
troubleshooting the frame sway and stabilizer circuits.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.31

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
E R
RETURN
LFT/LWR
EXT/RET
T FILTER
FRAME
ATTACH
SWAY
AUX
TILT
P
IN
T
MAIN CONTROL
VALVE HYDRAULIC PUMP
RESERVOIR
LEFT R R
RIGHT
SLAVE SLAVE
E E
CYLINDER CYLINDER
Pressure
Return
Suction
HYDRAULIC
OIL COOLER
Load Sense
MH3610
8.32 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
Before troubleshooting any If the attachment tilt cylinder Repair/replace cable connections.
Not
hydraulic circuit, ALWAYS retracts slowly, check cable OK Ensure attachment tilt section of
connections at main control main control valve is functioning.
following: If OK

reservoir Check the counterbalance on the Not
Replace counterbalance valve.
attachment tilt cylinder. OK
for leaks, kinks, If OK
interference, etc.
3. Air in the lines
Check main relief pressure on Not Adjust/repair/replace relief valve
main control valve. OK on main control valve.
If OK
NOTE:
circuits, refer to Section 8.7, Isolate and check each slave Not
Repair/replace slave cylinder(s).
cylinder for packing leaks. OK
correct pressure readings. If OK
Check packing in attachment Not Repair/replace attachment

tilt cylinder. OK tilt cylinder.
NOTE:
Check pump flow. Repair/replace pump.
times. The operation of the OK
If the attachment tilt cylinder

drifts and does not hold load, Not Replace counterbalance valve.
check the counterbalance valve OK
on the attachment tilt cylinder.
If OK
Isolate and check packing in each Not

slave cylinder. OK
If OK

Model 8042, 10042, 10054 Legacy Rev. 10/03 8.33

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
E R
RETURN
FILTER
LFT/LWR
EXT/RET
T
FRAME
ATTACH
SWAY
AUX
TILT
P
IN
T
MAIN CONTROL
RESERVOIR
LEFT R R
RIGHT
SLAVE SLAVE
E E
CYLINDER CYLINDER
Pressure
Return
Suction
HYDRAULIC
OIL COOLER
Load Sense
MH3620
8.34 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
Before troubleshooting any If the attachment tilt cylinder Repair/replace cable connections.
extends slowly, check cable Not
hydraulic circuit, ALWAYS OK Ensure attachment tilt section of
connections at main control main control valve is functioning.
following: If OK

reservoir Check main relief pressure on Not Adjust/repair/replace relief valve
main control valve. OK on main control valve.
for leaks, kinks, If OK
interference, etc.
3. Air in the lines
Check the pilot-operated check
Not
valve on the attachment tilt cylinder. OK
Replace pilot-operated check valve.
NOTE: If OK

circuits, refer to Section 8.7, Isolate and check each slave Not
“Hydraulic System Testing,” for cylinder for packing leaks. OK
correct pressure readings. If OK

NOTE: tilt cylinder. OK tilt cylinder.
Check pump flow. Repair/replace pump.
times. The operation of the OK
If the attachment tilt cylinder

drifts and does not hold load, Not
check the counterbalance valve Replace counterbalance valve.
OK
on the attachment tilt cylinder.
If OK
Isolate and check packing in each Not

slave cylinder. OK
If OK

Model 8042, 10042, 10054 Legacy Rev. 10/03 8.35

Hydraulic System
8.8.10 Pump and Cooling Circuit and Troubleshooting

(Refer to Section 8.8.26, “Pump and Cooling Circuit Description,” for a more detailed explanation of this circuit.)
RETURN
LFT/LWR
EXT/RET
T
FILTER
FRAME
ATTACH
SWAY
AUX
TILT
P
IN
T
MAIN CONTROL
RESERVOIR
PBG
C
PSG G
PLT T
P
SECONDARY
PS PB FUNCTION
FROM MANIFOLD
STABILIZER
CYLINDER
TO
STABILIZER
CYLINDER
Pressure
Return
Suction
HYDRAULIC
OIL COOLER
Load Sense
MH3630
8.36 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
3. Air in the lines
NOTE:
If the pump is noisy or if all

hydraulic functions are Not
OK
Repair/replace suction line.
slow, check the suction line
from the reservoir.
If OK
Check the oil flow Not

OK
to the pump.
If the cooler is not cooling

the oil, check that the Not
OK
Clean radiator and cooler.
radiator and cooler are not
clogged or obstructed.
If OK

“Hydraulic Oil Temperature
Switch.”
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.37

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.)
AUXILIARY
COUPLERS
RETURN
FILTER
LFT/LWR
EXT/RET
T
FRAME
ATTACH
SWAY
AUX
TILT
P
IN
T
MAIN CONTROL
RESERVOIR
Pressure
Return
Suction
HYDRAULIC
OIL COOLER
Load Sense
MH3640
8.38 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
3. Air in the lines
NOTE:
If there are no auxiliary Repair/replace cable

hydraulics functions, check Not connections. Ensure auxiliary
cable connections at main OK section of main control valve is
control valve. functioning.
If OK
Adjust/repair/replace
Check system relief on main Not
OK relief valve on the main
control valve.
control valve.
If OK
Check the flow at the end of Not

the circuit at the male coupler. OK
Not
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.39

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.)
AUXILIARY
COUPLERS
RETURN
LFT/LWR
EXT/RET
T
FILTER
FRAME
ATTACH
SWAY
AUX
TILT
P
IN
T
MAIN CONTROL
RESERVOIR
Pressure
Return
Suction
HYDRAULIC
OIL COOLER
Load Sense
MH3650
8.40 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
3. Air in the lines
NOTE:
If there are no auxiliary Repair/replace cable

hydraulics functions, check Not connections. Ensure auxiliary
cable connections at main OK section of main control valve is
control valve. functioning.
If OK
Check system relief on main Not Adjust/repair/replace relief valve

control valve. OK on the main control valve.
If OK
Check the flow at the end of the Not

circuit at the female coupler. OK
Not
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.41

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 RIGHT
OUTRIGGER OUTRIGGER
CYLINDER CYLINDER
E R
R E
MAIN CONTROL
VALVE
RETURN
LFT/LWR
EXT/RET
T
FILTER
FRAME
ATTACH
SWAY
AUX
TILT
P
IN
T
OUTRIGGER HYDRAULIC PUMP

SHUTTLE RESERVOIR
VALVE
B1 A2
A1 B2
LS
OUTRIGGER
VALVE
HYDRAULIC Pressure
OIL COOLER Return
Suction
Load Sense MH3860
8.42 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
Before troubleshooting any If the outriggers do not go Refer to Section 9.14.5,

Not
hydraulic circuit, ALWAYS up, check the left and right OK “Outrigger Switches (10042/
outrigger switches. 10054 Only).”
following:
1. Hydraulic oil level in the If OK
Refer to Section 9.7.42, “10042
reservoir Outrigger Circuit and
2. All hoses, tubes, fittings Check the solenoid valves on Troubleshooting,” and Section
Not
9.7.43, “10054 Outrigger Circuit
for leaks, kinks, the outrigger valve. OK
and Troubleshooting.”
interference, etc.
Check the spools in the Not

Replace solenoid valves.
NOTE: OK
solenoid valves.
circuits, refer to Section 8.7, If OK
Check the counterbalance valve Not
Replace counterbalance valve(s).
in each outrigger cylinder. OK
If OK
NOTE:
“Performance Specifications,” for Check outrigger shuttle valve Not
Replace shuttle valve.
approximate cylinder cycle on main control valve. OK
times. The operation of the

If OK
Check the left and right Not Repair/replace outrigger
outrigger cylinders for OK cylinder(s).
packing leaks.
If OK
Not
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.43

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 RIGHT
OUTRIGGER OUTRIGGER
CYLINDER CYLINDER
E R
R E
MAIN CONTROL
VALVE
RETURN
LFT/LWR
EXT/RET
T FILTER
FRAME
ATTACH
SWAY
AUX
TILT
P
IN
T
HYDRAULIC PUMP
OUTRIGGER RESERVOIR
SHUTTLE
VALVE
B1 A2
A1 B2
LS
OUTRIGGER
VALVE
HYDRAULIC Pressure
OIL COOLER Return
Suction
Load Sense
MH3870
8.44 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
Before troubleshooting any If the outriggers do not go

Not Refer to Section 9.14.5,
hydraulic circuit, ALWAYS down, check the left and OK “Outrigger Switches (10042/
right outrigger switches.
begin by checking the 10054 Only).”
following:
1. Hydraulic oil level in the If OK Refer to Section 9.7.42, “10042
reservoir Outrigger Circuit and
2. All hoses, tubes, fittings Troubleshooting,” and Section
Check the solenoid valves on Not 9.7.43, “10054 Outrigger Circuit
for leaks, kinks, the outrigger valve. OK
and Troubleshooting.”
interference, etc.
NOTE: Check the spools in the Not Replace solenoid valves.

solenoid valves. OK
circuits, refer to Section 8.7, If OK
Check the pilot-operated check Not Replace pilot-operated
valve in each outrigger cylinder. OK
check valve(s).
NOTE: If OK

“Performance Specifications,” for Check outrigger shuttle valve Not
OK Replace shuttle valve.
approximate cylinder cycle on main control valve.
times. The operation of the
system function should If OK
Check the left and right Repair/replace outrigger
Not
outrigger cylinders for OK cylinder(s).
packing leaks.
If OK
Not
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.45

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.)
FRONT AXLE
RETURN
FILTER
MAIN CONTROL VALVE
SHUTTLE
VALVE
POWER
STEERING
LFT/LWR
EXT/RET
T
UNIT
FRAME
ATTACH
SWAY
LS
AUX
P TILT
IN
T
RP
LT
STEER SELECT
HYDRAULIC
VALVE
RESERVOIR
P T
a b
G PBG DE DE
C
PSG T
P
PLT A B
SOLENOID COIL
LS STATE
PS PB
DE DE-ENERGIZED
E ENERGIZED
PUMP
SECONDARY
FUNCTION
MANIFOLD
Pressure
Return
HYDRAULIC Suction
OIL COOLER Load Sense REAR AXLE
MH3800
Before troubleshooting If the steering is slow or difficult,

Not Adjust/repair/replace pressure reducing
any hydraulic circuit, check the pressure at the “PSG” port OK valve on secondary function manifold.
of the secondary function manifold.
ALWAYS begin by
checking the
If OK
following:
1. Hydraulic oil level in
Check that the check valve fitting at the Not
the reservoir OK
Replace check valve fitting.
power steering unit is operating properly.
2. All hoses, tubes,
fittings for leaks, If OK
kinks, interference,
etc. Not
Check the shuttle valve. OK Replace shuttle valve.
3. Air in the lines
If OK
NOTE: Not
Replace power steering unit.
Check the power steering unit. OK
When checking pressures
in circuits, refer to Section
If OK
8.7, “Hydraulic System
Testing,” for correct
pressure readings. Not
Check packing in steering cylinders. OK
Repair/replace steering cylinder(s).
8.46 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
If there is no front wheel steering,

Not Adjust/repair/replace the pressure reducing
check the pressure at the “PSG” port OK valve on secondary function manifold.
If OK
Check the load sense pressure at the "PLT" Not Adjust/repair/replace the pressure reducing
port on the secondary function manifold. OK valve on secondary function manifold.
If OK
Not
If OK
Check the main system pressure on the Not

OK Adjust/replace the relief valve.
main control valve.
If OK
Check the pump compensator pressure.

Not Consult factory to adjust the
OK compensator pressure at the pump.
If OK

OK Replace check valve fitting.
If OK
If OK Not
Check the power steering unit. OK Replace power steering unit.
If OK
Check the front steering cylinder for Not

OK
packing leaks.
If OK
Not
Check pump flow. OK
Front or rear wheels are not parallel Not

Perform indexing procedure on vehicle.
in front or four-wheel steering mode. OK
If OK
Refer to Section 5.3.8, “ZF Axle Repair

Not Manuals,” for proper ZF Axle Repair
Check wheel alignment. OK
Manual for further information.
If OK
Not
Check the steer select valve. OK
Replace the steer select valve.
If OK
Not
Check packing in steering cylinders. OK Repair/replace steering cylinder(s).
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.47

Hydraulic System
8.8.16 Front-Wheel Steering Circuit (Right Turn) and Troubleshooting

FRONT AXLE
RETURN
FILTER
MAIN CONTROL VALVE
SHUTTLE
VALVE
POWER
STEERING
LFT/LWR
EXT/RET
T
UNIT
FRAME
ATTACH
SWAY
LS
AUX
P TILT
IN
T
RP
LT
STEER SELECT
HYDRAULIC
VALVE
RESERVOIR
P T
a b
G PBG DE DE
C
PSG T
P
PLT A B
SOLENOID COIL
LS STATE
PS PB
DE DE-ENERGIZED
E ENERGIZED
PUMP
SECONDARY
FUNCTION
MANIFOLD
Pressure
HYDRAULIC Return
OIL COOLER Suction
Load Sense REAR AXLE
MH3810

ALWAYS begin by
checking the
If OK
following:
the reservoir Check that the check valve fitting at the Not
fittings for leaks,
If OK
etc. Not
3. Air in the lines
If OK
NOTE: Not
If OK
8.48 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
If there is no front-wheel steering,

Not Adjust/repair/replace the pressure reducing
check the pressure at the “PSG” port OK valve on secondary function manifold.
If OK
Check the load sense pressure at the “PLT” Not Adjust/repair/replace the pressure reducing
If OK
Not
Check the shuttle valve. OK
If OK
Check the main system pressure on the Not Adjust/replace the relief valve.
main control valve. OK
If OK
Check the pump compensator pressure.

Not Consult factory to adjust the
If OK

If OK
If OK Not
If OK
Check the front steering cylinder for Not

OK
packing leaks.
If OK
Not
Check pump flow. OK
Front or rear wheels are not parallel Not Perform indexing procedure on vehicle.
If OK

Check wheel alignment. Not Manuals,” for proper ZF Axle Repair
OK
If OK
Not
If OK
Not
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.49

Hydraulic System
8.8.17 Four-Wheel Steering Circuit (Left Turn) and Troubleshooting

FRONT AXLE
RETURN
FILTER
MAIN CONTROL VALVE
SHUTTLE
VALVE
POWER
STEERING
LFT/LWR
EXT/RET
T
UNIT
FRAME
ATTACH
SWAY
AUX
LS
TILT
P
IN
T
RP
LT
STEER SELECT
HYDRAULIC
VALVE
RESERVOIR
P T
a b
G PBG E DE
C
PSG T
P
PLT A B
SOLENOID COIL
LS STATE
PS PB
DE DE-ENERGIZED
E ENERGIZED
PUMP
SECONDARY
FUNCTION
MANIFOLD
Pressure
HYDRAULIC Return
OIL COOLER Suction
MH3820

ALWAYS begin by
checking the If OK
following:
Verify that the check valve fitting at the Not
the reservoir OK
etc. Not
3. Air in the lines
If OK
NOTE: Not
in circuits, refer to Section If OK
Not
pressure readings. Check packing in steering cylinders. OK
8.50 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
Refer to the steering circuits and

If there is no steering, check the Not components in Section 9.7, “Electrical
steering system electrical components. OK System Troubleshooting,” and Section
9.14, “Switches and Solenoids.”
If OK
Check the pressure at the “PSG” port of the Not Adjust/repair/replace the pressure reducing
secondary function manifold. OK valve on secondary function manifold.
If OK
If OK
Not
Check the shuttle valve. OK
If OK
Check the main system pressure on the Not Adjust/replace the relief valve.
If OK
Check the pump compensator pressure. Not Consult factory to adjust the
If OK

power steering unit is operating properly. OK
If OK
Not
If OK
Check the front and rear steering cylinders Not

for packing leaks. OK
If OK
Not
Check pump flow. OK

If OK

Not
Check wheel alignment. OK Manuals,” for proper ZF Axle Repair
If OK
Not
If OK
Not
Check packing in steering cylinders. OK Repair/replace steering cylinder.
If there is no four-wheel or crab Not

Inspect/replace the steer select valve.
steering, check the steer select valve. OK
If OK
Not components in Section 9.7, “Electrical
Check the steer select switch and wiring. OK System Troubleshooting,” and Section
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.51

Hydraulic System
8.8.18 Four-Wheel Steering Circuit (Right Turn) and Troubleshooting

FRONT AXLE
RETURN
FILTER
MAIN CONTROL VALVE
SHUTTLE
VALVE
POWER
STEERING
LFT/LWR
EXT/RET
T
UNIT
FRAME
ATTACH
SWAY
LS
AUX
TILT
P
IN
T
RP
LT
STEER SELECT
HYDRAULIC
VALVE
RESERVOIR
P T
a b
G PBG E DE
C
PSG T
P
PLT A B
SOLENOID COIL
LS STATE
PS PB
DE DE-ENERGIZED
E ENERGIZED
PUMP
SECONDARY
FUNCTION
MANIFOLD
Pressure
HYDRAULIC Return
OIL COOLER Suction
MH3830

ALWAYS begin by
checking the
If OK
following:
the reservoir OK
etc. Not
3. Air in the lines
If OK
NOTE: Not
Not
Repair/replace cylinder(s).
8.52 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System

If OK
If OK
If OK
Not
If OK

main control valve.
If OK
If OK

power steering unitIf is
OKoperating properly. OK
If OK
Not
If OK

OK Repair/replace steering cylinder(s).
for packing leaks.
If OK
Not

OK
in front or four-wheel steering mode.
If OK

Not
Manuals,” for proper ZF Axle Repair
If OK
Not
Check the steer select valve. OK Replace the steer select valve.
If OK
Not

OK Inspect/replace the steer select valve.
steering, check the steer select valve.
If OK
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.53

Hydraulic System
8.8.19 Crab Steering Circuit (Left Turn) and Troubleshooting

FRONT AXLE
RETURN
FILTER
MAIN CONTROL VALVE
SHUTTLE
VALVE
POWER
STEERING
LFT/LWR
EXT/RET
T
UNIT
FRAME
ATTACH
SWAY
LS
AUX
TILT
P
IN
T
RP
LT
STEER SELECT
HYDRAULIC
VALVE
RESERVOIR
P T
a b
G PBG DE E
C
PSG T
P
PLT A B
SOLENOID COIL
LS STATE
PS PB
DE DE-ENERGIZED
E ENERGIZED
PUMP
SECONDARY
FUNCTION
MANIFOLD
Pressure
HYDRAULIC Return
OIL COOLER Suction
MH3840

check the pressure at the “PSG” port Not Adjust/repair/replace pressure reducing
any hydraulic circuit, OK valve on secondary function manifold.
ALWAYS begin by
checking the If OK
following:
the reservoir OK Replace check valve fitting.
etc. Not
3. Air in the lines
If OK
NOTE: Not
If OK
8.54 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System

If OK
If OK
If OK
Not
If OK

main control valve.
If OK
If OK

If OK
Not
If OK

for packing leaks.
If OK
Not

OK
If OK

Not
If OK
Not
If OK
Not

OK
Inspect/replace the steer select valve.
steering, check the steer select valve.
If OK
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.55

Hydraulic System
8.8.20 Crab Steering Circuit (Right Turn) and Troubleshooting

FRONT AXLE
RETURN
FILTER
MAIN CONTROL VALVE
SHUTTLE
VALVE
POWER
STEERING
LFT/LWR
EXT/RET
T
UNIT
FRAME
ATTACH
SWAY
LS
AUX
P TILT
IN
T
RP
LT
STEER SELECT
HYDRAULIC
VALVE
RESERVOIR
P T
a b
G PBG DE E
C
PSG T
P
PLT A B
SOLENOID COIL
LS STATE
PS PB
DE DE-ENERGIZED
E ENERGIZED
PUMP
SECONDARY
FUNCTION
MANIFOLD
Pressure
HYDRAULIC Return
OIL COOLER Suction
MH3850
Before If the steering is slow or difficult,

troubleshooting any check the pressure at the “PSG” port OK
of the secondary function manifold. valve on secondary function manifold.
hydraulic circuit,
ALWAYS begin by
If OK
checking the
following:
1. Hydraulic oil level in OK Replace check valve fitting.
the reservoir
2. All hoses, tubes, If OK
fittings for leaks,
kinks, interference, Not
etc.
If OK
NOTE: Not
Not
8.56 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System

If OK
If OK
If OK
Not
If OK

Adjust/replace the relief valve.
If OK
If OK

If OK
Not
If OK

for packing leaks.
If OK
Not

OK
If OK

Not
If OK
Not
Check the steer select valve. OK Replace the steer select valve.
If OK
Not
If there is no four-wheel or crab Not Inspect/replace the

steering, check the steer select valve. OK steer select valve.
If OK
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.57

Hydraulic System
8.8.21 Brake Circuit Description brake valves mounted next to each other in the same
casting. Each valve can operate independently of the
The brake system circuit, Section 8.8.1, “Brake Circuit
other.
and Troubleshooting,” includes the park brake and the
service brake, along with the secondary function
Fluid Flow When Brake Pedal is NOT Pressed
manifold, main control valve and various hoses, fittings
and other components. System pressure from the pump flows to the main control
When the engine is OFF and the ignition key switch is in valve and then to the secondary function manifold. From
the OFF position, the park brake is ON. The park brake is there, the oil is routed out to the brake valve “P” port. The
part of the front axle ONLY. brake valve is located above the brake pedal and beneath
the dash. With the pedal NOT depressed, the spool valves
The vehicle is designed so that the service brake can be are closed and no oil is allowed to flow to the axles.
used to stop the vehicle with the engine OFF. The service
brakes are contained within both the front and rear axles. Fluid Flow When Brake Pedal is Pressed
Refer to Section 5, “Axles, Drive Shafts, Wheels and
Tires,” for further information. System pressure from the pump flows to the main control
valve, to the secondary function manifold and to the
a. Park Brake Circuit (refer to page 8.18) brake valve. With the pedal depressed, spool valves
open and oil is allowed to flow through the brake valve
Only the front axle is equipped with a spring- and out to the axles. Valve operation occurs in two
applied, pressure-released park brake. The park modes: the power mode and the manual mode.
MT3590 brake operates via two solenoids at the secondary
function manifold. With the engine running and In the power mode of operation (engine ON), the service
the park brake switch ON, one of the solenoids is brake valve operates much the same as a pressure
normally open and the other is normally closed. This reducing valve. As force is applied to the brake pedal, the
prevents fluid flow in one direction but allows it in another. valve sends oil to the vehicle brakes at pressure that is
Spring pressure within the front axle engages the park proportional to the force that is applied to the pedal.
brake. Oil is prevented from flowing to the front axle and In the manual mode of operation (engine OFF), the brake
releasing the park brake. valve operates as a two-stage pump. The first stage
With the engine running and the park brake switch OFF, pumps a high volume of oil up to a low amount of
fluid flows from the hydraulic pump, to the secondary pressure. The second stage then pumps a low volume of
function valve, through the park brake solenoid valve, out oil for higher braking pressure.
the park brake “PB” port and to the park brake section of At rest (or standby), system pressure exists at the service
the front axle. Oil pressure overcomes the spring brake valve, ready for pedal application.
pressure within the front axle, and the park brake is The steps that follow describe service brake valve
released. Oil is prevented from flowing back to the function in both of the modes.
reservoir because of the closed solenoid valve at the
secondary function manifold. Power Mode
With the engine OFF and the park brake switch OFF,
When the engine is ON, the brakes operate in the power
spring pressure at the front axle engages the park brake.
mode.
b. Service Brake Circuit (refer to page 8.18) 1. Displacement of the brake pedal is transmitted to the
service brake valve (1) at the plunger (2).
A hydraulic line from secondary function manifold “PS”
port provides fluid flow to the service brake valve when 2. The series spring (3) transmits plunger displacement
the engine is running. A line returns oil back to the to the piston (4). The series spring also absorbs
reservoir from “T” port on the service brake valve. There slight pedal pressure variations and helps to provide
are also two lines for the rear wheel brakes and a load smoother braking.
sense line on the service brake valve. Pressure can be 3. At rest or standby, system pressure exists at the
checked at the secondary function manifold “PSG” port service brake valve (1), and the lines are vented to
and at the pressure tap fitting installed in the rear brake the reservoir. The reservoir venting is restricted as
line. pedal pressure is applied, causing the piston to
The service brake valve itself is a severe-duty type valve contact the piston sealing ring (5). The piston (4) is
used in a variety of agricultural and commercial blocked when the fluid return metering notches (6)
applications. The valve actually consists of two identical on the spool are covered by the spool bore.
8.58 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
1
4
2 3 6
10 5 7 9
8 MS1880
4. Pressure in both the front and rear axle brake lines is 3. The piston (4) and spool (7), functioning as pumps,
equal. A groove in each of the two spools opens to a send oil to the brake lines. Initially, the brake lines
cross-hole between the two spool bores, preventing are vented to the reservoir by an annular gap
uneven brake pressure. This feature is called the between a stepped-down piston diameter and the
“equalizer” function. piston bore. Flow to the reservoir is restricted when
5. Power-mode braking begins when the metering the piston contacts the piston sealing ring (5).
notches (6) in the spool (7) meter oil from the inlet 4. Volume generated by piston displacement causes
port to the spool chamber. Fluid flows from the spool the spool make-up check device (9) to unseat. Fluid
chamber, through the one-way orifice (8) and into flows into the spool chamber and out to the brake
the brake lines. Brake pressure is controlled by a lines.
force balance between the force applied at the pedal 5. Pressure in both the front and rear axle brake lines is
and the resulting force from pressure in the spool equal. A groove in each of the two spools opens to a
area. cross-hole between the two spool bores, preventing
6. The load sense bleed orifice helps provide stability uneven brake pressure. This feature is called the
and aids in purging air from the system. “equalizer” function.
6. At a set piston chamber pressure, a relief valve (10)
Manual Mode begins to meter oil and limits the pressure within the
In the event that hydraulic pressure at the inlet port is too piston chamber. The pressure in the piston chamber
low to provide the braking force required, the service becomes isolated from the pressure in the spool
brake valve automatically transitions to the manual mode chamber when the make-up check device (9)
to provide braking power. reseats itself.
Flow paths out of the valve that would rob efficiency are 7. Further displacement of the service brake pedal
automatically blocked in the manual mode. The inlet port causes higher pressure in the spool chamber. The
check valve seals off the inlet port, and the load sense load sense pin in the make-up check device (9) is
shutoff valve closes. The service brake valve then acts as sensitive to the increased pressure and transmits a
a two-stage pump. force to the relief ball. The increasing force on the
relief ball effectively lowers the relief setting within
1. Brake pedal displacement is transmitted to the
the piston chamber. Eventually, piston chamber
service brake valve (1) at the plunger (2).
pressure reaches zero, and the valve has moved
2. The series spring (3) transmits plunger displacement completely from the first stage to the second stage.
to the piston (4). The smaller area of the second stage permits the
brake valve to develop higher braking pressure.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.59

Hydraulic System
8. Controlling the force applied to the service brake The extend/retract cylinder includes a counterbalance
pedal controls the amount of braking power. valve and a pilot-operated check valve. The valves serve
9. If the first application of force applied to the service two main functions. One of the functions is to help prevent
brake pedal was not enough to deliver the braking component damage. The other valve function can be
required, the one way orifices at the work ports help described as follows:
give the brake valve “pump up” ability. The one-way • If the vehicle is traveling and the boom runs into
orifices allow unrestricted flow to the brake lines but a solid object, pressure will build up on the base
also restrict the rate of decompression. end of the cylinder. Without a counterbalance
valve, the cylinder rod would bend, damaging the
8.8.22 Boom Extend/Retract Circuit cylinder. With the counterbalance valve installed,
Description the pressure will build up until it reaches 3250 psi
(224 bar) and then the counterbalance valve will
Hydraulic flow is applied in the boom extend/retract circuit
be internally piloted open, allowing the pressure
by the hydraulic piston pump through the main control
to return to the reservoir. This condition will only
valve. System pressure is directed to either side of the
exist if the cylinder has been extended. If the cyl-
extend/retract cylinder by the shifting of the spool valve in
inder is already fully retracted, the counterbal-
the main control valve. The spool valve is shifted by the
ance valve will have no effect and damage can
operator joystick and its associated control cable.
result.
a. Boom Extend Position (refer to page 8.20) • Should any of the hydraulic lines going to the
extend/retract cylinder fail, there will be a loss of
When the joystick is in the boom EXTEND hydraulic system pressure to the cylinder. For
position, the spool valve is shifted by the cable, example, if there was a hydraulic line failure in
so flow is directed through extend/retract spool the pressurized retract line during retracting, the
MA7220
valve ports, through the counterbalance valve to counterbalance valve would lose pilot pressure,
the base end of the extend/retract cylinder. On the 10054 closing off flow returning to the reservoir. The oil
model, the extend lockout valve will prevent boom in the base end of the cylinder would then be
extension beyond 42 feet unless the outriggers are down. trapped, which would immediately stop boom
Refer to Section 9.7.43, “10054 Outrigger Circuit and retraction, preventing an elevated load from
Troubleshooting.” Return oil from the rod end of the uncontrolled retraction. The load can be lowered
cylinder exits through the check valve. The oil will pass safely to the ground by following the procedures
from the cylinder to the spool valve, to the oil cooler, to the in the appropriate Legacy Owners/Operators
return filter and then to the reservoir. Manual.
If system pressure exceeds 3250 psi (224 bar), the IMPORTANT: DO NOT attempt to reset a
extend/retract port relief will open and allow hydraulic oil counterbalance valve cartridge. In the event that a
to return to the reservoir. If the return filter is plugged, the counterbalance valve cartridge was disabled for
oil returning to the reservoir bypasses the filter when the emergency boom lowering or any unauthorized
internal pressure of the filter reaches 25 psi (1,7 bar). adjustments are ever made to this cartridge, remove and
replace the cartridge with a new part. Failure to replace
b. Boom Retract Position (refer to page 8.22) this cartridge with a new part may alter the holding
When the joystick is in the boom RETRACT characteristics of the counterbalance valve, creating an
position, the extend/retract spool valve is shifted unsafe condition for vehicle operation.
MA7230
by the cable so that system pressure is directed
through the spool valve, to the rod end of the 8.8.23 Boom Lift/Lower Circuit Description
extend/retract cylinder. The counterbalance valve is Hydraulic flow is applied in the lift/lower circuit by the
piloted open by high pressure, allowing return oil from the hydraulic piston pump through the main control valve.
base end of the cylinder to flow through the spool valve, System pressure is directed to either side of the left and
to the oil cooler, to the return filter and then to the reservoir. right lift/lower cylinders by the shifting of the spool valve
If system pressure reaches 3250 psi (224 bar), the main in the main control valve. The spool valve is shifted by the
relief valve opens, allowing hydraulic oil to return to the operator joystick and its associated control cable.
reservoir. 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.
8.60 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
a. Boom Lift Circuit (refer to page 8.24) IMPORTANT: DO NOT attempt to reset the
counterbalance valve cartridge. In the event that the
With the joystick in the boom lift position,
counterbalance valve cartridge was disabled for
pressure shifts the lift/lower spool valve in the
emergency boom lowering, or if any unauthorized
main control valve to direct system pressure
MA7200 adjustments are ever made to the cartridge, remove and
through the counterbalance valve to the base
replace the cartridge with a new part. Failure to replace
end of both the left and right lift/lower cylinders.
the cartridge with a new part may alter the holding
Return oil from the rod end of the cylinders flows through characteristics of the counterbalance valve, creating an
the pilot-operated check valve to the spool valve, to the unsafe condition for vehicle operation.
oil cooler, to the return filter and then to the reservoir.
If system pressure exceeds 3250 psi (224 bar), the main 8.8.24 Frame Sway and Stabilizer Circuit
relief will open, allowing oil to return to the reservoir. If the Description
return filter becomes plugged, return hydraulic oil will Hydraulic flow is applied in the frame sway circuit by the
bypass the filter when pressure reaches 25 psi (1,7 bar) hydraulic piston pump through the main control valve.
and return to the reservoir unfiltered. System pressure is directed to either side of the frame
sway cylinder by the shifting of the spool valve in the main
b. Boom Lower Circuit (refer to page 8.26) control valve. The spool valve is shifted by the operator
When the joystick is in the boom lowering joystick and its associated control cable. The stabilizer
position, pressure shifts the lift/lower spool valve circuit is connected to the frame sway circuit. For a
in the main control valve. Oil is then directed to description of the stabilizer circuit, refer to Section 10.13,
MA7210
the pilot-operated check valve to the rod end of “Boom Extend System Hydraulic Circuit Operation and
the left and right lift/lower cylinders. System pressure also Troubleshooting.”
pilots open the counterbalance valve in the base end of
the lift/lower cylinders. a. Frame Sway LEFT (refer to page 8.28)
The open counterbalance valve allows oil from the base With the joystick moved to the left, the spool
of the cylinders to flow to the main control valve, to the oil valve in the frame sway section of the main
cooler, to the return filter and then to the reservoir. MA7160
control valve assembly is shifted.
If system pressure exceeds 3250 psi (224 bar), the main System pressure is directed to the spool valve in
relief will open, allowing oil to return to the reservoir. If the the main control valve, and from there to the base end of
return filter becomes plugged, return hydraulic oil will the frame sway cylinder. Oil from the rod end of the frame
bypass the filter when pressure reaches 25 psi (1,7 bar) sway cylinder flows through a check valve, unseated by
and return to the reservoir unfiltered. system pressure, to the stabilizer cylinder, back to the
The counterbalance and pilot-operated check valves main control valve, to the oil cooler, to the return filter and
serve another main function for safety purposes. This then to the reservoir.
function can be described as follows:
b. Frame Sway RIGHT (refer to page 8.30)
• Should any of the hydraulic lines routed to the lift/
lower cylinders fail, there will be a loss of hydrau- With the joystick moved to the right, the spool
lic system pressure to the cylinder. For example, valve in the frame sway section of the main
if a hydraulic line failure occurred in the pressur- control valve assembly is shifted.
MA7170
ized lowering line during lowering, the counter- System pressure is directed to the spool valve,
balance valve would lose pilot pressure, closing back to the frame sway cylinder, where it flows to the rod
off flow returning to the reservoir. The oil in the end of the cylinder. Oil from the base end of the cylinder
base end of the cylinder would then be trapped, flows through the check valve, which was unseated by
which would immediately stop boom lowering system pressure, then to the spool valve, to the stabilizer
and prevent an elevated load from falling to the cylinder, back to the main control valve, to the oil cooler,
ground uncontrolled. The load can be lowered to the return filter and then to the reservoir.
safely to the ground by following the procedures
in the appropriate Legacy Owners/Operators
Manual.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.61

Hydraulic System
8.8.25 Attachment Tilt and Slave Circuit 8.8.26 Pump and Cooling Circuit Description
Description In the pump and cooling circuit, the pump draws fluid from
System pressure is applied in the attachment tilt and the hydraulic reservoir, and sends pressurized fluid to the
slave cylinder circuit from the attachment tilt section of main control valve.
the main control valve. The main control valve regulates maximum system
Fluid flow is directed to either side of the attachment tilt operating pressure for various vehicle functions. The
and slave cylinder pistons by shifting of the spool valve in piston pump sends fluid to the main control valve and to
the attachment tilt section of the main control valve the secondary function manifold. When fluid from the
assembly. The spool valve is shifted by the operator main control valve is returned to the reservoir, it is sent
joystick and its associated control cable. through the hydraulic oil cooler first. There is a return line
Moving the joystick BACKWARD controls attachment tilt from the main control valve to the tank that will bypass the
UP. Moving the joystick FORWARD controls attachment cooler when pressure reaches the 65 psi (4.5 bar).
tilt DOWN.
8.8.27 Auxiliary Hydraulics Circuit Description
a. DOWN Position (refer to page 8.32)
The auxiliary hydraulics circuit functions can be
With the joystick moved FORWARD, the
achieved by moving the auxiliary attachment
attachment tilts DOWN. The spool valve in the
control lever. Moving the control lever to the left
main control valve is shifted so system pressure
MT3780 MA7250 controls auxiliary function in one direction,
is directed to the rod end of the attachment tilt
usually forward, if the auxiliary device is so
cylinder and the slave cylinders.
designed. Moving the control lever to the right controls
The extension of the slave cylinders is fixed by the auxiliary functions in reverse, or the opposite direction.
position of the boom, so that only the attachment tilt
cylinder is retracted to tilt the attachment downward. The a. Male Coupler Pressurized (refer to page 8.38)
pilot pressure opens the counterbalance valve. The open
counterbalance valve allows return oil from the base of With the auxiliary attachment control lever moved
the attachment tilt cylinder to flow to ports of the to the right, pressure will shift the auxiliary spool
attachment tilt section of the main control valve, to the oil MA7260
valve, allowing system pressure to flow from the
cooler, to the return filter and then to the reservoir. auxiliary spool valve to the male connection of the
auxiliary hydraulics coupler. From the coupler, fluid flows
If system pressure reaches 3250 ±100 psi (224 ±7 bar) to the attachment, back to the female auxiliary coupler, to
the main relief will open and allow hydraulic oil to return the auxiliary spool valve, to the oil cooler, to the return
to the return filter and to the reservoir. In any case, if the filter and then to the reservoir.
return filter becomes restricted, hydraulic oil will bypass
the filter when the pressure reaches 25 psi (1,7 bar). b. Female Coupler Pressurized (refer to page 8.40)
b. UP Position (refer to page 8.34)
With the auxiliary attachment control lever
With the joystick moved BACKWARD, the moved to the left, pressure will shift the auxiliary
attachment tilts UP. The spool valve in the main spool valve, allowing oil to flow from the auxiliary
MA7270
control valve is shifted so system pressure is spool valve to the female connection of the
MT3790
directed to the base end of the attachment tilt auxiliary hydraulic coupler. From the coupler, fluid flows
cylinder and the slave cylinders. to the attachment, back to the male auxiliary coupler, to
If system pressure reaches 3250 ±100 psi (224 ±7 bar) the auxiliary spool valve, to the oil cooler, to the return
the main relief will open, allowing hydraulic oil to flow to filter and then to the reservoir.
the return filter and to the reservoir. If the return filter
becomes restricted, hydraulic oil will bypass the filter
when the pressure reaches 25 psi (1,7 bar).
Return oil from the rod side of the attachment tilt cylinder
is directed back to the attachment tilt section of the main
control valve through the spool valve, to the oil cooler, to
the return filter and then to the reservoir.
If the return filter becomes restricted, hydraulic oil will
bypass the filter when the pressure reaches 25 psi
(1,7 bar).
8.62 Model 8042, 10042, 10054 Legacy Rev. 10/03
Hydraulic System
8.8.28 Outrigger Circuit Description b. DOWN Position (refer to page 8.44)

(10042/10054) Pressing the bottom of the left and right
System pressure is applied to the outrigger circuit outrigger switches will lower the outriggers.
through the main control valve to the outrigger valve. MH3900
The other solenoids on the outrigger valve
Fluid flow is directed to either side of the outrigger are energized. The spools are shifted
cylinders by the outrigger valve. The valve is controlled allowing flow to the base end of the outrigger cylinders.
by the position of the left and right outrigger switches Return oil from the rod side of the outrigger cylinders is
located on the side console. directed back through the outrigger valve, to the main
control valve, to the oil cooler, to the return filter and then
a. UP Position (refer to page 8.42) to the reservoir.
Pressing the top of the left and right outrigger If the return filter becomes restricted, hydraulic oil will
switches will raise the outriggers. Two of the bypass the filter when the pressure reaches 25 psi
MH3890
solenoids on the outrigger valve are (1,7 bar).
energized. The spools are shifted allowing
flow to the rod end of the outrigger cylinders.
Pilot pressure opens the counterbalance valve. The open
counterbalance valve allows return oil from the base end
of the outrigger cylinders to flow back to the outrigger
valve, to the main control valve, to the oil cooler, to the
return filter and then to the reservoir.
If the return filter becomes restricted, hydraulic oil will
bypass the filter when the pressure reaches 25 psi
(1,7 bar).
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.63

Hydraulic System
4 MA7010
8.8.29 Steering Circuit Descriptions 2. Front-Wheel Steering Right Turn

(refer to page 8.48)
Vehicle steering includes front-wheel steering, four-
wheel steering and crab steering. When a right turn is made, the steering unit spool is
shifted so that system pressure from the secondary
a. Front-Wheel Steering function manifold is applied to the intake side of the
metering section of the power steering unit.
When the steer select switch (1) is in the front-
wheel steer (center) position (2), the front wheels A specific amount of hydraulic oil is exhausted from the
(3) will steer in the direction the steering wheel is metering section and routed to the power steering control
MT3870
turned and the rear wheels (4) will remain fixed. valve, internal to the power steering unit, where it is
channeled through the steer select valve to the right rod
1. Front-Wheel Steering Left Turn end of the front steering cylinder. Both solenoids in the
(refer to page 8.46) steer select valve are de-energized.
In the front-wheel steering mode, when a left turn is Oil from the left rod end of the front steering cylinder flows
made, system pressure from the secondary function to the power steering control valve, then to the oil cooler
manifold is applied through the intake side of the and to the return filter in the reservoir.
metering section of the power steering unit.
A specific amount of hydraulic oil is exhausted from the
metering section and routed to the power steering control
valve, internal to the power steering unit, where it is
channeled to the left rod end of the front steering cylinder.
Oil from the right rod end of the front steering cylinder
flows through the steer select valve to the power steering
unit, then to the oil cooler and to the return filter in the
reservoir. Both solenoids in the steer select valve are
deenergized.
8.64 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
7
5
6
8
MA7020
b. Four-Wheel Steering 2. Four-Wheel Steering Right Turn

When the steer select switch (5) is in the four-
wheel steer (rear) position (6), the front wheels With the steer select switch (5) in the four-wheel steer
(7) will steer in the direction the steering wheel is (rear) position (6), one of the steer select valve solenoids
MT3880
turned and the rear wheels (8) will steer in the is energized. The power steering unit control valve spool
opposite direction. is shifted so that the system pressure from the secondary
function manifold is applied to the intake side of the power
1. Four-Wheel Steering Left Turn
steering unit metering section.
With the steer select switch (5) in the four-wheel steer
metering section and routed back to the power steering
(rear) position (6), one of the steer select valve solenoids
control valve, internal to the power steering unit, where it
is energized. The power steering unit control valve spool
is channeled through the steer select valve to the right rod
is shifted so that the system pressure from the secondary
end of the rear steering cylinder.
function valve is applied to the intake side of the power
steering unit metering section. Oil from the left rod end of the rear steering cylinder flows
through the steer select valve to the right rod end of the
front steering cylinder. Oil from the left rod end of the front
steering cylinder flows back to the power steering control
control valve section, internal to the power steering unit,
valve, then to the return filter in the reservoir.
where it is channeled to the left rod end of the front
steering cylinder.
flows through the steer select valve to the left rod end of
the rear steering cylinder. Oil from the right rod end of the
rear steering cylinder flows through the steer select valve
and back to the power steering control valve, then to the
return filter in the reservoir.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.65

Hydraulic System
1
2
4 MA7030
c. Crab Steering 2. Crab Steering Right Turn (refer to page 8.56)

When the steer select switch (1) is in the crab With the steer select switch (1) in the crab steer (forward)
steer (forward) position (2), the front wheels (3) position (2), one of the steer select valve solenoids is
will steer in the direction the steering wheel is energized. The power steering control valve is shifted so
MT3890
turned and the rear wheels (4) will steer in the that system pressure from the secondary function
same direction. manifold is applied through the intake side of the power
steering unit metering section.
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. The power steering control valve is shifted so
is channeled through the steer select valve to the left rod
that system pressure from the secondary function
end of the rear steering cylinder.
manifold is applied through the intake side of the power
steering unit metering section. Oil from the right rod end of the rear steering cylinder
flows through the steer select valve to the right rod end of
the front steering cylinder. Oil from the left rod end of the
front steering cylinder flows to the power steering control
valve, then to the return filter in the reservoir.
is channeled to the left rod end of the front steering
cylinder.
flows through the steer select valve to the right rod end of
the rear steering cylinder. Oil from the left rod end of the
rear steering cylinder flows through the steer select valve
and back to the power steering control valve, then to the
return filter in the reservoir.
8.66 Model 8042, 10042, 10054 Legacy Rev. 10/03

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. Toggle the steer select switch back to the four-wheel
steer position and turn the steering wheel full left.
4. Toggle the steer select switch back to the front-wheel
steer position, and steer the front wheels full left.
5. Toggle the switch to the four-wheel steer position,
and return to center.
The vehicle should now be properly indexed in four-wheel
steering. If the wheels are still out-of-phase, repeat the
above procedure. If, after repeating the above procedure,
the wheels are still out-of-phase, refer to Section 8.8.17,
“Four-Wheel Steering Circuit (Left Turn) and
Troubleshooting,” and Section 8.8.18, “Four-Wheel
Steering Circuit (Right Turn) and Troubleshooting.”
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.67

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,
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).
7 4
5
3 6
11
~
10
1
9 ~
8
2
Front MH3460
8.68 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
Occasionally, fluid may seep, leak or be more forcefully 8.10.1 Hydraulic Reservoir Replacement
expelled from the filter head (11) when system pressure
The fuel tank/hydraulic reservoir (1 and 2) are one unit
exceeds the rating of the filter head or breather. If the
and are removed together. Refer to Section 7A.8.2, “Fuel/
return filter becomes plugged, return hydraulic oil will
Hydraulic Oil Tank,” or Section 7B.8.2, “Fuel/Hydraulic
bypass the filter when pressure reaches 25 psi (1,7 bar)
Oil Tank,” for information on the fuel tank/hydraulic
and return to the reservoir unfiltered.
reservoir removal. Support the fuel tank/hydraulic
Carefully examine fluid seepage or leaks from the reservoir with a suitable device. Loosen, but do not
hydraulic reservoir to determine the exact cause. Clean remove, the hex nuts (10) on the carriage assemblies.
the reservoir and note where any seepage occurs. Slide the unit to the right to allow the carriage bolt heads
to come through the slots in the frame.
DANGER: NEVER weld in, on, near or
Install the replacement fuel tank/hydraulic reservoir (1, 2),
around the hydraulic reservoir. Hydraulic fluid and
sliding the carriage bolt assemblies into the slots in the
fumes can cause the reservoir to explode. This
frame. Slide the unit to the left and secure it to the vehicle
can result in death or serious personal injury.
by tightening the hex nuts (10).
Leaks from a cracked or damaged reservoir require that
the reservoir be removed from the vehicle, flushed
completely with water and repaired by a certified welder
using approved techniques. If these conditions cannot be
met, the reservoir must be replaced in its entirety.
Contact Sky Trak distributor or the JLG Service
Department at 1-877-554-5438 or 1-717-485-6657,
should reservoir welding or replacement be required.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.69

Hydraulic System
8.11 HYDRAULIC SYSTEM PUMP 8.11.2 Pump Replacement
The piston pump (1) is attached to the transmission. The a. Pump Removal
rotation of the pump shaft causes the cylinder block, shoe
1. Park the vehicle on a firm, level surface, fully retract
plate and pistons to rotate. The angle of the yoke face
the boom, raise the boom, place the travel select lever
creates a reciprocating motion to each piston within the
in (N) NEUTRAL, place the neutral lock lever in the
cylinder block. As the pistons move out of the cylinder
(N) NEUTRAL LOCK position, engage the park brake
block, a vacuum is created and fluid is forced into the void
through a 2" inside diameter hose by atmospheric
pressure. The motion of the piston reverses, and fluid is 2. Place an Accident Prevention Tag on both the
pushed out of the cylinder block into the outlet port ignition key switch and the steering wheel, stating
through a 3/4" inside diameter hose to the secondary that the vehicle should not be operated. Refer to
function manifold. Section 1.5, “Accident Prevention Tags.”

boom unless the boom is blocked up. Always
1 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.
MH3310
WARNING: Hot hydraulic fluid can
Hydraulic system pressure begins at the pump. Various
factors are involved in creating the relatively high
pressure used in the hydraulic system. Pump rpm, 4. Unlock and open the rear door. Allow the hydraulic
controlled via a transmission input shaft (and dependent fluid to cool.
on engine rpm), the internal pump passageways and the
differential between pump inlet (2" I.D.) and outlet
(3/4" I.D.) openings, all contribute to pressure supplied.
death or serious injury. Relieve hydraulic
8.11.1 Pump Failure Analysis pressure before servicing any hydraulic
The pump is the “heart” of the hydraulic system, and component.
whenever there is a problem in the system, the pump 5. Drain the hydraulic oil reservoir. Refer to the
often is blamed. However, pump failure is seldom due to appropriate Legacy Owners/Operators Manual,
failure of pump components. Pump failure usually Hydraulic Oil and Filter Change.
indicates another problem in the hydraulic system.
6. Remove the transmission covers.
According to pump manufacturer statistics, 90-95 percent
of pump failures are due to one or more of the following 7. Thoroughly clean the pump and surrounding area,
causes: including all hoses and fittings before proceeding.
• Aeration Note: Cap all hoses as you remove them to prevent
• Cavitation unnecessary fluid spillage.
• Contamination 8. Remove the four capscrews (2) and four
• Excessive Heat lockwashers (3) securing the flange halves (4) to the
• Over-Pressurization pump (5). Remove the inlet hose (6) and o-ring (7).
• Improper Fluid
Note: It is not necessary to remove the T-bolt band
In the event of pump failure, investigate further to clamp (8) and inlet hose (6) from the hydraulic reservoir
determine the cause of the problem. outlet connection.
8.70 Model 8042, 10042, 10054 Legacy Rev. 10/03

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
8 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.
13 13. Remove the four capscrews (20), four lockwashers
9 10 (21) and four plain washers (22) securing the pump
11
14 17 (5) to the transmission. Remove the o-ring (23)
24 located between the transmission and the pump.
16 Wipe up any hydraulic oil spillage.
25
19 b. Tools Required for Pump Repair

23
The following tools are used for servicing the pump:
~
• Ball Peen Hammer
12 • Plastic Tip Hammer
18 5
7 • Hex (Allen) Wrenches (Metric)
• Wrenches (Metric)
15 3 • Flat Tip Screwdriver
4 2 • Lock Ring Pliers
22 • Torque Wrench
21
20 • Copper Hammer
6
• Brass Punch
c. General Repair Precautions

MH3230
1. To facilitate repair of the pump, and before any work
is done, read and understand all of the steps used in
Note: Before removing any fittings from the pump, note the disassembly and assembly procedures.
their orientation to ensure correct installation.
2. Perform procedures in a clean area. It is important to
9. Remove the four capscrews (9) and four service hydraulic equipment in an environment as
lockwashers (10) securing the flange halves (11) to clean as possible.
the check valve manifold (12). Remove the outlet
3. If it becomes necessary to pry sections apart, be
hose (13) and o-ring (14). Remove the tank hose
extremely careful to avoid damaging the machined
(15) from the check valve manifold.
surfaces. Excessive force used while prying can
10. Disconnect the case drain hose (16) from the fitting result in misalignment and serious damage to parts.
(17).
4. Match-mark the exterior surfaces of any housings
11. Disconnect the load sense lines (18) and "T" before separating the components. Use the marks to
connection (19). return components to their original positions during
12. Remove the four capscrews (24) and four assembly.
lockwashers (25) securing the check valve manifold 5. To help prevent damage, DO NOT grip machined
(12) to the pump (5). Remove the check valve surfaces in a vise.
manifold from the pump.
Note: If parts are difficult to fit together during assembly,
tap gently with a soft hammer. NEVER use an iron or
steel hammer to tap parts.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.71

Hydraulic System
6
1
2 22
17
9 19
18
21 20
9 7
13
14
15
10
24
12
22 11
6
8
16 9
23
MH3420
d. Pump Disassembly Note: Typically, it will only be necessary to separate the

1. Remove the four screws (1) securing the pressure flange section (8) from the housing (7) and valve block (3)
compensator subassembly (2) from the valve sections when disassembling the pump (4).
housing section (3) of the pump (4). Remove the Note: If it becomes necessary to pry the components
three o-rings (5). apart when separating pump sections, proceed carefully
2. Secure the pump (4) with the pump shaft (6) pointing and DO NOT damage the machined surfaces or internal
up in a suitable holding device or bench vise (if components. Dowel pins (9) will remain installed in most
possible). cases; DO NOT remove dowel pins unless they are
damaged.
3. Scribe or otherwise make a mark across the valve
housing (3), the housing (7) and the flange section 4. Remove the shaft seal retaining ring (10), using lock
(8), perpendicular to the parting lines for easy ring pliers.
identification and proper alignment during assembly 5. Remove the bearing (11).
later.
Note: Check the condition of the shaft seal (12).
Remove the shaft seal only if replacement is required.
8.72 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
6. Remove springs (13 and 14) and spring seat (15). 2. If installing, coat the outer edge of a new shaft seal
7. Lift the flange section (8) off the housing section (7). (12) with a non-hardening sealant (Permatex®
Remove the gasket (16) from between the two Aviation Form-A-Gasket No. 3 or equivalent). DO
sections. NOT damage the shaft seal. Press the seal into the
housing until seal is flush with the housing recess.
Note: In most cases, the parts inside the cylinder block Wipe off excess sealant.
(17) will not require removal.
CAUTION:
h. Pump Installation
Injury may result if the
retaining ring for the cylinder block spring is 1. While the pump is still on the bench, install all
removed without adequate protection. fittings, except the outlet hose fitting (25), orientating
them as noted during removal.
8. Pull the shaft (6) and the piston rotating assembly 2. Secure the check valve manifold (26) onto the pump
(17) out of the pump (4). DO NOT remove the (27) using the four lockwashers (28) and four capscrews
retaining ring (18) because the cylinder block spring (29).
(19) is under high compression.
9. Remove the valve plate (20) and bearing (21).
10. If necessary, remove the control piston assembly (22)
from the yoke (23) by removing the retaining clip from
the chain link (24).
e. Pump Cleaning
Clean all pump components with a suitable cleaner such
as trichlorethylene.
25
f. Pump Inspection
29
1. Inspect internal pump components for wear,
damage, etc. If inner surfaces of the pump DO NOT
display an ultra-smooth, polished finish, or are 28
damaged in any way, replace the damaged part.
Often, dirty hydraulic fluid causes failure of internal
pump seals and damage to the polished surfaces
within the pump and other hydraulic system
components.
26
2. If a dowel pin (9) or dowel-mounting hole is
damaged, replace the dowel or housing as required. 27
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.
3. Seal kits are available. Replace all flexible seals.
MH3230
g. Pump Assembly
Assembly is generally performed in the reverse order of
disassembly.
1. Rinse all parts in an approved solvent. Blow dry and
wipe the parts with a clean, lintless cloth before
beginning assembly.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.73

Hydraulic System
3. Place the pump (4) and a new, oiled o-ring (22) into 7. Connect the load sense lines (17) to the Tee fitting
position on the transmission. Align the pump shaft (18).
with the internal transmission gear, so that the 8. Install the tank hose (14) onto the check valve
machined teeth mesh together. manifold (11).
4. Align the bolt holes with the pump mount holes. 9. Place a new, oiled o-ring (13) into position over the
Secure the pump to the transmission with four plain opening on the check valve manifold (11). Secure
washers (21), four lockwashers (20) and four the outlet hose (12) with two flange halves (10), four
capscrews (19). lockwashers (9) and four capscrews (8).
5. If necessary, slide the T-bolt band clamp (7) onto the 10. Fill the hydraulic reservoir with clean, filtered
pump inlet hose (5). Secure the hose to the hydraulic hydraulic oil.
reservoir outlet connection with the T-bolt band clamp.
11. Prime the pump by filling the case drain port (23) with
6. Place a new oiled o-ring (6) into position over the fresh, filtered hydraulic oil from a clean container before
pump opening. Secure the inlet hose (5) with two installing the case drain connector (16) and hose (15).
flange halves (3), four lockwashers (2) and four
capscrews (1). 12. Check all routing of hoses and tubing for sharp
bends or interference with any rotating members. All
tube and hose clamps must be tight.

7 operation in closed areas with inadequate
fumes can result in death or serious injury.
13. Start the engine and run at approximately one-third
to one-half throttle for about one minute without
12 moving the vehicle or operating any hydraulic
8 9
10 functions.
13
WARNING:
16
15 Hydraulic oil leaking under
18 or any part of your body to check for hydraulic
22
~ 23 safety glasses and gloves to help provide
11 protection from spraying hydraulic oil. Use a
17 4 piece of cardboard or paper to search for
6 leaks.
2 14. Inspect for leaks and check all fluid levels. The
14
1 hydraulic reservoir oil level must be to the middle of
3
21 the sight gauge.
20
19 Note: Check for leaks and repair as required before
5
continuing.
MH3230 i. Pump Test

Refer to Section 8.7, “Hydraulic System Testing.”
1. Perform a flow meter test on the pump.
2. Check the load sense.
3. Check the system functions.
8.74 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.75

Hydraulic System
8.12 VALVES AND MANIFOLDS 10

11
Valves are devices that open or close passageways.
Manifolds contain circuit passageways involved in the
~
distribution of hydraulic fluid flowing under pressure. 9
There are various valves and manifolds in use on this 3
vehicle. As valves open and close, hydraulic fluid is 8
directed to flow through various passageways to the
7
prescribed circuit, causing vehicle functions to occur. 6
8.12.1 Main Control Valve 5 2

4 MH3350
The main control valve (1) is mounted on the frame under
the lower transmission cover.
a. Main Control Valve Removal
the boom, raise 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.
that the vehicle should not be operated. Refer to
Section 1.5, “Accident Prevention Tags.”

block the boom before doing any servicing that
requires the boom to be up. Unexpected lowering
1 of the boom may cause death or serious injury.
Front MH3750
The main control valve assembly (2) consists of various
working sections with their own valve assemblies, each
providing a specific hydraulic function. The section 4. Unlock and open the rear door. Allow the hydraulic
assemblies are the outlet (3), lift/lower (4), extend/retract fluid to cool.
(5), mid-inlet/outlet (6), frame sway (7), attachment tilt (8),
auxiliary hydraulics (9) and load sense outlet (10)
sections.
Note: If the vehicle has auxiliary hydraulics installed, the
auxiliary hydraulics section will have relief valves (11). If the
vehicle does not have auxiliary hydraulics installed, the
relief valve ports will be plugged.
8.76 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System

15
under pressure can penetrate the skin, causing 12
pressure before servicing any hydraulic 12
component.
5. With the engine OFF, operate all the hydraulic
functions to relieve trapped pressure. 14
6. Remove the transmission covers. Thoroughly clean 13
the main control valve and surrounding area, 16
including all hoses and fittings, before proceeding.
7. Place a suitable container to catch hydraulic fluid
~
drainage beneath the frame.
8. Label or otherwise mark and disconnect all the
hydraulic hoses, tubes and control cables at the
main control valve. Refer to Step 5 in Section 4.3.6,
“Joystick Assembly Replacement.”
9. Wipe up any hydraulic fluid spillage in, on, near and Front
MH3490
around the vehicle and the work area.
10. Remove the three hex flange nuts (12) and the
carriage bolts (13 and 14) securing the main control
valve (15) to the frame (16).
11. Remove the main control valve (15) from the frame.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.77

Hydraulic System
9
53 10
52 1
17 34
6
2 18
7 16 22
33
19 34 23 21
3
4 13
14
8
5
15 19
16 24
34
12
33 25
11
20 34
32
31
29
30
29
28 20
27 22
26
35
50
48 34
46
44
51
42 49 16
41 47 33
38 45
36 43
39
40
37
MH3480
8.78 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
b. Main Control Valve Disassembly Disassemble the Auxiliary Hydraulic Section

This section covers disassembly of one half (54) of the 1. Carefully separate the auxiliary hydraulic section (5)
main control valve, including the frame sway (55), from the attachment tilt section (11). Avoid dislodging
attachment tilt (56), auxiliary hydraulics (57) and load or losing the shuttle (12), spring (13) and poppet (14)
sense outlet (58) sections of the main control valve. in the attachment tilt section.
2. Remove the o-ring (15) from between the two
sections.
54
3. Remove the spring (6) and poppet (7) from the
auxiliary hydraulic section (5).
58 4. Remove the two relief valves (16).
5. Remove the two plugs (17), if installed, and o-rings
(18) from the top of the section.
57 6. Remove both socket head capscrews (21) securing
the cable retainer assembly (19) to the auxiliary
56 hydraulic section (5).
55
7. Remove the retainer (22), both sleeves (23), another
MH3350
retainer (22), wiper (24) and o-ring (25) from the
cable retainer assembly (19).
1. To disassemble the frame sway, attachment tilt,
auxiliary hydraulics and load sense outlet sections of 8. Remove both socket head capscrews (26) securing
the main control valve (1), remove the nuts (2 and the end mechanism (20) to the auxiliary hydraulic
52) from the end of the tie rods (3 and 53). Pull the section (5).
tie rods out through the sections. 9. Remove the spool cap (27), retainer (22), spool end
2. Disassemble each section assembly as required. (28), spring seat (29), spring (30), another spring
seat (29), wiper (31) and o-ring (32) from the end
Some sections include a pre-adjusted relief valve that mechanism (20).
regulates pressure in a specific circuit.
IMPORTANT: DO NOT adjust any of the relief valve Disassemble the Relief Valves
assemblies! Tampering with a relief valve will irrevocably
Note: If the vehicle includes auxiliary hydraulic, there
alter pressure in the affected circuit, requiring recalibration
will be relief valve assemblies (16) on the auxiliary
or a new relief valve.
hydraulic section. The other relief valve assemblies (33)
are part of the attachment tilt section.
Disassemble the Load Sense Outlet Section
The relief valves are preset at 3250 ±50 psi (224 ±3,5 bar).
1. Carefully separate the load sense outlet section (4) from
the auxiliary hydraulic section (5). Avoid dislodging or 1. Remove the relief valve (16 or 33) and o-ring (34) from
losing the spring (6) and poppet (7) in the auxiliary the applicable section assembly.
hydraulic section. 2. Grip the relief valve body (35) with a suitable tool,
2. Remove the o-ring (8) from between the two and use another tool to remove the nut (36),
sections. revealing an o-ring (37) and the adjustment screw
(38).
3. Remove the shut-off plug (9) and o-ring (10) from the
load sense outlet section (4). 3. Carefully remove the plug (39), spring (40) and pilot
poppet (41).
4. Remove the large o-ring (42), back-up ring (43),
small o-ring (44), large spring (45), small spring (46),
piston (47), o-ring (48), back-up ring (49) and relief
valve poppets (50 and 51).
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.79

Hydraulic System
24
5 7
9
3
4
5
10 21
2 22
24 11
6 1
23
18
17
15 20
16
15 19
14 6
13 8 26
12
25
MH3480
8.80 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
Disassemble the Attachment Tilt Section 5. Remove the retainer (8), both sleeves (9), another
retainer (8), wiper (10) and o-ring (11) from the cable
1. Carefully separate the attachment tilt section (1)
retainer assembly (5).
from the frame sway section (19). Avoid dislodging
or losing the shuttle (20), spring (21) and poppet (22) 6. Remove both socket head capscrews (12) securing
in the frame sway section. the end mechanism (6) to the frame sway section
(19).
sections. 7. Remove the spool cap (13), retainer (8), spool end
(14), spring seat (15), spring (16), another spring
3. Remove the shuttle (2), spring (3) and poppet (4)
from the attachment tilt section (1).
mechanism (6).
4. Remove the two relief valves (24). Refer to
“Disassemble the Relief Valves” on page 8.79. c. Main Control Valve Disassembly
5. Remove both socket head capscrews (7) securing This section covers the disassembly of the other half (27)
the cable retainer assembly (5) to the attachment tilt of the main control valve, including the outlet (28), lift/
section (1). lower (29), extend/retract (30) and mid-inlet/outlet (31)
6. Remove the retainer (8), both sleeves (9), another sections of the main control valve.
retainer (8), spacer (10) and o-ring (11) from the
cable retainer assembly (5). 31
30
7. Remove both socket head capscrews (12) securing
the end mechanism (6) to the attachment tilt section 29
(1).
8. Remove the spool cap (13), retainer (8), spool end
(14), spring seat (15), spring (16), another spring
28
mechanism (6).
Disassemble the Frame Sway Section

1. Carefully separate the frame sway section (19) from 27 MH3350
the mid-inlet/outlet section (25).
sections.
3. Remove the shuttle (20), spring (21) and poppet (22)
from the frame sway section (19).
4. Remove the two socket head capscrews (7) securing
the cable retainer assembly (5) to the frame sway
section (19).
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.81

Hydraulic System
1
12
57
59
61
56 63
66 58
60 55
62 54
33 64
32
65
53
38
37
29 28 36
34
52
31
40
30 12
41 39 54
42
7
44 35 8
5
10
51 27
50 26 14 3
48 49
47 11
46
9
39
6
45 13
43
4 2
13
17 19
21
23
16 15
18 25
20
22
24
14
MH3470
8.82 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
1. To disassemble the outlet, lift/lower, extend/retract Disassemble the Lift/Lower Section

and mid-inlet/outlet sections of the main control 1. Carefully separate the lift/lower section (26) from the
valve (1), remove the three nuts (2 and 3) from the extend/retract section (30). Avoid dislodging or
end of the three tie rods (4 and 5). Pull the tie rods losing the shuttle (31), spring (32) and poppet (33) in
out through the section assemblies. the extend/retract section.
2. Disassemble each section as required. 2. Remove the o-ring (34) from between the two
Some sections include a pre-adjusted relief valve that sections. Remove the shuttle (27), spring (28) and
regulates pressure in a specific circuit. poppet (29) from the lift/lower section (26).
IMPORTANT: DO NOT adjust any of the relief valve 3. Remove the anti-void assembly (35) from the lift/
assemblies! Tampering with a relief valve will irrevocably lower section (26).
alter pressure in the affected circuit, requiring recalibration 4. Remove the relief valve (36). Refer to “Disassemble
or a new relief valve assembly. the Relief Valve (Lift/Lower and Extend/Retract
Sections)” on page 8.85.
Disassemble the Outlet Section
1. Carefully separate the outlet section (6) from the lift/ the cable retainer assembly (38) to the lift/lower
lower section (26). Avoid dislodging or losing the section (26).
shuttle (27), spring (28) and poppet (29) in the lift/
6. Remove the retainer (39), both sleeves (40), another
lower section.
retainer (39), wiper (41) and o-ring (42) from the
2. Remove the o-ring (7) from between the two cable retainer assembly (38).
sections.
3. Remove the plugs (8 and 9) and o-rings (10 and 11) the end mechanism (44) to the lift/lower section (26).
from the outlet section (6).
8. Remove the spool cap (45), retainer (39), spool end
(46), spring seat (47), spring (48), another spring seat
Disassemble the Relief Valves (Outlet Section)
(49), wiper (50) and o-ring (51) from the end mechanism
The load sense relief valve (12) and the main relief valve (44).
(13) are part of the outlet section (6). The load sense Disassemble the Extend/Retract Section
relief valve is preset at 2600 psi (179 bar). The main relief
valve is preset at 3500 psi (241 bar). 1. Carefully separate the extend/retract section (30)
from the mid-inlet/outlet section (52). Avoid
1. Remove the load sense relief valve (12) from the dislodging or losing the shuttle (66) from the mid-
outlet section (6). inlet/outlet section.
2. Remove the o-ring (54) from the relief valve. 2. Remove the o-ring (53) from between the two
3. Grip the relief valve body (55) with a suitable tool, sections.
and use another tool to remove the nut (56), 3. Remove the shuttle (31), spring (32) and poppet (33)
revealing an o-ring (57) and the adjustment screw from the extend/retract section (30).
(58).
4. Remove the two socket head capscrews (37)
4. Remove the nut (59), o-ring (60), shim (61), spring securing the cable retainer assembly (38) to the
(62), spring retainer (63) and poppet (64). extend/retract section (30).
5. Remove the plug (65) from the body (55). 5. Remove the retainer (39), both sleeves (40), another
6. Remove the main relief valve (13) from the outlet retainer (39), wiper (41) and o-ring (42) from the
section (6). cable retainer assembly (38).
7. Remove the o-ring (14) from the relief valve. 6. Remove both socket head capscrews (43) securing
8. Grip the relief valve body (15) with a suitable tool, and the end mechanism (44) to the extend/retract section
use another tool to remove the nut (16), revealing an o- (30).
ring (17) and the adjustment screw (18). 7. Remove the spool cap (45), retainer (39), spool end
9. Remove the nut (19), o-ring (20), shim (21), spring (46), spring seat (47), spring (48), another spring
(22), spring retainer (23), and poppet (24). seat (49), wiper (50) and o-ring (51) from the end
mechanism (44).
10. Remove the plug (25) from the body (15).
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.83

Hydraulic System
26
27
28 3
23
4
3
4
25 22
24
4
3
2
7
9
11 3
13
6
15 8
17 10
19
21 12
4 14
16
18
20
5
MH3470
8.84 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
Disassemble the Relief Valve (Lift/Lower and Extend/ Disassemble the Mid-Inlet/Outlet Section
Retract Sections)
1. Remove the shuttle (28) from the mid-inlet/outlet
The relief valves (3) on the lift/lower section (1) and the section (22).
extend/retract section (2) are preset at 3250 ±50 psi 2. Remove the shut-off plug (23).
(224 ±3,5 bar).
3. Remove the remaining plugs (24 and 26) and o-rings
1. Remove the relief valve (3) from the appropriate (25 and 27).
section.
2. Remove the o-ring (4) from the relief valve. d. Main Control Valve Parts Cleaning
3. Grip the relief valve body (5) with a suitable tool and Clean all components with a suitable cleaner, such as
use another tool to remove the nut (6), revealing an triclorethylene, before continuing. Blow dry.
adjustment screw (7) and an o-ring (8).
4. Remove the spring (9) and poppet (10) from the plug e. Main Control Valve Parts Inspection
(11). Inspect all parts and internal passageways for wear,
5. Remove the o-ring (12), large spring (13), back-up damage, etc. If inner surfaces of any component DO NOT
ring (14), o-ring (15), small spring (16), poppet (17), display an ultra-smooth, polished finish, or are damaged
o-ring (18), back-up ring (19), small poppet (20) and in any way, replace the damaged part. Often, dirty
large poppet (21) from the body (5). hydraulic fluid causes failure of internal seals, damage to
the polished surfaces within the component, and wear of
and/or harm to other parts.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.85

Hydraulic System
26 8
25 9 16
5
1 6 15
21
2 12
13
3 7
15 4
19
14
20
11
10
21
27
18
17
24
22 23
15
21
MH3480
8.86 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
f. Main Control Valve Assembly Assemble the Attachment Tilt Section

This section covers the assembly of the load sense 1. Assemble the attachment tilt section (10) in the
outlet, auxiliary hydraulics, attachment tilt and frame reverse order of the disassembly procedure. Refer to
sway sections of the main control valve (16). “Disassemble the Attachment Tilt Section” on page
8.81.
with new parts to help ensure proper sealing and 2. Insert the shuttle (11), spring (12) and poppet (13)
operation. Lubricate seals and o-rings with clean into the attachment tilt (10) section.
hydraulic oil. 3. Place a new oiled o-ring (14) between the
attachment tilt section (10) and the auxiliary
Assemble the Load Sense Outlet Section hydraulics section (4), and slide the attachment tilt
1. Install a new oiled o-ring (9) and the plug (8) into the section onto the tie rods.
load sense section (3).
Assemble the Frame Sway Section
2. Loosely install three tie rod nuts (1 and 25) onto tie rods
(2 and 26) and insert into the load sense section (3). At 1. Assemble the frame sway section (17) in the reverse
the end of the assembly procedure when all main order of the disassembly procedure. Refer to
control valve sections are in place, the two tie rod nuts “Disassemble the Frame Sway Section” on page
(1) will be torqued 13-15 lb-ft (18-20 Nm) and the third 8.81.
tie rod nut (25) to 30-36 lb-ft (41-49 Nm). 2. Insert the spring (19), poppet (20) and shuttle (18)
into the frame sway section.
Assemble the Auxiliary Hydraulics Section
3. Place a new oiled o-ring (27) between the frame
1. Assemble the auxiliary hydraulics section (4) in the sway section (17) and the attachment tilt section (10)
reverse order of the disassembly procedure. Refer to and slide the frame sway section onto the tie rods.
“Disassemble the Auxiliary Hydraulic Section” on page 4. Place a new oiled o-ring (24) on the frame sway
8.79. section (17), and set entire assembly aside. It will be
2. Insert the spring (5) and poppet (6) into the auxiliary attached to the mid-inlet/outlet section (23) via the
hydraulics section (4). tie rods at the end of the assembly procedure.
3. Place a new oiled o-ring (7) between the auxiliary
hydraulics section (4) and the load sense outlet
section (3), and slide the auxiliary hydraulics section
onto the tie rods.
Assemble the Relief Valves for the Auxiliary Hydraulics

Section (4) and Attachment Tilt Section (10), if installed.
Note: There is a seal and spring kit package for
assembling the relief valves.
1. Assemble the relief valves (15 and 21) in the reverse
order of the disassembly procedure. Refer to
“Disassemble the Relief Valves” on page 8.79.
2. Using a wrench on the body (22), install the relief
valve onto the section.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.87

Hydraulic System
23
19
16
17
19
12
22 18 13
21
8
14 15
19 7
5
11 3
10
6
9
4
2
19
20
MH3470
8.88 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
g. Main Control Valve Assembly For each relief valve (19):

This section covers assembly of the outlet, lift/lower, 1. Assemble the relief valve (19) in the reverse order of
extend/retract and mid-inlet/outlet sections of the main the disassembly procedure. Refer to “Disassemble
control valve (1). the Relief Valve (Lift/Lower and Extend/Retract
Sections)” on page 8.85.
Note: ALWAYS replace o-rings with new o-rings
lubricated with clean hydraulic oil to help ensure a leak- 2. Using a wrench on the body (20), install the relief
proof seal and proper vehicle performance. valve (19) into the appropriate section assembly.
Assemble the Outlet Section Assemble the Extend/Retract Section
1. Assemble the outlet section (6) in the reverse order 1. Assemble the extend/retract section (14) in the
of the disassembly procedure. Refer to reverse order of the disassembly procedure. Refer to
“Disassemble the Outlet Section” on page 8.83. “Disassemble the Extend/Retract Section” on page
8.83.
2. Screw three nuts (2 and 3) onto three tie rods (4 and
5) and insert into the outlet section (6). 2. Insert the shuttle (15), spring (16) and poppet (17)
into the extend/retract section (14).
Assemble the Relief Valves (Outlet Section) 3. Place a new oiled o-ring (18) between the extend/
retract section (14) and the lift/lower section (10) and
Note: There is a seal and spring kit for assembling the
slide the extend/retract section onto the tie rods.
relief valve.
1. Assemble the load sense (8) and main relief valves Assemble the Mid-Inlet/Outlet Section
(9) in the reverse order of the disassembly
1. Assemble the Mid-Inlet/Outlet section (21) in the
procedure. Refer to “Disassemble the Relief Valves
reverse order of the disassembly procedure. Refer to
(Outlet Section)” on page 8.83.
“Disassemble the Mid-Inlet/Outlet Section” on page
2. Install the load sense (8) and the main relief valve (9) 8.85.
onto the outlet section (6).
2. Insert the shuttle (23) into the mid-inlet/outlet section
(21).
Assemble the Lift/Lower Section
3. Place a new oiled o-ring (22) between the extend/
1. Assemble the lift/lower section (10) in the reverse retract section (14) and the mid-inlet/outlet section
order of the disassembly procedure. Refer to (21).
“Disassemble the Lift/Lower Section” on page 8.83.
4. Torque the two tie rod nuts (2) to 43-53 lb-ft
2. Insert the shuttle (11), spring (12) and poppet (13) (58-72 Nm) and the third tie rod nut (3) to 66-82 lb-ft
into the section. (89-111 Nm), holding all sections together.
3. Place a new oiled o-ring (7) between the outlet 5. Retrieve the attachment tilt, frame sway and auxiliary
section (6) and the lift/lower section (10), and slide assembly. Tighten the three tie rod nuts from this
the lift/lower section onto the tie rods. assembly into the mid-inlet/outlet section. Refer to
“Assemble the Load Sense Outlet Section” on page
Assemble Relief Valves (Extend/Retract and Lift/Lower 8.87, Step 2 for the torque values.
Sections)
6. Ensure that the large o-ring in the frame sway
There are two relief valves (19) on the extend/retract section is properly seated between the frame sway
section (14). On the lift/lower section (10), the relief valve section and the mid-inlet/outlet section. Refer to
(19) is on the “A” side. The relief valves are preset at 3250 “Assemble the Frame Sway Section” on page 8.87,
±50 psi (224 ±3,5 bar). Step 4.
Note: There is a seal and spring kit for assembling the
relief valves.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.89

Hydraulic System
h. Main Control Valve Installation

1. Insert the carriage bolts (2 and 3) from the bottom
into the main valve (4).
4
1 to one-half throttle for about one minute without
moving the vehicle or operating any hydraulic functions.
1
3 or any part of your body to check for hydraulic
2 leaks. When checking for hydraulic leaks, wear
5 safety glasses and gloves to help provide
piece of cardboard or paper to search for
~
leaks.
8. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
Note: Check for leaks and repair as required before
continuing. Add hydraulic fluid to the reservoir as needed.
Front
MH3490 9. Wipe up any hydraulic fluid spillage in, on, near and
around the vehicle, work area and tools.
2. Loosely install the hex flange nuts (1) onto the
carriage bolts (2 and 3). 10. Install the transmission covers.
3. Install the main control valve (4) into the vehicle, i. Main Control Valve Test
aligning the carriage bolt heads (2 and 3) with the
slots (5) in the frame. Slide the main valve into Conduct a pressure check of the hydraulic system in its
position, and tighten the nuts (1). entirety. Adjust pressure(s) as required. Refer to Section
8.7, “Hydraulic System Testing.”
4. Prime the main control valve by filling the inlet
openings with fresh, filtered hydraulic oil from a
clean container, before attaching the hoses.
8.12.2 Secondary Function Manifold
5. Use new oiled o-rings as required. Reattach and The secondary function manifold (6) is a directional control
secure all hoses, clamps, etc. to the main control valve. Hydraulic oil from the pump flows into the secondary
valve. function manifold where the pressure is reduced before the
oil is directed to the power steering unit or the park brake.
6. Check the routing of all hoses, wiring and tubing for
sharp bends or interference with any rotating The secondary function manifold is a machined block with
members, and install tie wraps and/or protective ports for two pressure reducing valves, a pressure relief
conduit as required. Tighten all tube and hose valve, two park brake solenoid valves (one normally open
clamps. and one normally closed), a check valve and diagnostic test
nipples. The secondary function manifold is secured on the
left side of the frame with two carriage bolts and two hex
flange nuts.
8.90 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System


of the boom may cause death or serious injury.
~ 3. Temporarily block up or support the raised boom.
WARNING:
6
4. Unlock and open the rear door. Allow the hydraulic
fluid to cool.
Front MH3750 5. Remove the transmission covers.
Verify the correct operation of the solenoids before WARNING: Escaping hydraulic fluid
considering replacement of the secondary function under pressure can penetrate the skin, causing
manifold. Refer to Section 9, “Electrical System.” The death or serious injury. Relieve hydraulic
manifold itself is not serviceable and must be replaced if pressure before servicing any hydraulic
defective. component.
Note: DO NOT loosen, disassemble or attempt to adjust 6. Label or otherwise mark the hydraulic hoses in
any of the pressure valves unless specifically instructed relation to the secondary function manifold.
by JLG to do so! Tampering with a pressure valve will Disconnect and cap all hoses, fittings, solenoid wire
irrevocably alter pressure in the affected circuits. terminal leads, etc.
7. Remove the two hex flange nuts from the carriage
a. Secondary Function Manifold Replacement bolts securing the secondary function manifold to the
1. Park the vehicle on a firm, level surface, fully retract frame. Remove the secondary function manifold
the boom, raise the boom, place the travel select from the vehicle. Wipe up any hydraulic fluid spillage
lever in (N) NEUTRAL, place the neutral lock lever in in, on, near and around the vehicle.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.91

Hydraulic System
b. Secondary Function Manifold Disassembly, 4. Remove the 650 psi (45 bar) pressure relief valve
Cleaning, Inspection and Assembly (4).
1. Secure the secondary function manifold (1) in a 5. Remove the solenoid nuts (5), coils (6) and
suitable bench vise, if possible. cartridges (7).
6. Remove the check valve (8).
7. Clean all components with a suitable cleaner before
inspection.
8. Inspect the solenoid cartridges for proper operation.
Check by shifting the spool to ensure that it is
8
functioning properly. Check that the spring is intact.
Inspect the cartridge interior for contamination.
9. Inspect internal passageways of the secondary
function manifold and its component parts for wear,
damage, etc. If inner surfaces of the secondary
7 function manifold DO NOT display an ultra-smooth,
polished finish, or components are damaged in any
1
way, replace the secondary function manifold or
appropriate part. Often, dirty hydraulic fluid causes
failure of internal seals and damage to the polished
3 surfaces within the secondary function manifold.
6 Note: ALWAYS replace seals, o-rings, gaskets, etc.,
5 operation. Lubricate seals and o-rings with clean
7 hydraulic oil.
10. Secure the secondary function manifold (1) in a
2
bench vise or by other suitable means.
6
4 11. Install the pressure reducing valve assembly (2) and
5 torque to 60-70 lb-ft (81-95 Nm).
MH3260 12. Install the pressure reducing valve assembly (3) and
torque to 35-40 lb-ft (47-54 Nm).
2. Remove the 550 psi (38 bar) pressure reducing 13. Install the relief valve assembly (4) and torque to
valve (2). 25-30 lb-ft (34-41 Nm).
3. Remove the 2500 psi (172 bar) pressure reducing 14. Install the check valve (8) and torque to 25-30 lb-ft
valve (3). (34-41 Nm).
15. Install the solenoid cartridges (7) and torque to 25-30
lb-ft (34-41 Nm). Install the solenoid coils (6) and nuts
(5). Torque the nuts to 4-6 lb-ft (5-8 Nm).
8.92 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
c. Secondary Function Manifold Installation 8.12.3 Service Brake Valve

1. Align the secondary function manifold with its The service brake valve (9) is secured with four
mounting holes on the frame. capscrews and lockwashers at the base of the steering
2. Secure the secondary function manifold with two column support (10), concealed by the lower dash cover.
carriage bolts and hex flange nuts. Torque fasteners The service brakes themselves are part of the axles (the park
to specification. Refer to the fastener torque chart in brake is part of the front axle only). Refer to Section 5, “Axles,
Section 2.3, “Torques.” Drive Shafts, Wheels and Tires,” for further information.
3. Before attaching the hoses, prime the secondary
function manifold by filling the hydraulic hose ports 9
with fresh, filtered hydraulic fluid from a clean
container.
4. Use new oiled o-rings as required. Reattach and
secure all diagnostic test nipples, hoses, clamps,
wiring, etc.
sharp bends or interference with any rotating
members, and install tie wraps and/or protective
conduit as required. Tighten all tube and hose
clamps.

6. Start the engine and run at approximately one-third to 10
one-half throttle for about one minute without moving
the vehicle or operating any hydraulic functions.

or any part of your body to check for hydraulic MA7060

safety glasses and gloves to help provide a. Service Brake Valve Removal
piece of cardboard or paper to search for 1. Park the vehicle on a firm, level surface, fully retract
leaks. all hydraulic cylinders, ground the attachment (if
any), place the travel select lever in (N) NEUTRAL,
7. Inspect the secondary function manifold for leaks place the neutral lock lever in the (N) NEUTRAL
and check the level of the hydraulic fluid in the LOCK position, engage the park brake switch and
reservoir. Shut the engine OFF. shut the engine OFF.
Note: Check for leaks and repair as required before 2. Place an Accident Prevention Tag on both the
continuing. Add hydraulic fluid to the reservoir as needed. ignition key switch and the steering wheel, stating
8. Wipe up any hydraulic fluid spillage in, on, near and Section 1.5, “Accident Prevention Tags.”
d. Secondary Function Manifold Test

Conduct a pressure check of the park brake and steering
hydraulic circuits. Refer to Section 8.7, “Hydraulic System
Testing.”
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.93
Hydraulic System
6. Remove the four capscrews (8) and four

WARNING: Hot hydraulic fluid can lockwashers (9) mounting the service brake valve
cause severe burns. Wait for hydraulic fluid to (10) to the steering column support.
Note: DO NOT disassemble the service brake valve.
3. Unlock and open the rear door. Allow the hydraulic The service brake valve is not serviceable and must be
fluid to cool. replaced in its entirety, if defective.

death or serious injury. Relieve hydraulic 10
pressure before servicing any hydraulic
component.
4. To remove the service brake valve, both the lower
dash panel and the front dash panel must be
removed. Refer to Section 4.5, “Cab Removal.”
5. Label or otherwise mark the hydraulic hoses on the
top (1) and bottom (2) of the service brake valve (3).
Disconnect and cap all hoses, fittings, etc.
Note: When the outlet fittings (4) on the brake valve (3)
are removed, a conical spring (5), a wave plate (6) and
an orifice (7) may fall out. If replacement parts are
required, contact the factory.
9
3 4
1 7 6 5 8
MA7040
2
MA7050
8.94 Model 8042, 10042, 10054 Legacy Rev. 10/03

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.
5. Inspect the service brake valve and connections for
Note: ALWAYS replace seals, o-rings, gaskets, etc., leaks, and check the level of the hydraulic fluid in the
with new parts to help ensure proper sealing and reservoir. Shut the engine OFF.
hydraulic oil. Note: Check for leaks, and repair as required before
continuing. Add hydraulic fluid to the reservoir as
2. Use new oiled o-rings as required. Reattach and needed.
secure all valves, hoses, clamps, etc.
6. Wipe up any hydraulic fluid spillage in, on, near and
3. Check the routing of all hoses, and tubing for sharp
bends or interference with any rotating members,
and install tie wraps and/or protective conduit as
required. Tighten all tube and hose clamps.

to one-half throttle for about one minute, without
moving the vehicle or operating any hydraulic
functions.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.95

Hydraulic System
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 4. DO NOT open the brake bleeder without holding the
to perform this procedure. tubing firmly on the bleeder. There is pressure at the
brakes. Carefully open the bleeder with a 12 mm
WARNING: Avoid prolonged engine wrench. Have the assistant depress the brake pedal.
operation in closed areas with inadequate Close the brake bleeder when air bubbles no longer
ventilation. Failure to properly ventilate exhaust appear in the oil. Release the brake pedal. Remove
fumes can result in death or serious injury. the tubing from the brake bleeder.
1. Place the travel select lever in (N) NEUTRAL, place 5. Repeat Steps 3 and 4 for the right rear brake.
the neutral lock lever in the (N) NEUTRAL LOCK 6. Frame sway the vehicle full right, exposing the brake
position, engage the park brake switch, and start the bleeders on the left front and rear axles.
engine. 7. Repeat Steps 3 and 4 for the left front and left rear
2. Have the assistant frame sway the vehicle full left to brakes.
expose the brake bleeders on the right front and 8. Conduct a pressure and function check of the
right rear axles. service brake. Refer to Section 8.7, “Hydraulic
3. Remove the plastic cap from the front brake bleeder System Testing.”
(1). Attach one end of a length of transparent tubing
over the brake bleeder. Place the other end of this
tubing in a suitable transparent container that is
partially filled with hydraulic oil. The end of the tubing
must be below the oil level in the container.
8.96 Model 8042, 10042, 10054 Legacy Rev. 10/03

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 3. Unlock and open the rear door. Allow the hydraulic
(7). The shuttle valve contains a pressure dependent, fluid to cool.
two-way check and is a non-serviceable item. It must be 4. To remove the shuttle valve (2), remove the right
replaced in its entirety if defective. front console panel on the front dash. Refer to
Section 4.5, “Cab Removal,” for information on
4 removing the dash panel.
5
~ 3
component.
6 ~
5. Disconnect, label and cap all hydraulic fittings and
hoses during removal from the shuttle valve (2).
7 2
Disconnect the brake valve load sense line (5) and
MA7440 pull the shuttle valve assembly forward. Disconnect
the shuttle IN line (6) and the steering valve shuttle
a. Shuttle Valve Removal IN line (7). Wipe up any hydraulic fluid spillage.
1. Park the vehicle on a firm, level surface, fully retract b. Shuttle Valve Cleaning, Inspection and
all hydraulic cylinders, ground the attachment (if Reassembly
place the neutral lock lever in the (N) NEUTRAL 1. Clean the shuttle valve with a suitable cleaner before
LOCK position, engage the park brake switch and inspection.
shut the engine OFF. 2. Inspect internal passageways and the shuttle valve
2. Place an Accident Prevention Tag on both the overall for wear, damage, etc. If inner surfaces of the
ignition key switch and the steering wheel, stating component DO NOT display an ultra-smooth,
that the vehicle should not be operated. Refer to polished finish, or are damaged in any way, replace
Section 1.5, “Accident Prevention Tags.” the shuttle valve. Often, dirty hydraulic fluid causes
surfaces within the shuttle valve.
3. Replace a defective shuttle valve with a new part.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.97

Hydraulic System
c. Shuttle Valve Installation 5. Inspect for leaks and check the level of the hydraulic
with new parts to help ensure proper sealing and Note: Check for leaks and repair as required before
operation. Lubricate seals and o-rings with clean continuing. Add hydraulic fluid to the reservoir as
hydraulic oil. needed.
1. Reattach and secure hoses, fittings, etc. Attach the 6. Wipe up any hydraulic fluid spillage in, on, near and
shuttle IN steering valve line at port P1 (2) and the around the vehicle, work area and tools.
shuttle-in main control valve line at port P2 (3), and
the load sense brake valve line at port P3 (4) of the d. Shuttle Valve Test
shuttle valve (1).
Conduct a pressure check of the service brake and
steering hydraulic circuits. Refer to Section 8.7,
1 3 “Hydraulic System Testing.”
P2
8.12.5 Power Steering Valve
The power steering valve (5) is located at the base of the
4 steering wheel shaft, concealed by the lower dash cover.
The valve is not serviceable and must be replaced in its
entirety if defective.
P3
P1
2
MT2170
2. Check the routing of all hoses, wiring, etc., for sharp

required. Tighten all fittings.
3. Reinstall the display panel. Refer to Section 4.5,
“Cab Removal,” for information on installing the dash
panel.

4. Start the engine and run at approximately 1/3-1/2
throttle for about one minute, without moving the 5
vehicle or operating any hydraulic functions.

severe personal injury. DO NOT use your hand MA7360
8.98 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
a. Power Steering Valve Removal

all hydraulic cylinders, ground the attachment (if
place the neutral lock lever in the (N) NEUTRAL
LOCK position, engage the park brake switch and
shut the engine OFF. 6
that the vehicle should not be operated. Refer to 7

MA7520

3. Unlock and open the rear door. Allow the hydraulic WARNING: Avoid prolonged engine
fluid to cool. operation in closed areas with inadequate
under pressure can penetrate the skin, causing 4. Start the engine and run at approximately 1/3-1/2
death or serious injury. Relieve hydraulic throttle for about one minute without moving the
pressure before servicing any hydraulic vehicle or operating any hydraulic functions.
component.
4. To remove the power steering valve, remove the WARNING: Hydraulic oil leaking under
right console panel from the front dash. Refer to pressure can penetrate the skin and cause
Section 4.5, “Cab Removal.” severe personal injury. DO NOT use your hand
5. Label or otherwise mark the hydraulic hoses (6)
connected to the power steering valve (7).
Disconnect the hoses and cap all hoses, fittings, etc.
Wipe up any hydraulic fluid spillage.
6. Refer to Section 4.3.2, “Steering Wheel, Column and leaks.
Shifter,” for information on removing the steering
column. The steering column and power steering 5. Inspect for leaks and check the level of the hydraulic
valve are mounted together. DO NOT attempt to fluid in the reservoir. Shut the engine OFF.
disassemble the steering valve. Note: Check for leaks and repair as required before
continuing. Add hydraulic fluid to the reservoir as
b. Power Steering Valve Installation needed.
Note: ALWAYS replace seals, o-rings, gaskets, etc., 6. Wipe up any hydraulic fluid spillage in, on, near and
with new parts to help ensure proper sealing and around the vehicle, work area and tools.
hydraulic oil. c. Power Steering Test
1. Install the steering column, connecting it to the Conduct a pressure check of the steering hydraulic
power steering valve. circuits at the secondary function manifold. Refer to
2. Connect all the hydraulic hoses (6) to the power Section 8.7, “Hydraulic System Testing.”
steering valve (7).
conduit as required. Tighten all hose clamps.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.99

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 3
6 7 6
1 5 5
4 MA8370
Verify the correct operation of the steer select valve

solenoids before considering replacement of the valve.
Refer to Section 9.7, “Electrical System
Troubleshooting,” and Section 9.14.9, “Steer Select
Switches.” The housing (7) of the steer select valve is not
serviceable and must be replaced if defective.
Front a. Steer Select Manifold and Valve Removal

MH3750
The steer select valve (2) contains two solenoids (3) that the boom, raise the boom, place the travel select
direct the flow of hydraulic fluid according to steering lever in (N) NEUTRAL, place the neutral lock lever in
input. The valve is a direct, dual solenoid operated, spool- the (N) NEUTRAL LOCK position, engage the park
type main control valve. brake switch and shut the engine OFF.
The valve consists of a housing (7), two solenoids (3), a 2. Place an Accident Prevention Tag on both the
control spool (4) and two return springs (5). In the de- ignition key switch and the steering wheel, stating
energized state, the spool (4) is held by the return springs that the vehicle should not be operated. Refer to
(5) in the center position. Section 1.5, “Accident Prevention Tags.”
The spool is shifted via the action of the two wet-pin type
solenoids (3). The force of an acting solenoid pushes WARNING: DO NOT get under a raised
against the push pin (6) on the end of the spool (4). The boom unless the boom is blocked up. Always
spool is shifted from its normal position to the end position block the boom before doing any servicing that
for selected flow. requires the boom to be up. Unexpected lowering
When the solenoid is de-energized, the control spool (4)
is returned to its normal condition by the centering 3. Temporarily block up or support the raised boom.
springs (5).
8.100 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
b. Steer Select Valve and Manifold Disassembly,

WARNING: Hot hydraulic fluid can Cleaning, Inspection and Assembly
1. Place the steer select assembly on a suitable work
surface.
2. Separate the steer select valve (12) from the manifold
fluid to cool. (13) by removing the four socket head capscrews (14).
WARNING:
Discard the four o-rings (15).
Escaping hydraulic fluid
under pressure can penetrate the skin, causing 13 16
death or serious injury. Relieve hydraulic 12
component.
5. Label or otherwise mark the hydraulic hoses (8) in 14
relation to the steer select manifold (9). Disconnect
and cap all hoses, fittings, solenoid wire terminal
leads, etc. 17
9 8 16
11
MT2150
10
3. Remove the solenoid valves and cartridges (16)
from the steer select housing (17).
inspection.
8 Inspect the cartridge interior for contamination.
MA8310
6. Inspect internal passageways of the steer select
6. Remove the two socket head capscrews (10) manifold and valve for wear, damage, etc. If inner
securing the steer select manifold (9) to the surfaces of the manifold DO NOT display an ultra-
mounting plate on the frame. smooth, polished finish, or components are
damaged in any way, replace the manifold or
7. Remove the steer select manifold (9) with attached
appropriate part. Often, dirty hydraulic fluid causes
steer select valve (11) from the vehicle. Wipe up any
hydraulic fluid spillage in, on, near and around the
surfaces within the secondary function manifold.
vehicle.
hydraulic oil.
7. Install the solenoid valves and cartridges (16) in the
steer select housing (17).
8. Attach the steer select valve (12) to the manifold (13)
using four new, oiled o-rings (15) and the four socket
head capscrews (14).
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.101

Hydraulic System
c. Steer Select Manifold and Valve Installation 6. Wipe up any hydraulic fluid spillage in, on, near and
1. Attach the steer select manifold (2) and valve (4) to
the mounting plate on the frame using the two
d. Steering Test
socket head capscrews (3).
Refer to Section 8.7, “Hydraulic System Testing.”
2 1. Conduct a pressure check of the steering hydraulic

1 circuit at the secondary function manifold.
4
2. Check each steering mode for proper function.
8.12.7 Outrigger Valve (10042/10054)

3 The outrigger valve (5) allows the left and right outriggers
to be raised or lowered depending on the position of the
outrigger switches located on the side console in the cab.
1 MA8310
2. Connect the hydraulic hoses (1), fittings, solenoid

wire terminal leads, etc., to the steer select valve (4)
5
and manifold (2).
conduit as required. Tighten all tube and hose clamps.

fumes can result in death or serious injury. Front MH3750
4. Start the engine and run at approximately 1/3-1/2

throttle for about one minute, without moving the

leaks.
8.102 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
The outrigger valve (6) contains two solenoid valve

assemblies (7) that direct the flow of hydraulic fluid WARNING: Hot hydraulic fluid can
according to position of the outrigger switches. cause severe burns. Wait for hydraulic fluid to
7 4. Unlock and open the rear door. Allow the hydraulic

fluid to cool.
~
~ WARNING: Escaping hydraulic fluid
P component.
S
5. Remove the transmission covers.
T 6. Label or otherwise mark the hydraulic hoses (8) in
relation to the outrigger valve (9). Disconnect and
cap all hoses, fittings, solenoid wire terminal leads,
6 MH3910 etc.
Verify the correct operation of the outrigger valve

solenoids before considering replacement of the valve.
Refer to Section 9.7, “Electrical System
Troubleshooting.” 9 10
a. Outrigger Valve Removal 8
~
ignition key switch and the steering wheel, stating 11
that the vehicle should not be operated. Refer to 8

MH3760
boom unless the boom is blocked up. Always 7. Remove the two hex flange nuts (10) and two
block the boom before doing any servicing that carriage bolts (11) securing the outrigger valve (9) to
requires the boom to be up. Unexpected lowering the frame.
8. Remove the outrigger valve (9) from the vehicle.
3. Temporarily block up or support the raised boom. Wipe up any hydraulic fluid spillage in, on, near and
around the vehicle.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.103

Hydraulic System
b. Outrigger Valve Disassembly, Cleaning, Note: ALWAYS replace seals, o-rings, gaskets, etc.,
Inspection and Assembly with new parts to help ensure proper sealing and
1. Place the outrigger valve assembly on a suitable
hydraulic oil.
work surface.
2. Remove the solenoid valve assemblies (1) from the 7. Install the shuttle cartridges (5) into the outrigger
outrigger valve (2) by removing the four socket head valve (2). Torque to 35 lb-ft (48 Nm).
capscrews (3). Discard the four o-rings (4). 8. Attach the solenoid assemblies (1) to the outrigger
valve (2) using four new, oiled o-rings (4) and the
four socket head capscrews (3).
3 c. Outrigger Valve Installation

1. Insert the two carriage bolts (9) through the bottom
of the outrigger valve (7) and loosely attach the hex
flange nuts (8) to the carriage bolts.
2. Position the outrigger valve (7) so that the heads of
the carriage bolts go through the slots in the frame.
4
1 Tighten the hex flange nuts.
2
7 8
P
6
~
S
T
5 MH3880
3. Remove the shuttle cartridges (5) from the outrigger

valve (2).
4. Clean all components with a suitable cleaner before 9
6
inspection.
MH3760
Inspect the cartridge interior for contamination. 3. Connect the hydraulic hoses (6), fittings, solenoid
6. Inspect internal passageways of the outrigger valve wire terminal leads, etc., to the outrigger valve.
for wear, damage, etc. If inner surfaces of the valve 4. Check the routing of all hoses and wiring for sharp
DO NOT display an ultra-smooth, polished finish, or bends or interference with any rotating members,
components are damaged in any way, replace the and install tie wraps and/or protective conduit as
valve or appropriate part. Often, dirty hydraulic fluid required. Tighten all hose clamps.
causes failure of internal seals and damage to the
polished surfaces within the secondary function
manifold.
8.104 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
8.12.8 Outrigger Shuttle Valve (10042/10054)

The outrigger shuttle valve (10) is attached to the main
control valve (11) with a straight fitting (12). The shuttle
valve joins the outrigger load sense line (13) and the
steer/brake load sense line (14) and selects the higher
5. Start the engine and run at approximately 1/3-1/2 signal to feed to the main control valve shuttle line. The
throttle for about one minute, without moving the shuttle valve contains a pressure-dependent, two-way
vehicle or operating any hydraulic functions. check valve and is a nonserviceable item. It must be
replaced in its entirety if defective.
protection from spraying hydraulic oil. Use a 12 15
piece of cardboard or paper to search for 10
14
leaks.
fluid in the reservoir. Shut the engine OFF. 11 16
Note: Check for leaks and repair as required before 13

MH3770
around the vehicle, work area and tools. a. Outrigger Shuttle Valve Removal
d. Outrigger Valve Test 1. Park the vehicle on a firm, level surface, fully retract
Raise and lower the outriggers to check the outrigger lever in (N) NEUTRAL, place the neutral lock lever in
hydraulic circuit for proper function. the (N) NEUTRAL LOCK position, engage the park

Model 8042, 10042, 10054 Legacy Rev. 10/03 8.105

Hydraulic System
c. Outrigger Shuttle Valve Installation

4. Unlock and open the rear door. Allow the hydraulic hydraulic oil.
fluid to cool.
1. Reattach and secure hoses, fittings, etc. Attach the
5. Remove the transmission covers. shuttle valve to the main control valve at port P2
WARNING:
(10), the load sense outrigger line at port P1 (9), and
Escaping hydraulic fluid the load sense brake valve line at port P3 (11) of the
under pressure can penetrate the skin, causing shuttle valve (8).
pressure before servicing any hydraulic 2. Check the routing of all hoses, wiring, etc., for sharp
component.
6. Disconnect, label and cap all hydraulic fittings and required. Tighten all fittings.
hoses during removal from the shuttle valve (1).
Disconnect the outrigger load sense line (4).
Disconnect the brake load sense line (5). Disconnect 8 10
P2
the outrigger shuttle valve from the main control
valve (2). Remove the fittings (3, 6 and 7). Wipe up
any hydraulic fluid spillage.
11
P3
P1
3 6
1 9
5
MT2170
2 7 3. Install the lower transmission cover.
4 WARNING: Avoid prolonged engine

MH3770
b. Shuttle Valve Cleaning, Inspection and fumes can result in death or serious injury.
Reassembly 4. Start the engine and run at approximately 1/3-1/2
1. Clean the shuttle valve with a suitable cleaner before throttle for about one minute, without moving the
inspection. vehicle or operating any hydraulic functions.
2. Inspect internal passageways and the shuttle valve
overall for wear, damage, etc. If inner surfaces of the
component DO NOT display an ultra-smooth,
polished finish, or are damaged in any way, replace
the shuttle valve. Often, dirty hydraulic fluid causes
surfaces within the shuttle valve.
3. Replace a defective shuttle valve with a new part.
8.106 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
a. Extend Lockout Valve Removal

protection from spraying hydraulic oil. Use a 2. Place an Accident Prevention Tag on both the
piece of cardboard or paper to search for leaks. ignition key switch and the steering wheel, stating
Note: Check for leaks and repair as required before WARNING: DO NOT get under a raised
continuing. Add hydraulic fluid to the reservoir as boom unless the boom is blocked up. Always
needed. block the boom before doing any servicing that
d. Outrigger Shuttle Valve Test
Raise and lower the outriggers to check the outrigger WARNING: Hot hydraulic fluid can
hydraulic circuit for proper function. cause severe burns. Wait for hydraulic fluid to
8.12.9 Extend Lockout Valve (10054) 4. Unlock and open the rear door. Allow the hydraulic
Model 10054 has an extend lockout valve (12) which fluid to cool.
prevents the boom from being extended beyond 42 feet 5. Remove the transmission covers.
unless the outriggers are lowered onto firm terrain. Once
the outriggers are lowered, pressure switches located on
each outrigger cylinder close and energize the solenoid
on the boom extend lockout valve. The boom can then be death or serious injury. Relieve hydraulic
fully extended. pressure before servicing any hydraulic
component.
12
Front MH3750
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.107

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 C1
(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). T
V1
11
2
5 12
8
4 MH3790
7 9
inspection.
6
1 3. Inspect the solenoid cartridge for proper operation.
Inspect the cartridge interior for contamination.
4. Inspect internal passageways and the extend lockout
10
valve overall for wear, damage, etc. If inner surfaces
3
of the component DO NOT display an ultra-smooth,
polished finish, or are damaged in any way, replace
MH3780 the extend lockout valve. Often, dirty hydraulic fluid
8. Remove the hex flange nut (9) and the carriage bolt polished surfaces within the valve.
(10) securing the extend lockout valve (1) to the
frame. Note: ALWAYS replace seals, o-rings, gaskets, etc.,
9. Remove the extend lockout valve (1) from the
vehicle. Wipe up any hydraulic fluid spillage.
hydraulic oil.
b. Extend Lockout Valve Disassembly, Cleaning, 5. Install the solenoid valve (12).
Inspection and Reassembly 6. Install the pressure sensing valve (13). Torque to 65
1. Secure the extend lockout valve (11) in a suitable lb-ft (88 Nm).
bench vise if possible. Remove the solenoid nut, coil
and cartridge (12) from the valve. Remove the
pressure sense valve (13) from the valve.
8.108 Model 8042, 10042, 10054 Legacy Rev. 10/03

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).
14 5. Start the engine and run at approximately 1/3-1/2
throttle for about one minute, without moving the

15 severe personal injury. DO NOT use your hand
17
16 continuing. Add hydraulic fluid to the reservoir as
needed.
d. Extend Lockout Valve Test

MH3990
Conduct a test of the extend lockout valve.

2. Install the carriage bolt (16) and the hex flange nut
(17) securing the extend lockout valve (14) to the 1. Park the vehicle on a firm, level surface.
frame (15). 2. With the boom fully retracted and lowered, lower the
3. Use new oiled o-rings. Reattach and secure hoses, outriggers.
fittings and wiring terminal. 3. Extend the boom to 54 feet. The boom should
4. Check the routing of all hoses, wiring, etc., for sharp extend fully and should not stop at 42 feet.
required. Tighten all fittings.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.109

Hydraulic System
8.13 HYDRAULIC CYLINDERS 8.13.1 General Cylinder Disassembly

Instructions
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
WARNING: To help prevent severe burns,
proceed with caution when applying heat to parts.
(swing carriage and side tilt) hydraulic cylinders on the
vehicle. IMPORTANT: Avoid the use of excessive heat, which
will damage parts and make them unusable.
Some cylinder parts are sealed with a special organic
sealant and locking compound. Before attempting to
disassemble these parts, remove any accessible seals
from the area of the bonded parts. Wipe off any hydraulic
1 3 oil, then heat the part(s) uniformly to break the bond. A
2 temperature of 300-400° F (149-204° C) will destroy the
bond. Avoid overheating, or the parts may become
4 distorted or damaged. Apply sufficient torque for removal
while the parts are still hot. The sealant often leaves a
5 white, powdery residue on threads and other parts, which
6 must be removed by brushing with a soft brass wire brush
prior to reassembly.
WARNING: Significant pressure may be

7 trapped inside the cylinder. Exercise caution when
removing a counterbalance valve or a pilot-
Front operated check valve from a cylinder. Escaping
(Outriggers on Models hydraulic fluid under pressure can penetrate the
8 10042 and 10054 Only) skin, causing death or serious injury.
MH3660
There are many factors involved with the proper DO NOT attempt to salvage cylinder seals, sealing rings
disassembly, cleaning, inspection, repair and reassembly or o-rings. ALWAYS use a new, complete seal kit when
of hydraulic cylinders; therefore, only qualified professionals rebuilding hydraulic components. Consult the parts
with proper training, supervision, tools and equipment should catalog for ordering information.
rebuild the cylinders used on this vehicle. Note: An additional o-ring may be included at the base
For example, special pin spanner wrenches of the correct of the cylinder rod. This additional o-ring may be discarded,
size are needed to disassemble the cylinders. Also, the as it served only in a temporarily protective role.
lift/lower cylinder rod locknut must be torqued to 1750-
2000 lb-ft (2373-2712 Nm); this requires a special torque 8.13.2 General Cylinder Cleaning Instructions
wrench and/or torque multiplier. If the proper knowledge and Clean all reusable metal parts thoroughly after
equipment are not available, the cylinders must be sent out disassembly and prior to inspection. Use an approved
for rebuilding by a competent professional at a company that solvent such as trichlorethylene.
specializes in rebuilding agricultural and commercial heavy-
equipment hydraulic cylinders. 8.13.3 General Cylinder Assembly Instructions
Rebuild cylinders only in a clean, well-lighted area where
1. Before reassembly, ensure that parts are clean and
all components can be carefully and thoroughly
free from foreign matter. Use an approved solvent for
inspected. If leaving a cylinder dismantled for any length
cleaning, such as trichlorethylene.
of time longer than the immediate rebuilding period, and
especially in high-humidity environments, coat the metal 2. Use the proper tools for specific installation tasks.
parts with a suitable preservative and place them in Clean tools are required for installation.
protective storage. 3. Protect the finish on the rod at all times. Damage to
Refer to the specific instructions for removal, rebuilding the rod can cause premature seal failure.
and installation of each cylinder.
8.110 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
4. ALWAYS use new oiled o-rings, seals, gaskets, etc. a. Attachment Tilt Cylinder Removal
DO NOT overstretch seals, wipers and o-rings. After
1. Remove any attachment from the vehicle. Park the
installing such parts, verify that they are not twisted
vehicle on a firm, level surface, fully retract the boom.
in their grooves.
Allow sufficient work space at the front of the boom.
5. To aid in installation, lubricate piston seals and the Raise the boom enough to allow the quick attach or the
seal installation path with clean, filtered hydraulic oil. bottom of the gooseneck to clear the ground. Place the
6. Lubricate the outer surfaces of the seals and o-rings travel select lever in (N) NEUTRAL, place the neutral
and the inside of the tube, piston and head gland lock lever in the (N) NEUTRAL LOCK position, engage
with clean, filtered hydraulic oil. Use a suitable the park brake switch and shut the engine OFF.
installation or compression tool when installing the 2. Place an Accident Prevention Tag on both the
piston and head gland into the cylinder to help ignition key switch and the steering wheel, stating
prevent twisting or damaging the seals and o-rings. that the vehicle should not be operated. (Refer to
When sliding the rod and piston assembly in the Section 1.5, “Accident Prevention Tags.”)
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.
7. Follow the manufacturer’s instructions when cool before servicing any hydraulic component.
applying primer, locking or retaining compounds that
are specified in the cylinder assembly procedures.
The use of primer is recommended in some cases to fluid to cool.
WARNING:
decrease cure time. Allow sealant to cure fully before
proceeding with the assembly procedure. The curing Escaping hydraulic fluid
process may be hastened by the use of a heat gun under pressure can penetrate the skin, causing
to blow warm, dry air on the parts. death or serious injury. Relieve hydraulic
8. After assembling a cylinder, test the cylinder at low
component.
operating pressures. Verify that the piston and rod
move freely in both directions. 4. Label or otherwise mark the hydraulic hoses in
9. Increase the operating pressure to the maximum relation to the attachment tilt cylinder. Disconnect
pressure recommended for the cylinder. Check for and cap both hoses and attachment tilt cylinder
external leakage and for free movement in both fittings. Refer to Section 3, “Boom.”
directions. 5. Remove the retaining bolt at the rod end of the
10. Retract the piston fully. Cap the hydraulic fittings. attachment tilt cylinder. Remove the lower pivot pin.
6. Attach a suitable sling to an appropriate lifting device
8.13.4 Attachment Tilt Cylinder and to the attachment tilt cylinder. Make sure the
The attachment tilt cylinder (9) is attached at the front of device used can actually support the cylinder.
the inner boom inside the gooseneck (10). 7. Remove the two 2" external retaining rings securing
the attachment tilt cylinder base pin to the boom.
8. Remove the lower attachment tilt cylinder pin by
10 tapping it out through the bottom of the quick attach
(if installed).
9. Remove the attachment tilt cylinder base pin by
tapping it out through the top of the gooseneck.
10. Remove the attachment tilt cylinder from the vehicle.
Wipe up any hydraulic fluid spillage in, on, near or
around the vehicle.
9
MH3670
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.111

Hydraulic System
18
1
19
8
3
17
2 20
20
5 9
13 21
4
6
12
16
15
14
11 7
10
22
23 MH2860
For Early Production

b. Attachment Tilt Cylinder Disassembly trapped inside the cylinder. Exercise caution
when removing a counterbalance valve or a pilot-
Note: An additional o-ring may be included at the base
operated check valve from a cylinder. Escaping
of the cylinder rod. This additional o-ring may be
hydraulic fluid under pressure can penetrate the
discarded, as it served only in a temporarily protective role.
skin, causing death or serious injury.
1. Clean the attachment tilt cylinder (1) with a suitable
cleaner before inspection. Remove all dirt, debris 4. Slowly remove the 4000 psi (276 bar) counterbalance
and grease from the cylinder. valve (5) and the pilot-operated check valve (6) from
IMPORTANT: Avoid using excess force when clamping the attachment tilt cylinder.
the cylinder in a vise. Apply only enough force to hold the 5. Extend the rod (4) to allow access to the base of the
cylinder securely. Excessive force can damage the cylinder.
cylinder tube (2). IMPORTANT: Protect the finish on the rod at all times.
2. If necessary, remove the grease fitting (3) from the Damage to the surface of the rod can cause seal failure.
end of the rod (4). 6. Using a pin spanner wrench, unscrew the head
3. Clamp the trunnion end of the attachment tilt gland (7) from the tube (2). The head gland was
cylinder in a soft-jawed vise or other acceptable originally torqued to 300-400 lb-ft (407-542 Nm), so
holding equipment if possible. 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: When sliding the rod and piston assembly
in 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.
8.112 Model 8042, 10042, 10054 Legacy Rev. 10/03
Hydraulic System
7. Carefully pull the rod (4) along with the head gland c. Attachment Tilt Cylinder Cleaning
(7) and all attachments straight out of the tube (2).
1. Thoroughly clean the inner surface of the attachment
8. Fasten the rod end in a soft-jawed vise, and put a tilt cylinder with trichlorethylene or another approved
padded support below and near the threaded end of cleaner.
the rod to help prevent damage to the rod.
2. Discard all seals, back-up rings and o-rings. Replace
9. Remove the locknut (9) from the rod (4). The locknut with new items from complete seal kits (21) to help
is a deformed-thread type nut torqued at 1850-2000 ensure proper cylinder function.
lb-ft (2508-2712 Nm).
3. Clean all metal parts with an approved cleaning
Note: It may be necessary to apply heat to break the solvent such as trichlorethylene. Carefully clean
bond of the sealant between the locknut (9) and the rod cavities, grooves, threads, etc.
(4) before the piston (8) can be removed. Some parts of
Note: If a white, powdery residue is present on threads
cylinders are sealed with a special organic sealant and
and parts, it can be removed. Clean the residue away
locking compound.
with a soft brass wire brush prior to reassembly, and
Before attempting to disassemble these parts, remove wipe with Loctite “T” cleaner before reinstallation.
any accessible seals from the area of the bonded joint.
Wipe off any hydraulic oil and heat the joint uniformly to d. Attachment Tilt Cylinder Inspection
break the bond. A temperature of 300-400° F (149-204° C)
1. Inspect internal surfaces and all parts for wear, damage,
will destroy the bond. Avoid overheating or the parts may
etc. If the inner surface of the tube (2) does not display a
become distorted or damaged. Apply sufficient torque or
smooth finish, or is scored or damaged in any way,
pressure for removal while the parts are still hot.
replace the tube. Often, dirty hydraulic fluid causes
Breakdown of sealant will leave a white, powdery failure of internal seals and damage to the smooth
residue on threads and parts. Clean the residue away surface within the tube.
with a soft brass wire brush prior to reassembly, and 2. Remove slight scratches on the piston, rod or inner
wipe with Loctite “T” cleaner before reinstallation. surface of the tube with very fine grit emery cloth.
10. Remove the piston (8) and head gland (7) from the Use the emery cloth in a rotary motion to polish out
rod (4). and blend the scratch(es) into the surrounding surface.
11. Remove the o-ring (10), back-up ring (11), and o- 3. Inspect all other components for wear, damage, etc.
ring (12) from the head gland (7). Clean parts with trichlorethylene.
12. Remove the locking insert (13) from its hole in the 4. Check that the rod (4) is straight. If it is bent, a new
head gland threads. Pry or drill out the insert as rod must be installed.
required. DO NOT damage the head gland threads.
A new locking insert will be required for reassembly. e. Attachment Tilt Cylinder Assembly
13. Remove the precision wearbands (14), the deep Z- Note: Follow Section 8.13.3, “General Cylinder
seal with rod back-up (15) and the sealed outside Assembly Instructions.”
diameter heavy-duty rod wiper (16) from the head
1. Install the sealed outside diameter heavy-duty rod
gland (7).
wiper (16) into the outer end of the head gland (7). The
14. Remove both precision wearbands (17) and the wiper lip (22) should be toward the outer end of the
capped T-seal (18) from the piston (8). head gland and the seal lips toward the inner end of
Note: The T-seal actually consists of four components; a the head gland. Use tools that will not damage the
wide, flexible inner band, the flexible T-seal band itself seals.
and two supportive split caps that mount on either side of 2. Install new oiled o-ring (10), back-up ring (11), oiled
the “T” itself. o-ring (12), precision wearbands (14) and deep
Z-seal with rod back-up (15) onto the head gland (7)
15. Remove the small o-ring (19) from within the piston
orienting the edge (23).
(8).
3. Install the small new oiled o-ring (19) into the rod-
16. If the bushings (20) need replacement, support the
end of the piston (8).
rod (4) in a soft-jawed vise or other suitable holding
device. Carefully press the bushings from the rod.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.113

Hydraulic System
18
1
19
8 3
17
2 20
20
5 9
13 21
6 4
12
16
15
14
11 7
10
22
23 MH2860
4. Install both precision wearbands (17) and the IMPORTANT: When sliding the rod and piston assembly
capped T-seal (18) onto the piston (8). in the tube, prevent the threaded end of the tube from
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 8. Carefully insert the rod (4) with all attachments
the “T” itself. straight into the tube (2).
5. Install the head gland (7) and piston (8) onto the rod 9. Using a pin spanner wrench, thread the head gland
(4). (7) almost completely into the tube (2), leaving just
enough room to install a new locking insert (13) into
IMPORTANT: Protect the finish on the rod at all times. its hole in the head gland threads.
Damage to the surface of the rod can cause seal failure.
10. Install a new locking insert (13). Thread the head
6. Fasten the rod end in a soft-jawed vise and put a gland (7) tightly into the tube and torque to 500-600
padded support below and near the threaded end of lb-ft (678-813 Nm).
the rod to help prevent damage to the rod. Apply
Loctite #271 (red) and install the locknut (9) onto the 11. Using new oiled o-rings, thread the 4000 psi (276 bar)
rod (4). Torque the nut to 1850-2000 lb-ft (2508-2712 counterbalance valve (5) and the pilot-operated
Nm). The threads will deform upon tightening, check valve (6) into the attachment tilt cylinder.
locking the nut in place. Torque to 30-35 lb-ft (41-47 Nm).
IMPORTANT: Avoid using excess force when clamping 12. If necessary, install a grease fitting (3) into the
the cylinder in a vise. Apply only enough force to hold the tapped hole in the end of the rod (4). Lubricate the
cylinder securely.Excessive force can damage the cylinder. bushings (20) in the rod end through the grease
fitting with multi-purpose grease before the vehicle is
7. Place the attachment tilt cylinder tube (2) in a soft- operated.
jawed vise or other acceptable holding equipment if
possible.
8.114 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
24
32
26
27
30
25
31
28
29
MH4290
For Current Production 4. Slowly remove the 4000 psi (276 bar) counterbalance
valve (28) and the pilot-operated check valve (29)
b. Attachment Tilt Cylinder Disassembly from the attachment tilt cylinder.
Note: An additional o-ring may be included at the base 5. Extend the rod (27) to allow access to the base of
of the cylinder rod. This additional o-ring may be the cylinder.
discarded, as it served only in a temporarily protective role. IMPORTANT: Protect the finish on the rod at all times.
1. Clean the attachment tilt cylinder (24) with a suitable Damage to the surface of the rod can cause seal failure.
cleaner before inspection. Remove all dirt, debris 6. Remove the lock screw (30) from the flange of the
and grease from the cylinder. head gland (31).
IMPORTANT: Avoid using excess force when clamping 7. Using a pin spanner wrench, unscrew the head
the cylinder in a vise. Apply only enough force to hold the gland (31) from the tube (25). The head gland was
cylinder securely. Excessive force can damage the originally torqued to 300 ±50 lb-ft (407 ±68 Nm), so
cylinder tube (25). a considerable amount of force is required to remove
2. If necessary, remove the grease fitting (26) from the it. Carefully slide the head gland down along the rod
end of the rod (27). toward the eyelet end, away from the cylinder tube.
3. Clamp the trunnion end of the attachment tilt 8. When sliding the rod and piston assembly in the
cylinder in a soft-jawed vise or other acceptable tube, prevent the threaded end of the tube from
damaging the piston (32). Keep the rod centered
holding equipment if possible.
within the tube to help prevent binding.
trapped inside the cylinder. Exercise caution
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.115

Hydraulic System
24 18
16
25
6
17
4 1
7
15 21
3
14 2 17
5 20
19
13
9
8 10
22
23 12
11 MH4290
9. Carefully pull the rod (1) along with the head gland Breakdown of sealant will leave a white, powdery
(2) and all attachments straight out of the tube (3). residue on threads and parts. Clean the residue away
10. Fasten the rod end in a soft-jawed vise, and put a with a soft brass wire brush prior to reassembly, and
padded support below and near the threaded end of wipe with Loctite “T” cleaner before reinstallation.
the rod to help prevent damage to the rod. 13. Remove the piston (7) and head gland (2) from the
11. Remove the two setscrews (4) from the locknut (5). rod (1).
Under each setscrew is a nylon ball (6). Be sure to 14. Remove the o-ring (8), back-up ring (9), and o-ring
remove the nylon balls from the locknut. Discard the (10) from the head gland (2).
nylon balls.
15. Remove the precision wearbands (11), the deep Z-
12. Remove the locknut (5) from the rod (1). The locknut seal with rod back-up (12) and the sealed outside
is torqued at 1735-1885 lb-ft (2352-2556 Nm). diameter heavy-duty rod wiper (13) from the head
Note: It may be necessary to apply heat to break the gland (2).
bond of the sealant between the locknut (5) and the rod 16. Remove the precision wearband (14) and the
(1) before the piston (7) can be removed. Some parts of capped T-seal (15) from the piston (7).
locking compound.
wide, flexible inner band, the flexible T-seal band itself
Before attempting to disassemble these parts, remove and two supportive split caps that mount on either side of
any accessible seals from the area of the bonded joint. the “T” itself.
Wipe off any hydraulic oil and heat the joint uniformly to
17. Remove the small o-ring (16) from the groove in the
end of the rod (1).
become distorted or damaged. Apply sufficient torque or 18. If the bushings (17) need replacement, support the
pressure for removal while the parts are still hot. rod (1) in a soft-jawed vise or other suitable holding
device. Carefully press the bushings from the rod.
8.116 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
c. Attachment Tilt Cylinder Cleaning Note: The T-seal actually consists of four components; a
1. Thoroughly clean the inner surface of the attachment
and two supportive split caps that mount on either side of
tilt cylinder with trichlorethylene or another approved
the “T” itself.
cleaner.
2. Discard all seals, back-up rings and o-rings. Replace 5. Install the head gland (2) and piston (7) onto the rod
with new items from complete seal kits (18) to help (1).
ensure proper cylinder function. IMPORTANT: Protect the finish on the rod at all times.
3. Clean all metal parts with an approved cleaning Damage to the surface of the rod can cause seal failure.
solvent such as trichlorethylene. Carefully clean 6. Fasten the rod end in a soft-jawed vise and put a
cavities, grooves, threads, etc. padded support below and near the threaded end of
the rod to help prevent damage to the rod. Apply
Loctite #271 (red) and install the locknut (5) onto the
rod (1). Torque the nut to 1735-1885 lb-ft (2352-2556
Nm).
wipe with Loctite “T” cleaner before reinstallation.
7. Place new nylon balls (6) into the threaded holes of
d. Attachment Tilt Cylinder Inspection the locknut (5). Insert the setscrews (4) into the
holes and tighten until the nylon balls are deformed
1. Inspect internal surfaces and all parts for wear, damage, into the threads of the rod.
smooth finish, or is scored or damaged in any way, IMPORTANT: Avoid using excess force when clamping
replace the tube. Often, dirty hydraulic fluid causes the cylinder in a vise. Apply only enough force to hold the
failure of internal seals and damage to the smooth cylinder securely.Excessive force can damage the cylinder.
surface within the tube. 8. Place the attachment tilt cylinder tube (3) in a soft-
2. Remove slight scratches on the piston, rod or inner jawed vise or other acceptable holding equipment if
surface of the tube with very fine grit emery cloth. possible.
Use the emery cloth in a rotary motion to polish out IMPORTANT: When sliding the rod and piston assembly
and blend the scratch(es) into the surrounding surface. in the tube, prevent the threaded end of the tube from
3. Inspect all other components for wear, damage, etc. damaging the piston (7). Keep the rod centered within
Clean parts with trichlorethylene. the tube to help prevent binding.
4. Check that the rod (1) is straight. If it is bent, a new 9. Carefully insert the rod (1) with all attachments
rod must be installed. straight into the tube (3).
10. Using a pin spanner wrench, thread the head gland
e. Attachment Tilt Cylinder Assembly (2) completely into the tube (3). Torque to 300 ±50
lb-ft (407 ±68 Nm).
Note: Follow Section 8.13.3, “General Cylinder
Assembly Instructions.” 11. Apply Loctite #242 (blue) to the threads of the lock
screw (21) and thread into the flange of the head
1. Install the sealed outside diameter heavy-duty rod gland (2). Torque to 3-4 lb-ft (4-5 Nm).
wiper (13) into the outer end of the head gland (2). The
wiper lip (19) should be toward the outer end of the 12. Using new oiled o-rings, thread the 4000 psi (276 bar)
head gland and the seal lips toward the inner end of counterbalance valve (22) and the pilot-operated
the head gland. Use tools that will not damage the check valve (23) into the attachment tilt cylinder (24).
seals. Torque to 30-35 lb-ft (41-47 Nm).
2. Install new oiled o-ring (10), back-up ring (9), oiled 13. If necessary, install a grease fitting (25) into the
o-ring (8), precision wearbands (11) and deep Z-seal tapped hole in the end of the rod (1). Lubricate the
with rod back-up (12) onto the head gland (2) bushings (17) in the rod end through the grease
orienting the edge (20). fitting with multi-purpose grease before the vehicle is
operated.
3. Install the small new oiled o-ring (16) into the groove
in the end of the rod (1).
4. Install the precision wearband (14) and the capped
T-seal (15) onto the piston (7).
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.117

Hydraulic System
f. Attachment Tilt Cylinder Installation g. Attachment Tilt Cylinder Pressure Checking and
Circuit Bleeding
1. Attach a suitable sling to an overhead crane or other
suitable device and to the attachment tilt cylinder. 1. Attach a 4000 psi (276 bar) gauge to the test fitting
Make sure the device used can actually support the on the main control valve to test the system
cylinder. Place the attachment tilt cylinder in position pressure. Pressure readings should be 3000 ±100
within the gooseneck. Refer to Section 3, “Boom.” psi (207 ±7 bar). Refer to Section 8.7, “Hydraulic
2. Install the lower attachment tilt cylinder pin by System Testing.” To check the cylinder pressure,
tapping it through the bottom of the quick attach (if consult the factory.
installed). Install the retaining bolt. 2. With no accessory installed on the quick attach, start
3. Coat the attachment tilt cylinder base pin with anti- with the lift/lower and attachment tilt cylinders fully
seize compound, and install the pin by tapping it in retracted.
through the top of the gooseneck. 3. Fully extend the attachment tilt cylinder. Hold the
4. Secure the attachment tilt cylinder base pin to the attachment tilt joystick at full extend while fully
boom with two 2" external retaining rings. raising the lift/lower cylinder.
5. Install the lower pivot pin and quick attach as required. 4. Fully retract the attachment tilt cylinder. Hold the
attachment tilt joystick at full retract while fully
6. Connect the attachment tilt cylinder hydraulic hoses retracting the lift/lower cylinder.
in relation to the labels or markings made during
5. Repeat Steps 3 and 4 five times.
removal.

7. Start the engine and run at approximately one-third to
one-half throttle for about one minute without moving the

fluid in the reservoir. Add hydraulic fluid to the
reservoir as needed. Shut the engine OFF.
10. Conduct a pressure check of the attachment tilt
cylinder hydraulic circuit and bleed the circuit as
outlined in the procedure that follows.
8.118 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
8.13.5 Slave Cylinders a. Slave Cylinder Removal

Each slave cylinder (1) is secured to the vehicle frame 1. Park the vehicle on a firm, level surface, fully retract
and outer boom with cylinder mount pins, capscrews and all hydraulic cylinders, then raise the boom to
nuts. 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.
1 ignition key switch and the steering wheel, stating
1
~
WARNING:
~

fluid to cool.

death or serious injury. Relieve hydraulic pressure
MH3700
4. Label or otherwise mark the hydraulic hoses in
relation to the slave cylinder being removed.
Disconnect and cap the hydraulic hoses and slave
cylinder fittings.
5. Securely support the slave cylinder. Remove the
nuts, capscrews and cylinder pins securing the slave
cylinder to the vehicle frame and outer boom.
6. With the help of at least one assistant, remove the
slave cylinder from the vehicle. Wipe up any
vehicle.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.119

Hydraulic System
12
3
5
16
17
11
20
4
10 7
9
13
8
15 14
6
7
2
19
18 MH2871
b. Slave Cylinder Disassembly 4. Using a pin spanner wrench, unscrew the head gland
(4) from the tube (2). The head gland was originally
torqued at 300-400 lb-ft (407-542 Nm), so a
of the cylinder rod. This additional o-ring may be discarded,
considerable amount of force is required to remove it.
as it served only in a temporarily protective role.
Carefully slide the head gland down along the rod
1. Clean the slave cylinder (1) with a suitable cleaner toward the eyelet end, away from the cylinder tube (2).
before inspection. Remove all dirt, debris and grease
from the cylinder.
IMPORTANT: Avoid using excess force when clamping damaging the piston (5). Keep the rod centered within
the cylinder in a vise. Apply only enough force to hold the the tube to help prevent binding.
cylinder securely. Excessive force can damage the
5. Carefully pull the rod (3) with all attachments straight
cylinder tube (2).
out of the tube (2).
2. Place the slave cylinder (1) in a soft-jawed vise or
6. Fasten the rod end in a soft-jawed vise and put a
other acceptable holding equipment if possible.
padded support below and near the threaded end of
3. Extend the rod (3) to allow access to the base of the the rod to help prevent damage to the rod.
cylinder.
7. Remove the o-ring (6), back-up ring (8) and o-ring
IMPORTANT: Protect the finish on the rod at all times. (9) from the head gland.
8. Remove the locking insert (7) from its hole in the
head gland threads. Pry or drill out the insert as
A new locking insert will be required for reassembly.
8.120 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
9. Remove the precision wearbands (10) and the d. Slave Cylinder Inspection
capped T-seal (11) from the piston (5). 1. Inspect internal surfaces and all parts for wear, damage,
Note: The T-seal actually consists of four components; a etc. If the inner surface of the tube (2) does not display a
wide, flexible inner band, the flexible T-seal band itself, smooth finish, or is scored or damaged in any way,
and two supportive split caps that mount on either side of replace the tube. Often, dirty hydraulic fluid causes
the “T” itself. failure of internal seals and damage to the smooth
surface within the tube.
10. Remove the locknut (12) from the rod (3). The
deforming-thread type nut was coated with Loctite 2. Remove slight scratches on the piston, rod, or inner
#271 (red) and torqued to 900-1050 lb-ft (1220-1424 surface of the tube with very fine grit emery cloth. Use
Nm). Discard the nut. the emery cloth in a rotary motion to polish out and
blend the scratch(es) into the surrounding surface.
Note: It may be necessary to apply heat to break the
3. Clean parts with trichlorethylene.
bond of the sealant between the locknut (12) and the rod
(3) before the piston (5) can be removed. Some parts of 4. Check that the rod (3) is straight. If it is bent, install a
cylinders are sealed with a special organic sealant and new rod.
locking compound.
e. Slave Cylinder Assembly
Before attempting to disassemble these parts, remove
Assembly Instructions.”
break the bond. A temperature of 300-400° F (149-204° C) IMPORTANT: Use a suitable installation tool or
will destroy the bond. Avoid overheating or the parts may compression sleeve to help prevent twisting or damaging
become distorted or damaged. Apply sufficient torque or the seals and o-rings, when installing the piston and
pressure for removal while the parts are still hot. head gland into the cylinder. When sliding the rod and
piston assembly in the tube, DO NOT damage the piston
Breakdown of sealant will leave a white, powdery
by scraping it against the threads in the tube. Keep the
residue on threads and parts. Clean the residue away
rod in line with the tube to prevent binding.
wipe with Loctite “T” cleaner before reinstallation. 1. Fasten the rod end in a soft-jawed vise, and put a
11. Remove the piston (5) and head gland (4) from the the rod to help prevent damage to the rod.
rod (3).
2. Install the back-up ring (17) and the small o-ring (16)
12. From the head gland (4), remove the deep Z-seal in the piston (5).
with rod back-up (13), the sealed outside diameter
heavy-duty rod wiper (14) and the precision 3. Install the sealed outside diameter heavy-duty rod
wearbands (15). wiper (14). The wiper lip (18) should be toward the
outer end of the head gland and the seal lips toward
13. From the piston (5), remove the small o-ring (16) and the inner end of the head gland. Use tools that will
the back-up ring (17). not damage the seals.
c. Slave Cylinder Cleaning

1. Remove all hydraulic fluid, dirt and debris from the
inner surface of the cylinder.
with new items from a complete seal kit (20) to help
ensure proper cylinder function.
solvent such as trichlorethylene. Carefully clean
cavities, grooves, threads, etc.
wipe with Loctite “T” cleaner before reinstallation.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.121

Hydraulic System
12
3
5
16
17
11
20
4
7
10
9 13
8
15 14
6
7
2
19
18
MH2871
4. Install the deep Z-seal with rod back-up (13) in the IMPORTANT: When sliding the rod and piston assembly
head gland (4) orienting the edge (19). into the tube, prevent the threaded end of the tube from
5. Carefully install the head gland (4) onto the rod (3). damaging the piston (5). Keep the rod centered within
the tube to help prevent binding. Protect the finish on the
6. Carefully install the piston (5) onto the rod (3). rod at all times. Damage to the surface of the rod can
Note: If a white, powdery residue remains on the cause seal failure.
threads and parts, clean the residue away with a soft 11. Carefully insert the rod (3) with all attachments
brass wire brush prior to reassembly, and wipe with straight into the tube (2).
Loctite “T” cleaner before proceeding. 12. Using a pin spanner wrench, thread the head gland
7. Apply Loctite Threadlocker #271 (red) to the locknut (4) into the tube (2). Torque the head gland to 300-
(12). Thread the locknut onto the rod (3) and torque 400 lb-ft (407-542 Nm).
to 900-1050 lb-ft (1220-1424 Nm). The threads will f. Slave Cylinder Installation
deform upon tightening, locking the nut in place. 1. Align the slave cylinder with its mounting bosses
8. Install the capped T-seal (11) and precision within the rear frame uprights.
wearbands (10) onto the piston (5). 2. Align the mount pin bolt holes with the slave cylinder
Note: The T-seal actually consists of four components; a mount holes. Align the self-aligning bearing. Secure
wide, flexible inner band, the flexible T-seal band itself, the slave cylinder with the cylinder pins, capscrews
and two supportive split caps that mount on either side of and nuts. Torque the capscrews and nuts to
the “T” itself. specification. Refer to the fastener torque chart in
Section 2.3, “Torques.”
9. Install new oiled o-ring (9), back-up ring (8) and oiled
o-ring (6) onto the head gland (4).
10. Install new locking inserts (7) into the head gland.
8.122 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
3. Use new oiled o-rings, and reattach and secure the 8.13.6 Extend/Retract Cylinder
hydraulic hoses to the slave cylinder fittings. The extend/retract cylinder (21) is located under the
WARNING:
boom, attached to the rear of the outer boom and the front
Avoid prolonged engine of the intermediate boom.
4. Start and run the engine at approximately one-third
to one-half throttle for about one minute, without
functions.

21
fluid in the reservoir. Shut the engine OFF. Add MH3690
hydraulic fluid if required.
6. Conduct a pressure check of the attachment tilt/ a. Extend/Retract Cylinder Removal
slave cylinder hydraulic circuit, and bleed the circuit
1. Park the vehicle on a firm, level surface, and fully
as outlined in the procedure that follows.
retract all hydraulic cylinders. Place the travel select
7. Wipe up any hydraulic fluid spillage in, on, near and lever in (N) NEUTRAL, place the neutral lock lever in
around the vehicle, work area and tools. the (N) NEUTRAL LOCK position, engage the park
brake switch and shut the engine OFF. Support the
g. Slave Cylinder Pressure Checking and Circuit boom in a horizontal and level position with blocking.
Bleeding
1. Attach a 4000 psi (276 bar) gauge to the test fitting ignition key switch and the steering wheel, stating
on the main control valve to test the system that the vehicle should not be operated. Refer to
pressure. Pressure readings should be 3000 ±100 Section 1.5, “Accident Prevention Tags.”
psi (207 ±7 bar). Refer to Section 8.7, “Hydraulic
System Testing.” To check each cylinder pressure, WARNING: Hot hydraulic fluid can
consult the factory. cause severe burns. Wait for hydraulic fluid to
2. With no accessory installed on the quick attach, start cool before servicing any hydraulic component.
with the lift/lower and attachment tilt cylinders fully 3. Unlock and open the rear door. Allow the hydraulic
retracted.
fluid to cool.
3. Fully extend the attachment tilt cylinder. Monitor
pressure while fully raising the lift/lower cylinder. WARNING: Escaping hydraulic fluid
4. Fully retract the attachment tilt cylinder. Monitor under pressure can penetrate the skin, causing
pressure while fully retracting the lift/lower cylinder. death or serious injury. Relieve hydraulic
5. Repeat Steps 3 and 4 five times. pressure before servicing any hydraulic
component.
4. Operate the hydraulic controls after the engine has
stopped, to relieve any trapped pressure.
relation to the extend/retract cylinder. Disconnect
and cap both hoses and the cylinder fittings.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.123

Hydraulic System
2
4 12
17 24
13 18 22
19 5
3 23
7
14
16
15 20 25 26
9 6
8
21 11
20 10
MH2880
6. Attach a suitable sling to an overhead crane or other IMPORTANT: Avoid using excess force when clamping
suitable device and to the extend/retract cylinder. the cylinder in a vise. Apply only enough force to hold the
Make sure the device used can actually support the cylinder securely. Excessive force can damage the
cylinder. cylinder tube (2).
7. Remove the two 2" external retaining rings securing 2. Secure the extend/retract cylinder in a soft-jawed
the extend/retract cylinder rod pin to the vise, or other acceptable holding equipment if possible.
intermediate boom section. Remove the pin.
8. Remove the two 2" external retaining rings securing WARNING: Significant pressure may be
the extend/retract cylinder base pin to the outer trapped inside the cylinder. Exercise caution when
boom. Remove the pin. removing a counterbalance valve or a pilot-
9. Remove the extend/retract cylinder from the vehicle.
hydraulic fluid under pressure can penetrate
Wipe up any hydraulic fluid spillage in, on, near or
the skin, causing death or serious injury.
around the vehicle.
3. Slowly remove the counterbalance valve (3) and the
b. Extend/Retract Cylinder Disassembly pilot-operated check valve (4).
Note: An additional o-ring may be included at the base IMPORTANT: DO NOT tamper with or attempt to reset
of the cylinder rod. This additional o-ring may be discarded, the counterbalance valve cartridge. If adjustment or
as it served only in a temporarily protective role. replacement is necessary, replace a counterbalance
valve with a new part.
1. Clean the extend/retract cylinder (1) with a suitable
cleaner. Remove all dirt, debris and grease from the 4. Extend the rod (5) as required to allow access to the
cylinder. base of the cylinder.
IMPORTANT: Protect the finish on the rod at all times.
8.124 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
5. Using a pin spanner wrench, unscrew the head Breakdown of sealant will leave a white, powdery
gland (6) from the tube (2). The head gland was residue on threads and parts. Clean the residue away
originally torqued to 300-400 lb-ft (407-542 Nm), so with a soft brass wire brush prior to reassembly, and
a considerable amount of force is required. Carefully wipe with Loctite “T” cleaner before reinstallation.
slide the head gland down along the rod toward the
11. Remove the rod spacer (17).
eyelet end, away from the cylinder tube (2).
12. From within the piston (7), remove the back-up ring
(18) the o-ring (19).
out of the tube, prevent the threaded end of the tube
from damaging the piston (7). Keep the rod centered 13. Remove the o-ring (8), back-up ring (9), locking
within the tube to help prevent binding. insert (10) and o-ring (11) from the head gland (6).
Remove them from the rod (5).
6. Carefully pull the rod (5) with all attachments straight
out of the tube (2). 14. Remove the head gland (6) from the rod (5).
7. Fasten the rear of the rod in a soft-jawed vise, and 15. From within the head gland (6), remove the precision
put a padded support below and near the threaded wearbands (20) and, if installed, the buffer seal (21).
end of the rod to help prevent damage to the rod. Remove the sealed outside diameter heavy-duty rod
wiper (22), the U-cup seal (23) and the o-ring (24).
8. Remove the setscrews (12 and 13) from the piston
(7). The setscrews are used to provide a secondary
c. Extend/Retract Cylinder Cleaning
lock on the piston. Pry or drill out the setscrews as
required. DO NOT damage the piston threads. New 1. Remove all hydraulic fluid, dirt and debris from the
setscrews will be required for reassembly. inner surface of the cylinder tube (2).
9. Remove the precision wearbands (14), the piston 2. Discard all seals, back-up rings, o-rings, etc.
seal (15) and the square ring (16) from the piston. Replace with new items from complete seal kits (25
10. Remove the piston (7) from the rod (5). The piston and 26) to help ensure proper cylinder function.
was installed with Loctite #271 and torqued to 1800- 3. Clean all metal parts with an approved cleaning
2000 lb-ft (2441-2712 Nm). solvent such as trichlorethylene. Carefully clean
bond of the sealant between piston (7) and the rod (5) Note: If a white, powdery residue is present on threads
before the piston can be removed. Some parts of and parts, it can be removed. Clean the residue away
cylinders are sealed with a special organic sealant and with a soft brass wire brush prior to reassembly, and
locking compound. wipe with Loctite “T” cleaner before reinstallation.
Before attempting to disassemble these parts, remove
d. Extend/Retract Cylinder Inspection
Wipe off any hydraulic oil and heat the joint uniformly to 1. Inspect internal surfaces and all parts for wear,
break the bond. A temperature of 300-400° F (149-204° C) damage, etc. If the inner surface of the tube (2) does
will destroy the bond. Avoid overheating or the parts may not display a smooth finish, or is scored or damaged
become distorted or damaged. Apply sufficient torque or in any way, replace the tube. Often, dirty hydraulic
pressure for removal while the parts are still hot. fluid causes failure of internal seals and damage to
the smooth surface within the tube.
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.
4. Check that the rod (5) is straight. If it is bent, install a
new rod.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.125

Hydraulic System
24
26 23 1
22 21
2 11
25 3 14 20
6 12
4
15
5
7
19 9
13
16
8 17
7 18
10 MH2880
e. Extend/Retract Cylinder Assembly 8. Carefully slide the head gland (9), then the rod
spacer (21) onto the rod (20).
Assembly Instructions.” 9. Carefully slide the piston (3) onto the rod (20). Apply
Loctite Threadlocker #271 to the piston and torque
1. Install a new small oiled o-ring (1) and new back-up the piston to 1800-2000 lb-ft (2440-2712 Nm).
ring (2) into the piston (3).
10. Apply Loctite Threadlocker #243 to the setscrew
2. Install the square ring (4), the piston seal (5) and threads. Thread the first setscrew (22) and then the
both precision wearbands (6) onto the piston (3). second (23) into the piston (3). Torque the setscrews
3. Install the precision wearbands (7) and the buffer to 155-165 lb-in (18-19 Nm).
seal (8), if used, into the front end of the head gland IMPORTANT: Avoid using excess force when clamping
(9). Orient the buffer seal as shown (10). the cylinder in a vise. Apply only enough force to hold the
4. Install the o-ring (11) and the U-cup seal (12) cylinder securely. Excessive force can damage the
orienting the edge (13). cylinder.
5. Install the sealed outside diameter heavy-duty rod 11. Secure the extend/retract cylinder tube (24) in a soft-
wiper (14). The wiper lip (15) should be toward the jawed vise or other acceptable holding equipment if
outer end of the head gland (9) and the seal lips possible.
toward the inner end of the head gland. Use tools 12. Lubricate the inside of the tube (24) and outside of
that will not damage the seals. the piston (3) and head gland (9) with clean, filtered
6. Install a new oiled o-ring (16), locking insert (17), hydraulic oil.
back-up ring (18) and oiled o-ring (19) onto the head 13. Apply a compression sleeve or other suitable tool to
gland (9). the head gland (9) and piston (3) in order to
7. Secure the rod (20) in a soft-jawed vise, and put a compress the o-rings, back-up rings and seals, while
padded support below and near the threaded end of inserting the assembled piston, rod and head gland
the rod to help prevent damage to the rod. into the tube (24).
8.126 Model 8042, 10042, 10054 Legacy Rev. 10/03
Hydraulic System
IMPORTANT: When sliding the rod (20) and piston 5. Secure the extend/retract cylinder rod pin to the
assembly into the tube, prevent the threaded end of the boom with two 2" external retaining rings.
tube from damaging the piston (3). Keep the rod 6. Connect the extend/retract cylinder hydraulic hoses
centered within the tube to help prevent binding. Protect in relation to the labels or markings made during
the finish on the rod at all times. Damage to the surface
removal.
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 ventilation. Failure to properly ventilate exhaust
(9) into the tube (24). Torque the head gland to 300- fumes can result in death or serious injury.
400 lb-ft (407-542 Nm).
7. Start the engine and run at approximately one-third to
16. Lubricate the counterbalance valve (25) and the one-half throttle for about one minute without moving the
pilot-operated check valve (26) with clean, filtered vehicle or operating any hydraulic functions.
hydraulic oil. Using new oiled o-rings, thread the
counterbalance valve and the pilot-operated check
valve into the cylinder. Torque the valves to 150-160
lb-ft (203-217 Nm). death or serious injury.
IMPORTANT: DO NOT tamper with or attempt to reset
the counterbalance valve cartridge. If adjustment or 8. Inspect for leaks and check the level of the hydraulic
replacement is necessary, replace a counterbalance fluid in the reservoir. Add hydraulic fluid to the
valve with a new part. reservoir as needed. Shut the engine OFF.
17. Test the cylinder at low operating pressure (100 psi 9. Wipe up any hydraulic fluid spillage in, on, near and
or 7 bar). Verify that the piston and the rod move around the vehicle, work area and tools.
freely in both directions. 10. Conduct a pressure check of the attachment tilt
18. Increase the operating pressure to the maximum cylinder hydraulic circuit and bleed the circuit as
amount for the cylinder 3000 psi (207 bar), and outlined in the procedure that follows.
again check for free movement in both directions. g. Extend/Retract Cylinder Pressure Checking and
19. Retract the rod fully into the tube, and cap and plug Circuit Bleeding
the hydraulic hose ports. 1. Attach a 4000 psi (276 bar) gauge to the test fitting
on the main control valve to test the system
f. Extend/Retract Cylinder Installation pressure. Pressure readings should be 3000 ±100
1. Attach a suitable sling to an overhead crane or other
System Testing.” To check the cylinder pressure,
suitable device and to the extend/retract cylinder.
consult the factory.
Make sure the device used can actually support the
cylinder. Place the extend/retract cylinder in position 2. With no accessory installed on the quick attach, start
guiding the rod end through the retainer on the outer with the lift/lower and attachment tilt cylinders fully
boom. retracted.
Note: Check the condition of the rubber bumper located 3. Fully extend the extend/retract cylinder. Hold the
on the retainer. Replace if damaged. Refer to Section joystick at full extend while fully raising the lift/lower
3.3.3, “Outer Boom Removal.” cylinder.
4. Fully retract the attachment tilt cylinder. Hold the
2. Coat the extend/retract cylinder base pin with anti-
attachment tilt joystick at full retract while fully
seize compound and install the pin by tapping it in.
retracting the lift/lower cylinder.
3. Secure the extend/retract cylinder base pin to the
boom with two 2" external retaining rings.
4. Guide the rod end into position aligning the eye with
the intermediate boom mounting holes. Coat the
extend/retract cylinder rod pin with anti-seize
compound and install the pin by tapping it in.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.127

Hydraulic System
8.13.7 Lift/Lower Cylinder 3. Unlock and open the rear door. Allow the hydraulic
The lift/lower cylinders (1) are anchored to the underside fluid to cool.
WARNING:
of the outer boom and to the vehicle frame.
Escaping hydraulic fluid
component.
4. Label or otherwise mark the lift/lower cylinder hydraulic

hoses. Disconnect and cap all hoses and fittings.
5. Attach a sling to the lift/lower cylinder and to a
suitable hoist or overhead crane. Support the lift/
lower cylinder in the sling.
6. Remove the locknut, capscrew and rod end mount pin
1
from the cylinder. Allow the cylinder to retract so that
it can clear the mounting bracket on the outer boom.
~
7. Remove the locknut, capscrew and base end mount

pin from the cylinder.
8. Safely and carefully, remove the lift/lower cylinder
from the vehicle. Wipe up any hydraulic fluid spillage
in, on, near and around the vehicle.
For S/N 13198 thru 19234

MH3700
b. Lift/Lower Cylinder Disassembly

a. Lift/Lower Cylinder Removal
discarded, as it served only in a temporarily protective
role.
requires the boom to be up. Unexpected lowering 1. Clean the lift/lower cylinder (2) with a suitable
of the boom may cause death or serious injury. cleaner. Remove all dirt, debris and grease from the
cylinder.
IMPORTANT: Avoid using excess force when clamping
all hydraulic cylinders, ground the attachment (if
the cylinder in a vise. Apply only enough force to hold the
place the neutral lock lever in the (N) NEUTRAL LOCK
cylinder tube (3).
position, engage the park brake switch, raise and
support the boom to allow removal of the lift/lower 2. Secure the lift/lower cylinder in a soft-jawed vise or
cylinder and shut the engine OFF. other acceptable holding equipment if possible.
2. Place an Accident Prevention Tag on both the 3. Slowly remove the counterbalance valve (4) and pilot-
ignition key switch and the steering wheel, stating operated check valve (5) from the tube (3).
that the vehicle should not be operated. Refer to IMPORTANT: DO NOT tamper with or attempt to reset
Section 1.5, “Accident Prevention Tags.” the counterbalance valve cartridge. If adjustment or
WARNING:
replacement is necessary, replace the counterbalance
Hot hydraulic fluid can valve with a new part.
4. Extend the rod (6) as required to allow access to the
base of the cylinder.
8.128 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
3 8
12
5
11
6
10
7
MH2890
5. Using a pin spanner wrench, unscrew the locking collar Before attempting to disassemble these parts, remove
(7) from the tube (3). The locking collar was any accessible seals from the area of the bonded joint.
originally torqued to 300-400 lb-ft (407-542 Nm), so Wipe off any hydraulic oil and heat the joint uniformly to
a considerable amount of force is required. break the bond. A temperature of 300-400° F (149-204° C)
6. Carefully slide the locking collar (7) and the head will destroy the bond. Avoid overheating or the parts may
gland (8) down along the rod toward the eyelet end, become distorted or damaged. Apply sufficient torque or
away from the cylinder tube (3). pressure for removal while the parts are still hot.
IMPORTANT: When sliding the rod and piston assembly Breakdown of sealant will leave a white, powdery
out of the tube, prevent the threaded end of the tube residue on threads and parts. Clean the residue away
from damaging the piston (9). Keep the rod centered with a soft brass wire brush prior to reassembly, and
within the tube to help prevent binding. wipe with Loctite “T” cleaner before reinstallation.
7. Carefully pull the rod (6) with all attachments straight 10. Remove the piston (9) from the rod (6).
out of the tube (3). 11. Remove both precision wearbands (11) and the
8. Fasten the rod in a soft-jawed vise, and put a capped T-seal (12) from the piston (9).
Note: The T-seal actually consists of four components: a
9. Remove the locknut (10) from the rod (6). The nut was and two supportive split caps that mount on either side of
installed with Loctite #271 (red) and torqued to 1750- the “T” itself.
2000 lb-ft (2373-2712 Nm).
bond of the sealant between the locknut (10) and the rod
locking compound.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.129

Hydraulic System
1 6
2
13
12
14
10
16
11
7
3
18 9
8 4
5
17 19
15
20
MH2890
12. Remove the small o-ring (11) from within the piston Note: If a white, powdery residue is present on threads
(7). and parts, it can be removed. Clean the residue away
13. Remove the o-ring (12) and back-up ring (13) from with a soft brass wire brush prior to reassembly, and
the head gland (6). Slide the rings off the rod (4) to wipe with Loctite “T” cleaner before reinstallation.
remove them from the rod.
d. Lift/Lower Cylinder Inspection
14. Remove the precision wearbands (14) from within
the head gland (6). Remove the sealed, outside 1. Inspect internal surfaces and all parts for wear,
diameter heavy-duty rod wiper (17) and the deep Z- damage, etc. If inner surface of the tube (1) does not
seal with back-up (15) from the other end of the display a smooth finish, or is scored or damaged in
head gland. Remove the rod spacer (16). any way, replace the tube. Often, dirty hydraulic fluid
c. Lift/Lower Cylinder Cleaning smooth surface within the tube.
1. Remove all hydraulic fluid, dirt and debris from the 2. Remove slight scratches on the piston, rod or inner
inner surface of the cylinder tube (1). surface of the tube with very fine grit emery cloth.
Use the emery cloth in a rotary motion to polish out
2. Discard all seals, back-up rings, o-rings, etc. and blend the scratch(es) into the surrounding
Replace with new items from complete seal kits (18) surface.
to help ensure proper cylinder function.
solvent such as trichlorethylene. Carefully clean 4. Check that the rod (4) is straight. If it is bent, install a
cavities, grooves, threads, etc. new rod.
8.130 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
e. Lift/Lower Cylinder Assembly IMPORTANT: When sliding the rod (4) and piston
assembly into the tube, prevent the threaded end of the
Note: Follow Section 8.13.3, “General Cylinder Assembly
tube from damaging the piston (7). Keep the rod
Instructions.”
centered within the tube to help prevent binding. Protect
1. Install a new small oiled o-ring (11) into the piston the finish on the rod at all times. Damage to the surface
(7). of the rod can cause seal failure.
2. Install the capped T-seal (10) and both precision 12. Carefully insert the rod (4) with all attachments
wearbands (9) onto the piston (7). straight into the tube (1).
Note: The T-seal actually consists of four components: a 13. Using a pin spanner wrench, thread the locking
wide, flexible inner band, the flexible T-seal band itself, collar (5) into the tube (1). Torque the locking collar
and two supportive split caps that mount on either side of to 300-400 lb-ft (407-542 Nm).
the “T” itself. IMPORTANT: DO NOT tamper with or attempt to reset
3. Install the precision wearbands (14) into the forward the counterbalance valve cartridge (2). If adjustment or
end of the head gland (6). Install the deep Z-seal replacement is necessary, replace a counterbalance
with back-up (15) orienting the edge (20). Install the valve with a new part.
sealed, outside diameter heavy-duty rod wiper (17). 14. Lubricate the counterbalance valve (2) and the pilot-
The wiper lip (19) should be toward the outer end of operated check valve (3) with clean, filtered
the head gland and the seal lips toward the inner hydraulic oil. Using new oiled o-rings, thread the
end of the head gland. Use tools that will not valves into tube (1). Torque to 30-35 lb-ft (41-47 Nm).
damage the seals. 15. Test the cylinder at low operating pressure (100 psi
4. Install a new oiled o-ring (12) and back-up ring (13) or 7 bar). Verify that the piston and the rod move
onto the head gland (6). freely in both directions.
5. Fasten the rear of the rod in a soft-jawed vise, and 16. Increase the operating pressure to the maximum
put a padded support below and near the threaded amount for the cylinder 3000 psi (207 bar), and
end of the rod to help prevent damage to the rod. again check for free movement in both directions.
6. Carefully slide the head gland (6) onto the rod (4). 17. Retract the rod fully into the tube, and cap and plug
Slide the rod spacer (16) onto the rod. the hydraulic hose ports.
7. Carefully slide the piston (7) onto the rod (4).
8. Apply Loctite Threadlocker #271 (red) to the threads
of the locknut (8). Thread the locknut onto the rod (4).
Torque to 1750-2000 lb-ft (2373-2712 Nm).
cylinder tube (1).
9. Secure the lift/lower cylinder in a soft-jawed vise or
10. Lubricate the inside of the tube (1) and outside of the
piston (7) and head gland (6) with clean, filtered
hydraulic oil.
11. Apply a compression sleeve or other suitable tool to
the head gland (6) and piston (7) in order to
compress the o-rings, back-up rings and seals, while
inserting the assembled piston, rod and head gland
into the tube (1).
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.131

Hydraulic System
1
21
20
11 14
12 13
9
8
2
3 6
10
7
17 5
19
18
16
15
18
4 19 15
17 16 MH4300
For S/N 19235 & After 4. Extend the rod (5) as required to allow access to the
base of the cylinder.
b. Lift/Lower Cylinder Disassembly IMPORTANT: Protect the finish on the rod at all times.
Note: An additional o-ring may be included at the base Damage to the surface of the rod can cause seal failure.
of the cylinder rod. This additional o-ring may be 5. Using a pin spanner wrench, unscrew the locking collar
discarded, as it served only in a temporarily protective (6) from the tube (2). The locking collar was
role. originally torqued to 300-400 lb-ft (407-542 Nm), so
1. Clean the lift/lower cylinder (1) with a suitable a considerable amount of force is required.
cleaner. Remove all dirt, debris and grease from the 6. Carefully slide the locking collar (6) and the head
cylinder. gland (7) down along the rod toward the eyelet end,
IMPORTANT: Avoid using excess force when clamping away from the cylinder tube (2).
the cylinder in a vise. Apply only enough force to hold the IMPORTANT: When sliding the rod and piston assembly
cylinder securely. Excessive force can damage the out of the tube, prevent the threaded end of the tube
cylinder tube (2). from damaging the piston (8). Keep the rod centered
2. Secure the lift/lower cylinder in a soft-jawed vise or within the tube to help prevent binding.
other acceptable holding equipment if possible. 7. Carefully pull the rod (5) with all attachments straight
3. Slowly remove the counterbalance valve (3) and pilot- out of the tube (2).
operated check valve (4) from the tube (2). 8. Fasten the rod in a soft-jawed vise, and put a
IMPORTANT: DO NOT tamper with or attempt to reset padded support below and near the threaded end of
the counterbalance valve cartridge. If adjustment or the rod to help prevent damage to the rod.
replacement is necessary, replace the counterbalance
8.132 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
9. Remove the two setscrews (9) from the locknut (10). c. Lift/Lower Cylinder Cleaning
Under each setscrew is a nylon ball (11). Be sure to
remove the nylon balls from the locknut. Discard the
inner surface of the cylinder tube (2).
nylon balls.
2. Discard all seals, back-up rings, o-rings, etc.
10. Remove the locknut (10) from the rod (5). The
Replace with new items from a complete seal kit (21)
locknut is torqued at 1735-1885 lb-ft (2352-2556
to help ensure proper cylinder function.
Nm).
Note: It may be necessary to apply heat to break the solvent such as trichlorethylene. Carefully clean
bond of the sealant between the locknut (10) and the rod cavities, grooves, threads, etc.
cylinders are sealed with a special organic sealant and Note: If a white, powdery residue is present on threads
locking compound. and parts, it can be removed. Clean the residue away
Before attempting to disassemble these parts, remove wipe with Loctite “T” cleaner before reinstallation.
Wipe off any hydraulic oil and heat the joint uniformly to d. Lift/Lower Cylinder Inspection
will destroy the bond. Avoid overheating or the parts may 1. Inspect internal surfaces and all parts for wear,
become distorted or damaged. Apply sufficient torque or damage, etc. If inner surface of the tube (2) does not
pressure for removal while the parts are still hot. display a smooth finish, or is scored or damaged in
any way, replace the tube. Often, dirty hydraulic fluid
Breakdown of sealant will leave a white, powdery causes failure of internal seals and damage to the
residue on threads and parts. Clean the residue away smooth surface within the tube.
wipe with Loctite “T” cleaner before reinstallation. 2. Remove slight scratches on the piston, rod or inner
surface of the tube with very fine grit emery cloth.
11. Remove the piston (8) from the rod (5). Use the emery cloth in a rotary motion to polish out
12. Remove the precision wearband (12) and the and blend the scratch(es) into the surrounding
capped T-seal (13) from the piston (8). surface.
Note: The T-seal actually consists of four components: a 3. Clean parts with trichlorethylene.
wide, flexible inner band, the flexible T-seal band itself, 4. Check that the rod (5) is straight. If it is bent, install a
and two supportive split caps that mount on either side of new rod.
the “T” itself.
13. Remove the small o-ring (14) from the end of the rod
(5).
14. Remove the o-ring (15) and back-up ring (16) from
the head gland (7).
15. Remove the precision wearbands (17) from within
the head gland (7). Remove the sealed, outside
diameter heavy-duty rod wiper (18) and the deep Z-
seal with back-up (19) from the other end of the
head gland. Remove the rod spacer (20).
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.133

Hydraulic System
1
16
3
4
14
17
5 2
18
20
19
15
7 8
6 9
11
13
12
21 10
8 10
12
6
13
MH4300
e. Lift/Lower Cylinder Assembly 4. Install a new oiled o-ring (12) and back-up ring (13)
onto the head gland (7).
Note: Follow Section 8.13.3, “General Cylinder Assembly
Instructions.” 5. Fasten the rear of the rod in a soft-jawed vise, and
put a padded support below and near the threaded
1. Install a new small oiled o-ring (1) into the groove in end of the rod to help prevent damage to the rod.
the end of the rod (2).
6. Carefully slide the head gland (7) onto the rod (2).
2. Install the capped T-seal (3) and the precision Slide the rod spacer (14) onto the rod.
wearband (4) onto the piston (5).
7. Carefully slide the piston (5) onto the rod (2).
8. Apply Loctite Threadlocker #271 (red) to the threads
of the locknut (15). Thread the locknut onto the rod
(2). Torque the nut to 1735-1885 lb-ft (2352-2556
the “T” itself.
Nm).
3. Install the precision wearbands (6) into the forward 9. Place new nylon balls (16) into the threaded holes of
end of the head gland (7). Install the deep Z-seal the locknut (15). Insert the setscrews (17) into the
with back-up (8) orienting the edge (9). Install the holes and tighten until the nylon balls are deformed
sealed, outside diameter heavy-duty rod wiper (10). into the threads of the rod.
The wiper lip (11) should be toward the outer end of
the head gland and the seal lips toward the inner
end of the head gland. Use tools that will not
damage the seals.
8.134 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
IMPORTANT: Avoid using excess force when clamping f. Lift/Lower Cylinder Installation
cylinder tube (18).
10. Secure the lift/lower cylinder in a soft-jawed vise or block the boom before doing any servicing that
other acceptable holding equipment if possible. requires the boom to be up. Unexpected
11. Lubricate the inside of the tube (18) and outside of lowering of the boom may cause death or
the piston (5) and head gland (7) with clean, filtered serious injury.
hydraulic oil.
1. Raise and support the boom to allow installation of
12. Apply a compression sleeve or other suitable tool to the lift/lower cylinder.
the head gland (7) and piston (5) in order to
2. Attach a sling to the lift/lower cylinder and to a hoist
compress the o-rings, back-up rings and seals, while
or an overhead crane. Safely and carefully, position
inserting the assembled piston, rod and head gland
the lift/lower cylinder inside the frame aligning the
into the tube (18).
rod and base eyelets with mounting bosses of the
IMPORTANT: When sliding the rod (2) and piston boom and frame.
assembly into the tube, prevent the threaded end of the
3. Secure the cylinder with cylinder mount pins,
tube from damaging the piston (5). Keep the rod
capscrews and nuts.
centered within the tube to help prevent binding. Protect
the finish on the rod at all times. Damage to the surface 4. Connect all hoses according to the labels or other
of the rod can cause seal failure. marks used to identify their locations during removal.
WARNING:
13. Carefully insert the rod (2) with all attachments
straight into the tube (18). Escaping hydraulic fluid
14. Using a pin spanner wrench, thread the locking death or serious injury.
collar (19) onto the tube (18). Torque the locking
collar to 300-400 lb-ft (407-542 Nm). 5. Operate the vehicle in order to check all boom
IMPORTANT: DO NOT tamper with or attempt to reset functions and check for hydraulic system leaks.
the counterbalance valve cartridge (20). If adjustment or 6. Wipe up any hydraulic fluid spillage in, on, near and
replacement is necessary, replace a counterbalance around the vehicle. Perform the pressure check and
valve with a new part. circuit bleeding procedure below.
15. Lubricate the counterbalance valve (20) and the
pilot-operated check valve (21) with clean, filtered g. Lift/Lower Cylinder Pressure Checking and
hydraulic oil. Using new oiled o-rings, thread the Circuit Bleeding
valves into tube (18). Torque to 30-35 lb-ft (41-47 Nm). 1. Attach a 4000 psi (276 bar) gauge to the test fitting
16. Test the cylinder at low operating pressure 100 psi on the main control valve to test the system
(7 bar). Verify that the piston and the rod move freely pressure. Pressure readings should be 3000 ±100
in both directions. psi (207 ±7 bar). Refer to Section 8.7, “Hydraulic
System Testing.” To check each cylinder pressure,
17. Increase the operating pressure to the maximum
consult the factory.
amount for the cylinder 3000 psi (207 bar), and
again check for free movement in both directions. 2. With no accessory installed on the quick attach, start
with the lift/lower and attachment tilt cylinders fully
18. Retract the rod fully into the tube, and cap and plug
retracted.
the hydraulic hose ports.
3. Fully raise and fully extend the boom. Hold the
joystick at full extend, while fully raising the lift/lower
cylinder.
4. Fully retract the attachment tilt cylinder. Hold the
joystick at full retract, while fully lowering the boom.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.135

Hydraulic System
8.13.8 Frame Sway Cylinder a. Frame Sway Cylinder Removal

The frame sway cylinder (1) is attached to the right side 1. Park the vehicle on a firm, level surface, fully retract
of the frame at the front axle and to the cast loop on the all hydraulic cylinders, ground the attachment (if
axle. any), place the travel select lever in (N) NEUTRAL,
position, engage the park brake switch and shut the
engine OFF.
1
WARNING: Hot hydraulic fluid can cause

severe burns. Wait for hydraulic fluid to cool
3. Unlock and open the rear. Allow the hydraulic fluid to
cool.
MH3710
component.
relation to the cylinder being removed. Safely
position suitable supports between the frame and
axle to prevent the frame from leaning to one side.
5. Disconnect and cap all hoses and fittings, etc.
6. Use a sling and hoist or other suitable lifting device
to support the cylinder. Remove the nuts,
capscrews, and cylinder mount pins securing the
cylinder to the frame and anchor plate.
7. Remove the cylinder from the vehicle. Wipe up any
vehicle.
8.136 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
2
5
6
3
3
MT1900
b. Frame Sway Cylinder Disassembly

of the cylinder rod. This additional o-ring may be when removing a counterbalance valve or a pilot-
discarded, as it served only in a temporarily protective operated check valve from a cylinder. Escaping
role. hydraulic fluid under pressure can penetrate the
1. Clean the frame sway cylinder (2) with a suitable skin, causing death or serious injury.
cleaner. Remove all dirt, debris and grease from the 3. Slowly remove the pilot-operated check valves (3)
cylinder. from the frame sway cylinder.
IMPORTANT: Avoid using excess force when clamping 4. Remove the locking insert (4) from its hole in the
the cylinder in a vise. Apply only enough force to hold the head gland threads. Pry or drill out the insert as
cylinder securely. Excessive force can damage the cylinder. required. DO NOT damage the head gland threads. A
2. Secure the frame sway cylinder (2) in a soft-jawed new locking insert will be required for reassembly.
vise or other holding device, and place a suitable IMPORTANT: Protect the finish on the rod at all times.
container beneath the cylinder to catch hydraulic Damage to the rod can cause premature seal failure.
fluid run-off.
5. Use a pin spanner wrench to unthread the head
gland (5) from the tube (6). 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.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.137

Hydraulic System
1 15
4
14
13
12
17
16 19
9
11
8 3
7
5
2
20
10
18
2 MT1900
IMPORTANT: When sliding the rod and piston assembly Note: The T-seal actually consists of four components: a
out of the tube, DO NOT damage the piston by scraping wide, flexible inner band, the flexible T-seal band itself,
it against the threads in the tube. Keep the rod in line and two supportive split caps that mount on either side of
with the tube to prevent binding. the “T” seal band.
6. Carefully withdraw the rod (6) straight out of the tube 13. Remove the o-ring (12), the back-up ring (13) and
(5). Keep the rod straight during withdrawal to help the o-ring (14) from the head gland (4).
avoid scratching, nicking or damaging the tube.
14. Remove the heavy-duty rod wiper (15) from the head
7. Secure the rod eyelet and remove the locknut (7) from gland (4).
the threaded end of the rod. Discard the nut; a new
15. Remove the precision wearband (16) and deep
nut will be required for reassembly.
Z-seal with rod back-up (17) from inside the head
Note: Heating the nut (7) to approximately 300° F gland (4).
(150° C) may also be required to break the seal formed c. Frame Sway Cylinder Internal Cleaning
by the Loctite Threadlocker #271 (red) applied to the nut
when installed. The application of significant force is 1. Remove all hydraulic fluid, dirt and debris from the
required to overcome the 1100-1250 lb-ft (1492-1695 inner surface of the cylinder.
Nm) of torque the nut was tightened to when originally 2. Discard all seals, back-up rings and o-rings. Replace
installed. with new items from a complete seal kit (18) to help
ensure proper cylinder function.
8. Remove the piston (8) from the rod (6).
9. Remove the small o-ring (9) from the piston (8).
10. Remove the head gland (4) from the rod (6). cavities, grooves, threads, etc.
11. Remove both precision wearbands (10) from the
piston (8).
12. Remove the capped T-seal (11) from the piston (8).
8.138 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
d. Frame Sway Cylinder Inspection and Repair 10. Secure the rod eyelet in a soft-jawed vise or other
suitable holding device. Place a padded support
1. Inspect all parts for wear, damage, etc. If inner
below the threaded end of the rod to help prevent
surfaces of the cylinder (1) do not display an ultra-
damaging the rod.
smooth, polished finish, or are damaged in any way,
replace the damaged part. Often, dirty hydraulic fluid 11. Apply Loctite Primer “T” and Threadlocker #271
causes failure of internal seals and damage to the (red), to a new locknut (7) in accordance with Loctite
polished surfaces within the component. instructions. Install the nut onto the threaded end of
the rod (6). Torque the nut to 1100-1250 lb-ft (1492-
2. Inspect the inside of the tube (5) for scoring and
1695 Nm).
other damage. If the tube is damaged, replace it with
a new tube. IMPORTANT: Avoid using excess force when clamping
3. Remove small scratches on the rod or inside of the
tube with very fine grit emery cloth. Use the emery
cylinder tube (5).
cloth in a rotary motion to polish out and blend
scratch(es) into the surrounding surface. 12. Fasten the tube (5) in a soft-jawed vise or other
suitable holding device.
4. Clean the parts with trichlorethylene after repair.
13. To aid in installation, lubricate the o-rings and the
5. Check that the rod (6) is straight. If the rod is bent,
inside of the tube, piston and head gland with clean,
install a new rod.
filtered hydraulic oil.
e. Frame Sway Cylinder Assembly
IMPORTANT: Use a suitable installation tool or
Note: Follow Section 8.13.3, “General Cylinder Assembly compression sleeve to help prevent twisting or damaging
Instructions.” the seals and o-rings when installing the piston (8) and
head gland (4) into the cylinder. When sliding the rod
1. Install the deep Z-seal with rod back-up (17) into the
and piston assembly into the tube, DO NOT damage the
head gland, orienting the edge (20).
piston by scraping it against the threads in the tube.
2. Install the precision wearband (16) into the head Keep the rod in line with the tube to prevent binding.
gland.
14. Keep the rod (6) straight, and carefully insert the rod
3. Install the heavy-duty rod wiper (15) with the raised into the tube (5). Avoid scratching, nicking or
portion of the wiper lip seal (19) oriented toward the damaging the tube while installing the rod.
rod eyelet. The wiper lip should be toward the outer
15. Begin threading the head gland (4) into the tube (5).
end of the head gland and the seal lips toward the
Place the locking insert (3) in its hole in the head
inner end of the head gland. Use tools that will not
gland threads, just before the hole is threaded into
damage the seals.
the tube. Use a suitable pin spanner wrench to
4. Install a new oiled o-ring (14), back-up ring (13) and thread the head gland (4) completely into the tube
oiled o-ring (12) onto the head gland (4). If the back- (5). Torque the head gland to 300-400 lb-ft (407-542
up ring is not flat on both sides, the side with the arc Nm).
must be toward the o-ring.
16. Lubricate the pilot-operated check valves (2) with
5. Install the head gland (4) onto the rod (6). If clean, filtered hydraulic oil. Using new oiled o-rings,
necessary, use a soft hammer to drive the head thread the pilot-operated check valves into tube (5).
gland onto the rod. Torque valves to 35-40 lb-ft (47-54 Nm).
6. Install the new small oiled o-ring (9) into the piston 17. Test the cylinder at low operating pressure 100 psi
(8). (6,9 bar) to verify that the piston and rod move freely
7. Install the capped T-seal (11) onto the piston (8). in both directions.
Note: The T-seal actually consists of four components: a 18. Increase the operating pressure to the maximum for
wide, flexible inner band, the flexible T-seal band itself, the cylinder 3250 psi (224 bar), and check for external
and two supportive split caps that mount on either side of leakage and for free movement in both directions.
the “T” seal band. 19. Retract the piston fully.
8. Install the two precision wearbands (10) onto the
piston (8).
9. Install the piston (8) onto the rod (6).
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.139

Hydraulic System
f. Frame Sway Cylinder Installation 8. Start the engine and run at approximately one-third
to one-half throttle for about one minute without
1. Lubricate the cylinder pins with multi-purpose,
lithium-based grease.
functions. Operate the joystick to fully sway the
2. Use a sling and hoist or other suitable lifting device frame left and right at least five times each.
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 death or serious injury.
cylinder pin through the cylinder eyelet, frame mount
and self-aligning bearing. Secure the pin with a 9. Inspect for leaks and check the level of the hydraulic
capscrew and hex-locknut. Torque to 18 lb-ft (24 Nm). fluid in the reservoir. Shut the engine OFF. Add
4. Use new flat-faced, oiled o-rings when installing the
upper and lower hydraulic hoses. Install and tighten 10. Wipe up any hydraulic fluid spillage in, on, near and
the hoses onto the appropriate fittings.

g. Frame Sway Cylinder Pressure Checking and
Circuit Bleeding
ventilation. Failure to properly ventilate exhaust 1. Attach a 4000 psi (276 bar) gauge to the test fitting
fumes can result in death or serious injury. on the main control valve to test the system
pressure. Pressure readings should be 3000 ±100
5. With the help of an assistant, start the engine. psi (207 ±7 bar). Refer to Section 8.7, “Hydraulic
Carefully and slowly, operate the joystick frame sway System Testing.” To check the cylinder pressure,
function to properly align the rod with the anchor consult the factory.
plate as required. Turn the engine OFF.
2. Start with the frame sway and stabilizer cylinders
6. Install the lower cylinder pin. Drive the lubricated balanced, that is, with the frame level.
cylinder pin through the rod eyelet, anchor plate and
self-aligning bearing. Secure the pin with a capscrew 3. Sway the vehicle fully left. Hold the joystick at full
and hex-locknut. Torque nut to 18 lb-ft (24 Nm). sway left for several seconds, then sway the vehicle
fully right and hold the joystick at full sway right for
7. Remove all tools, etc. from the vehicle. Carefully several seconds. Observe the readings on the gauge
remove the blocking supporting the vehicle frame at during the frame sway operations.
the front and rear axles.
4. Level the frame. While leveling the frame, check the
pressure reading on the gauge.
8.140 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
8.13.9 Stabil-TRAK Cylinder a. Stabilizer Cylinder Removal

The stabilizer cylinder (1) is attached to the left side of the 1. Park the vehicle on a firm, level surface, fully retract
frame at the rear axle and to the cast loop on the axle. all hydraulic cylinders, ground the attachment (if
position, engage the park brake switch and shut the
engine OFF.
~ WARNING: Hot hydraulic fluid can cause

1
fluid to cool.
MH3720 WARNING: Escaping hydraulic fluid

The Stabil-TRAK™ manifold attached to the stabilizer death or serious injury. Relieve hydraulic
cylinder at the left rear of the vehicle provides the pressure before servicing any hydraulic
operating characteristics for the patented Stabil-TRAK™ component.
system.
relation to the cylinder being removed. Safely
position suitable supports between the frame and
axle to prevent the frame from leaning to one side.
to support the cylinder. Remove the nuts,
capscrews, and cylinder mount pins securing the
cylinder to the frame and anchor plate.
7. Remove the cylinder from the vehicle. Wipe up any
vehicle.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.141

Hydraulic System
10
19
1 9
18
17 24
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 trapped inside the cylinder. Exercise caution
Note: An additional o-ring may be included at the base operated check valve from a cylinder. Escaping
of the cylinder rod. This additional o-ring may be hydraulic fluid under pressure can penetrate the
discarded, as it served only in a temporarily protective skin, causing death or serious injury.
role.
3. Slowly remove the two pilot-operated check valves (3),
1. Clean the stabilizer cylinder (1) with a suitable the pressure reducing valve (4) and the five solenoid
cleaner. Remove all dirt, debris and grease from the valves (5 and 6) on the manifold block (7) if
cylinder. replacement of any of these components is required.
IMPORTANT: Avoid using excess force when clamping Label the solenoid valves with the locations stamped
the cylinder in a vise. Apply only enough force to hold the on the manifold. Remove the solenoid cartridges
cylinder securely. Excessive force can damage the from the manifold.
cylinder tube (2). 4. Remove the locking insert (8) from its hole in the
2. Secure the stabilizer cylinder (1) in a soft-jawed vise head gland threads. Pry or drill out the insert as
or other holding device, and place a suitable required. DO NOT damage the head gland threads. A
container beneath the cylinder to catch hydraulic new locking insert will be required for reassembly.
fluid run-off. Note: The head gland (9) is installed at a torque of 300-
400 lb-ft (407-542 Nm). Use suitable tools to remove the
head gland.
8.142 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
5. Use a pin spanner wrench to unthread the head c. Stabilizer Cylinder Internal Cleaning
installed at a torque of 300-400 lb-ft (407-542 Nm),
remove it. Carefully slide the head gland down along 2. Discard all seals, back-up rings and o-rings. Replace
the rod toward the eyelet end, away from the cylinder with new items from the complete seal kits (22) to
tube. help ensure proper cylinder function.
IMPORTANT: Protect the finish on the rod at all times. 3. Clean all metal parts with an approved cleaning
Damage to the rod can cause premature seal failure. solvent such as trichlorethylene. Carefully clean
6. Carefully withdraw the rod (10) straight out of the
tube (2). Keep the rod straight during withdrawal to
d. Stabilizer Cylinder Inspection and Repair
help avoid scratching, nicking or damaging the tube.
IMPORTANT: When sliding the rod and piston assembly 1. Inspect all parts for wear and damage. If inner
out of the tube, DO NOT damage the piston (12) by surfaces of the cylinder (1) DO NOT display an ultra-
scraping it against the threads in the tube. Keep the rod smooth, polished finish, or are damaged in any way,
in line with the tube to prevent binding. replace the damaged part. Often, dirty hydraulic fluid
7. Secure the rod eyelet and remove the locknut (11) polished surfaces within the component.
from the threaded end of the rod. Discard the nut; a
new nut will be required for reassembly. 2. Inspect the inside of the tube (2) for scoring and
other damage. If the tube is damaged, replace it with
Note: Heating the nut to approximately 300° F (150° C) a new tube.
may also be required to break the seal formed by the
Loctite Threadlocker #271 (red) applied to the nut when
installed. The application of significant force is required
cloth in a rotary motion to polish out small
to overcome the 1100-1250 lb-ft (1492-1695 Nm) of
imperfections in the metal and blend scratch(es) into
torque the nut was tightened to when originally installed.
the surrounding surface.
8. Remove the piston (12) from the rod (10). 4. Clean the parts with trichlorethylene after repair.
9. Remove the small o-ring (13) from the piston. 5. Check that the rod (10) is straight. If the rod is bent,
Remove both precision wearbands (14) and the install a new rod.
capped T-seal (15) from the piston (12).
Note: The T-seal actually consists of four components; a e. Stabilizer Cylinder Assembly
wide, flexible inner band, the flexible T-seal band itself, Note: Follow Section 8.13.3, “General Cylinder
and two supportive split caps that mount on either side of Assembly Instructions.”
the “T” seal band.
1. Install the deep Z-seal with rod back-up (21) into the
10. Remove the head gland (9) from the rod (10). head gland (9), orienting the edge (23).
11. Remove the o-ring (16), the back-up ring (17) and 2. Install the precision wearband (20) into the head
the o-ring (18) from the head gland (9). gland (9).
12. Remove the heavy-duty rod wiper (19). Remove the 3. Install the heavy-duty rod wiper (19) with the raised
precision wearband (20) and deep Z-seal with rod portion of the wiper lip seal (24) oriented toward the
back-up (21) from inside the head gland (9). rod eyelet. The wiper lip should be toward the outer
Note: Discard all seals and o-rings. ALWAYS replace end of the head gland and the seal lips toward the
seals, o-rings, gaskets, etc. with new parts to help inner end of the head gland. Use tools that will not
ensure proper sealing and operation. damage the seals.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.143

Hydraulic System
10
1 9
18
17
16
6
15
8
13
3 14
4
5 12
11
~
7
3
MH2900
4. Install new oiled o-ring (18), back-up ring (17) and 10. Secure the rod eyelet in a soft-jawed vise or other
oiled o-ring (16) onto the head gland (9). If the back- suitable holding device. Place a padded support
up ring is not flat on both sides, the side with the arc below the threaded end of the rod to help prevent
must be toward the o-ring. damaging the rod.
5. Install the head gland (9) onto the rod (10). If 11. Apply Loctite Primer “T” and Threadlocker #271
necessary, use a soft hammer to drive the head (red) to a new locknut (11) in accordance with Loctite
gland onto the rod. instructions. Install the nut onto the threaded end of
6. Install the new small oiled o-ring (13) into the piston the rod. Torque the nut to 1100-1250 lb-ft (1492-
(12). 1695 Nm).
7. Install the capped T-seal (15) onto the piston (12). IMPORTANT: Avoid using excess force when clamping
Note: The T-seal actually consists of four components; a cylinder securely. Excessive force can damage the
wide, flexible inner band, the flexible T-seal band itself, cylinder tube (2).
12. Fasten the cylinder tube (2) in a soft-jawed vise or
other suitable holding device.
8. Install the two precision wearbands (14) onto the 13. Lubricate the o-rings and the inside of the tube,
piston (12). piston and head gland with clean, filtered hydraulic
9. Install the piston (12) onto the rod (10). oil. This will aid in installation.
8.144 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System

compression sleeve to help prevent twisting or damaging
the seals and o-rings when installing the piston (12) and
and piston assembly in the tube, DO NOT damage the
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). Avoid scratching, nicking or
damaging the tube while installing the rod.
15. Begin threading the head gland (9) into the tube (2).
Place the locking insert (8) in its hole in the head
gland threads just before the hole is threaded into
the tube. Use a suitable pin spanner wrench to
thread the head gland (9) completely into the tube
(2). Torque the head gland to 300-400 lb-ft (407-542
Nm).
16. Using new oiled o-rings, thread the two pilot-operated
check valves (3), the pressure reducing valve (4) and
the five solenoid valves (5 and 6) into the manifold
block (7). Torque the five solenoid cartridges (5 and
6) to 25-30 lb-ft (34-41 Nm). Torque the check valves
(3) and the pressure reducing valve (4) to 35-40 lb-ft
(47-54 Nm). Place the solenoid coils on the
cartridges and torque the solenoid nuts to 4-6 lb-ft
(5-8 Nm).
17. Test the cylinder (1) at low operating pressure 100
psi (7 bar) to verify that the piston and rod move
freely in both directions.
18. Increase the operating pressure to the maximum for
the cylinder 4000 psi (275 bar) and check for
external leakage and for free movement in both
directions.
19. Retract the piston fully.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.145

Hydraulic System
5 3 5
4
6
21
20
19 22
2
16
17
18 10
17
16
8
7 19
3 9
18 1
13
21
20
15
14 15 14
12
11 MH4310
For S/N 19357 & After

b. Stabilizer Cylinder Disassembly trapped inside the cylinder. Exercise caution
role.
3. Slowly remove the two pilot-operated check valves (3),
1. Clean the stabilizer cylinder (1) with a suitable the pressure reducing valve (4) and the five solenoid
cleaner. Remove all dirt, debris and grease from the valves (5 and 6) on the manifold block (7) if
cylinder. replacement of any of these components is required.
IMPORTANT: Avoid using excess force when clamping Label the solenoid valves with the locations stamped
the cylinder in a vise. Apply only enough force to hold the on the manifold. Remove the solenoid cartridges
cylinder securely. Excessive force can damage the from the manifold.
cylinder tube (2). 4. Remove the lock screw (8) from the head gland
2. Secure the stabilizer cylinder (1) in a soft-jawed vise flange (9).
or other holding device, and place a suitable
Note: The head gland (9) is installed at a torque of 300
container beneath the cylinder to catch hydraulic
±50 lb-ft (407 ±68 Nm). Use suitable tools to remove the
fluid run-off. head gland.
8.146 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
5. Use a pin spanner wrench to unthread the head c. Stabilizer Cylinder Internal Cleaning
installed at a torque of 300 ±50 lb-ft (407 ±68 Nm),
remove it. Carefully slide the head gland down along 2. Discard all seals, back-up rings and o-rings. Replace
the rod toward the eyelet end, away from the cylinder with new items from the complete seal kits (22) to
tube. help ensure proper cylinder function.
IMPORTANT: Protect the finish on the rod at all times. 3. Clean all metal parts with an approved cleaning
Damage to the rod can cause premature seal failure. solvent such as trichlorethylene. Carefully clean
6. Carefully withdraw the rod (10) straight out of the
tube (2). Keep the rod straight during withdrawal to
d. Stabilizer Cylinder Inspection and Repair
help avoid scratching, nicking or damaging the tube.
IMPORTANT: When sliding the rod and piston assembly 1. Inspect all parts for wear and damage. If inner
out of the tube, DO NOT damage the piston (11) by surfaces of the cylinder (1) DO NOT display an ultra-
scraping it against the threads in the tube. Keep the rod smooth, polished finish, or are damaged in any way,
in line with the tube to prevent binding. replace the damaged part. Often, dirty hydraulic fluid
7. Secure the rod eyelet and remove the locknut (12) polished surfaces within the component.
from the threaded end of the rod.
2. Inspect the inside of the tube (2) for scoring and
Note: Heating the nut to approximately 300° F (150° C) other damage. If the tube is damaged, replace it with
may also be required to break the seal formed by the a new tube.
Loctite Threadlocker #271 (red) applied to the nut when
installed. The application of significant force is required
to overcome the 1175-1400 lb-ft (1593-1898 Nm) of
cloth in a rotary motion to polish out small
torque the nut was tightened to when originally installed.
imperfections in the metal and blend scratch(es) into
8. Remove the piston (11) from the rod (10). the surrounding surface.
9. Remove the small o-ring (13) from the groove in the 4. Clean the parts with trichlorethylene after repair.
end of the rod (10). Remove the precision wearband 5. Check that the rod (10) is straight. If the rod is bent,
(14) and the capped T-seal (15) from the piston (11). install a new rod.
10. Remove the head gland (9) from the rod (10).
11. Remove the o-ring (16), the back-up ring (17) and
the o-ring (18) from the head gland (9).
12. Remove the heavy-duty rod wiper (19). Remove the
precision wearbands (20) and deep Z-seal with rod
back-up (21) from inside the head gland (9).
Note: Discard all seals and o-rings. ALWAYS replace
seals, o-rings, gaskets, etc. with new parts to help
ensure proper sealing and operation.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.147

Hydraulic System
18 20
20
19
21 4 3
1
6
16 5
9
7
7 8 10
9
17
22
2
18
8
5 23
11
1
4
12
14 12
14
15
13
MH4310
e. Stabilizer Cylinder Assembly 5. Install the head gland (2) onto the rod (10). If
necessary, use a soft hammer to drive the head
gland onto the rod.
Assembly Instructions.”
6. Install the new small oiled o-ring (11) into on the end
1. Install the deep Z-seal with rod back-up (1) into the of the rod (10).
head gland (2), orienting the edge (3).
7. Install the capped T-seal (12) onto the piston (13).
2. Install the precision wearbands (4) into the head
gland (2). Note: The T-seal actually consists of four components; a
3. Install the heavy-duty rod wiper (5) with the raised
portion of the wiper lip seal (6) oriented toward the
rod eyelet. The wiper lip should be toward the outer
end of the head gland and the seal lips toward the 8. Install the precision wearband (14) onto the piston
inner end of the head gland. Use tools that will not (13).
damage the seals. 9. Install the piston (13) onto the rod (10).
4. Install new oiled o-ring (7), back-up ring (8) and oiled
o-ring (9) onto the head gland (2). If the back-up ring
is not flat on both sides, the side with the arc must be
toward the o-ring.
8.148 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
10. Secure the rod eyelet in a soft-jawed vise or other 18. Test the cylinder (23) at low operating pressure [100
suitable holding device. Place a padded support psi (7 bar)] to verify that the piston and rod move
below the threaded end of the rod to help prevent freely in both directions.
damaging the rod. 19. Increase the operating pressure to the maximum for
11. Apply Loctite Threadlocker #271 (red) to the locknut the cylinder [4000 psi (275 bar)] and check for
(15) in accordance with Loctite instructions. Install external leakage and for free movement in both
the nut onto the threaded end of the rod. Torque the directions.
nut to 1175-1400 lb-ft (1593-1898 Nm). 20. Retract the piston fully
the cylinder in a vise. Apply only enough force to hold the f. Stabilizer Cylinder Installation
1. Lubricate the cylinder pins with multi-purpose,
cylinder tube (16).
lithium-based grease.
12. Fasten the cylinder tube (16) in a soft-jawed vise or
other suitable holding device.
to help install the cylinder. Orient the cylinder with
13. Lubricate the o-rings and the inside of the tube, the cylinder eyelet on top and the rod eyelet on the
piston and head gland with clean, filtered hydraulic bottom.
oil. This will aid in installation.
3. Install the upper cylinder pin. Drive the lubricated
IMPORTANT: Use a suitable installation tool or cylinder pin through the cylinder eyelet, frame mount
compression sleeve to help prevent twisting or damaging and self-aligning bearing. Secure the pin with a
the seals and o-rings when installing the piston (13) and capscrew and hex locknut. Torque to 18 lb-ft (24 Nm).
4. Use new flat-faced oiled o-rings when installing the
and piston assembly in the tube, DO NOT damage the
upper and lower hydraulic hoses. Install and tighten
the hoses onto the appropriate fittings on the
Keep the rod in line with the tube to prevent binding.
manifold.
14. Keep the rod (10) straight and carefully insert the rod
into the tube (16). Avoid scratching, nicking or g. Stabilizer Cylinder Pressure Checking and
damaging the tube while installing the rod. Circuit Bleeding
15. Apply Loctite #242 (blue) to the threads of the head 1. Attach a 4000 psi (276 bar) gauge to the test fitting
gland (2) and thread into the tube (16). Use a on the main control valve to test the system
suitable pin spanner wrench to thread the head pressure. Pressure readings should be 3000 ±100
gland (2) completely into the tube (16). Torque the psi (207 ±7 bar). Refer to Section 8.7, “Hydraulic
head gland to 300 ±50 lb-ft (407 ±68 Nm). System Testing.” To check the cylinder pressure,
16. Apply Loctite #242 (blue) to the threads of the lock consult the factory.
screw (17) and thread into the flange of the head 2. Start the vehicle. Level the frame.
gland (2). Torque to 3-4 lb-ft (4-5 Nm).
3. Sway the vehicle fully left. Hold the joystick at full
17. Using new oiled o-rings, thread the two pilot-operated sway left for several seconds, then sway the vehicle
check valves (18), the pressure reducing valve (19) fully right and hold the joystick at full sway right for
and the five solenoid valves (20 and 21) into the several seconds. Observe the readings on the gauge
manifold block (22). Torque the five solenoid during the frame sway operations.
cartridges (20 and 21) to 20-25 lb-ft (27-34 Nm).
Torque the check valves (18) and the pressure 4. Level the frame. While leveling the frame, check the
reducing valve (19) to 35-40 lb-ft (47-54 Nm). Place pressure reading on the gauge.
the solenoid coils on the cartridges and torque the 5. Repeat Steps 3 and 4 five times.
solenoid nuts to 4-6 lb-ft (5-8 Nm).
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.149

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
~
all hydraulic cylinders except the outrigger cylinders.
Lower the outriggers, but DO NOT allow the 2
outriggers to touch the ground. Place the travel
select lever in (N) NEUTRAL, place the neutral lock 1
lever in the (N) NEUTRAL LOCK position, engage
the park brake switch and shut the engine OFF.
3
MH3740
WARNING: Hot hydraulic fluid can cause


fluid to cool.

component.

relation to the outrigger cylinder being removed.
Disconnect and cap the hydraulic hoses and
outrigger cylinder fittings.
On Model 10054, disconnect the wiring connector to
each outrigger cylinder pressure switch.
5. Securely support the outrigger cylinder. Remove the
elastic hex locknut, capscrew and cylinder pin
securing the outrigger cylinder to the outrigger leg
on the outrigger frame. Discard the locknut.
With the help of at least one assistant, remove the
outrigger cylinder from the vehicle. Wipe up any hydraulic
fluid spillage in, on, near and around the vehicle.
8.150 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
5
4
7 6
MH2911
For Early Production 2. Place the outrigger cylinder in a soft-jawed vise or

b. Outrigger Cylinder Disassembly
role.
1. Clean the outrigger cylinder (4) with a suitable skin, causing death or serious injury.
cleaner before inspection. Remove all dirt, debris
and grease from the cylinder. 3. Slowly remove the counterbalance valve (6) and the
pilot-operated check valve (7) from the outrigger
cylinder.
cylinder tube (5).
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.151

Hydraulic System
3
2
6
7
8
14
15
10
4
16
11
1
13 5
12
17
18 MH2911
4. Extend the rod (1) to allow access to the base of the 6. Carefully pull the rod (1) with all attachments straight
cylinder. out of the tube (3).
IMPORTANT: Protect the finish on the rod at all times. 7. Fasten the rod end in a soft-jawed vise and put a
Damage to the surface of the rod can cause seal failure. padded support below and near the threaded end of
5. Using a pin spanner wrench, unscrew the head gland the rod to help prevent damage to the rod.
(2) from the tube (3). The head gland was originally 8. Remove the o-ring (5), back-up ring (7) and o-ring
torqued at 300-400 lb-ft (407-542 Nm), so a (8) from the head gland (2).
considerable amount of force is required to remove it. 9. Remove the locking inserts (6) from their installation
Carefully slide the head gland down along the rod holes in the head gland threads. Pry or drill out the
toward the eyelet end, away from the cylinder tube (3). inserts as required. DO NOT damage the head
IMPORTANT: When sliding the rod and piston assembly gland threads. New locking inserts will be required
into the tube, prevent the threaded end of the tube from for reassembly.
damaging the piston (4). Keep the rod centered within 10. Remove the precision wearbands (9) and the
the tube to help prevent binding. capped T-seal (10) from the piston (4).
the “T” itself.
8.152 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
11. Remove the locknut (11) from the rod (1). The 2. Remove slight scratches on the piston, rod, or inner
deforming-thread type nut was coated with Loctite surface of the tube with very fine grit emery cloth. Use
#271 (red) and torqued to 1300-1500 lb-ft (1763- the emery cloth in a rotary motion to polish out and
2034 Nm). Discard the nut. blend the scratch(es) into the surrounding surface.
Note: It may be necessary to apply heat to break the 3. Clean parts with trichlorethylene.
bond of the sealant between the locknut (11) and the rod 4. Check that the rod (1) is straight. If it is bent, install a
(1) before the piston (4) can be removed. Some parts of new rod.
locking compound. e. Outrigger Cylinder Assembly
Before attempting to disassemble these parts, remove Note: Follow Section 8.13.3, “General Cylinder
any accessible seals from the area of the bonded joint. Assembly Instructions.”
Wipe off any hydraulic oil and heat the joint uniformly to IMPORTANT: Use a suitable installation tool or
break the bond. A temperature of 300-400° F (149-204° C) compression sleeve to help prevent twisting or damaging
will destroy the bond. Avoid overheating or the parts may the seals and o-rings when installing the piston and head
become distorted or damaged. Apply sufficient torque or gland into the cylinder. When sliding the rod and piston
pressure for removal while the parts are still hot. assembly in the tube, DO NOT damage the piston by
Breakdown of sealant will leave a white, powdery scraping it against the threads in the tube. Keep the rod
residue on threads and parts. Clean the residue away in line with the tube to prevent binding.
with a soft brass wire brush prior to reassembly, and 1. Fasten the rod end in a soft-jawed vise, and put a
wipe with Loctite “T” cleaner before reinstallation. padded support below and near the threaded end of
12. Remove the piston (4) and head gland (2) from the the rod to help prevent damage to the rod. Install the
rod (1). small o-ring (15) in the piston (4).
13. From the head gland (2), remove the deep Z-seal 2. Install the sealed outside diameter heavy-duty rod
with rod back-up (12), the sealed outside diameter wiper (13). The wiper lip (17) should be toward the
heavy-duty rod wiper (13) and the precision outer end of the head gland and the seal lips toward
wearbands (14). the inner end of the head gland. Use tools that will
not damage the seals.
14. From the piston (4), remove the small o-ring (15).
3. Install the deep Z-seal with rod back-up (12) in the
c. Outrigger Cylinder Cleaning head gland (2) orienting the edge (18).
4. Install the precision wearbands (14) into the head
gland (2).
5. Carefully install the head gland (2) onto the rod (1).
with new items from a complete seal kits (16) to help 6. Carefully install the piston (4) onto the rod (1).
ensure proper cylinder function. Note: If a white, powdery residue remains on the
3. Clean all metal parts with an approved cleaning threads and parts, clean the residue away with a soft
solvent such as trichlorethylene. Carefully clean brass wire brush prior to reassembly, and wipe with
cavities, grooves, threads, etc. Loctite “T” cleaner before proceeding.
Note: If a white, powdery residue is present on threads 7. Apply Loctite Threadlocker #271 (red) to a new
and parts, it can be removed. Clean the residue away locknut (11). Thread the locknut onto the rod (1) and
with a soft brass wire brush prior to reassembly, and torque to 1300-1500 lb-ft (1763-2034 Nm). The
wipe with Loctite “T” cleaner before reinstallation. threads will deform upon tightening, locking the nut
in place.
d. Outrigger Cylinder Inspection
failure of internal seals and damage to the smooth
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.153

Hydraulic System
10
8
6
12 11
5
1
3
MH2911
8. Install the capped T-seal (1) and precision 11. Carefully insert the rod (9) with all attachments
Note: The T-seal actually consists of four components: a 12. Using a pin spanner wrench, thread the head gland
wide, flexible inner band, the flexible T-seal band itself, (8) into the tube (10). Torque the head gland to 300-
and two supportive split caps that mount on either side of 400 lb-ft (407-542 Nm).
the “T” itself. IMPORTANT: DO NOT tamper with or attempt to reset
9. Install new oiled o-ring (4), back-up ring (5) and oiled the counterbalance valve (11). If adjustment or
o-ring (7) onto the head gland (8). replacement is necessary, replace a counterbalance
10. Install two new locking inserts (6) into their holes in
the head gland (8) threads. 13. Lubricate the counterbalance valve (11) and the
pilot-operated check valve (12) with clean, filtered
IMPORTANT: When sliding the rod and piston assembly hydraulic oil. Using new oiled o-rings, thread the
into the tube, prevent the threaded end of the tube from valves into the tube (10). Torque to 30-35 lb-ft
damaging the piston (3). Keep the rod centered within (41-47 Nm).
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.
8.154 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
13
14
16
15
MH4320
For Current Production 2. Place the outrigger cylinder in a soft-jawed vise or

b. Outrigger Cylinder Disassembly
role.
1. Clean the outrigger cylinder (13) with a suitable skin, causing death or serious injury.
cleaner before inspection. Remove all dirt, debris
and grease from the cylinder. 3. Slowly remove the counterbalance valve (15) and
the pilot-operated check valve (16) from the
outrigger cylinder.
cylinder tube (14).
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.155

Hydraulic System
15
9
10
5
4
9
11
2
1
14
18
17
3
8
13
12
16 14 6
7
8
6 7 MH4320
4. Extend the rod (1) to allow access to the base of the 7. Carefully pull the rod (1) with all attachments straight
cylinder. out of the tube (4).
IMPORTANT: Protect the finish on the rod at all times. 8. Fasten the rod end in a soft-jawed vise and put a
Damage to the surface of the rod can cause seal failure. padded support below and near the threaded end of
5. Remove the lock screw (2) from the flange of the the rod to help prevent damage to the rod.
head gland (3). 9. Remove the o-ring (6), back-up ring (7) and o-ring
6. Using a pin spanner wrench, unscrew the head gland (8) from the head gland (3).
(3) from the tube (4). The head gland was originally 10. Remove the precision wearbands (9) and the
torqued at 300 ±50 lb-ft (407 ±68 Nm), so a capped T-seal (10) from the piston (5).
considerable amount of force is required to remove it.
toward the eyelet end, away from the cylinder tube (4).
IMPORTANT: When sliding the rod and piston assembly the “T” itself.
into the tube, prevent the threaded end of the tube from
damaging the piston (5). Keep the rod centered within 11. Remove the locknut (11) from the rod (1). The
the tube to help prevent binding. locknut was coated with Loctite #271 (red) and
torqued to 1650-1800 lb-ft (2237-2440 Nm).
8.156 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
Note: It may be necessary to apply heat to break the 2. Remove slight scratches on the piston, rod, or inner
bond of the sealant between the locknut (11) and the rod surface of the tube with very fine grit emery cloth. Use
(1) before the piston (5) can be removed. Some parts of the emery cloth in a rotary motion to polish out and
cylinders are sealed with a special organic sealant and blend the scratch(es) into the surrounding surface.
locking compound. 3. Clean parts with trichlorethylene.
Before attempting to disassemble these parts, remove 4. Check that the rod (1) is straight. If it is bent, install a
any accessible seals from the area of the bonded joint. new rod.
break the bond. A temperature of 300-400° F (149-204° C) e. Outrigger Cylinder Assembly
will destroy the bond. Avoid overheating or the parts may Note: Follow Section 8.13.3, “General Cylinder
become distorted or damaged. Apply sufficient torque or Assembly Instructions.”
Breakdown of sealant will leave a white, powdery compression sleeve to help prevent twisting or damaging
residue on threads and parts. Clean the residue away the seals and o-rings when installing the piston and head
with a soft brass wire brush prior to reassembly, and gland into the cylinder. When sliding the rod and piston
wipe with Loctite “T” cleaner before reinstallation. assembly in the tube, DO NOT damage the piston by
12. Remove the piston (5) and head gland (3) from the scraping it against the threads in the tube. Keep the rod
rod (1). in line with the tube to prevent binding.
13. From the head gland (3), remove the deep Z-seal 1. Fasten the rod end in a soft-jawed vise, and put a
with rod back-up (12), the sealed outside diameter padded support below and near the threaded end of
heavy-duty rod wiper (13) and the precision the rod to help prevent damage to the rod. Install the
wearband (14). small o-ring (15) in the groove in the end of the rod
(1).
14. From the groove in the end of the rod (1), remove the
small o-ring (15). 2. Install the sealed outside diameter heavy-duty rod
wiper (13). The wiper lip (17) should be toward the
c. Outrigger Cylinder Cleaning outer end of the head gland and the seal lips toward
the inner end of the head gland. Use tools that will
1. Remove all hydraulic fluid, dirt and debris from the not damage the seals.
3. Install the deep Z-seal with rod back-up (12) in the
2. Discard all seals, back-up rings and o-rings. Replace head gland (3) orienting the edge (18).
with new items from a complete seal kits (16) to help
ensure proper cylinder function. 4. Install the precision wearband (14) into the head
gland (3).
solvent such as trichlorethylene. Carefully clean 5. Carefully install the head gland (3) onto the rod (1).
cavities, grooves, threads, etc. 6. Carefully install the piston (5) onto the rod (1).
Note: If a white, powdery residue is present on threads Note: If a white, powdery residue remains on the
and parts, it can be removed. Clean the residue away threads and parts, clean the residue away with a soft
with a soft brass wire brush prior to reassembly, and brass wire brush prior to reassembly, and wipe with
wipe with Loctite “T” cleaner before reinstallation. Loctite “T” cleaner before proceeding.
d. Outrigger Cylinder Inspection 7. Apply Loctite Threadlocker #271 (red) to the locknut
(11). Thread the locknut onto the rod (1) and torque
to 1650-1800 lb-ft (2237-2440 Nm).
failure of internal seals and damage to the smooth
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.157

Hydraulic System
1
3
9
2
12
10
8
11
7
4
6
5
5
6 4
MH4320
8. Install the capped T-seal (1) and precision 10. Carefully insert the rod (8) with all attachments
Note: The T-seal actually consists of four components: a 11. Apply Loctite #242 (blue) to the threads of the head
wide, flexible inner band, the flexible T-seal band itself, gland (7). Using a pin spanner wrench, thread the
and two supportive split caps that mount on either side of head gland (7) into the tube (9). Torque the head
the “T” itself. gland to 300 ±50 lb-ft (407 ±68 Nm).
9. Install new oiled o-ring (4), back-up ring (5) and oiled 12. Apply Loctite #242 (blue) to the threads of the lock
o-ring (6) onto the head gland (7). screw (10) and thread into the flange of the head
gland (7). Torque to 3-4 lb-ft (4-5 Nm).
in the tube, prevent the threaded end of the tube from IMPORTANT: DO NOT tamper with or attempt to reset
damaging the piston (3). Keep the rod centered within the counterbalance valve (11). If adjustment or
the tube to help prevent binding. Protect the finish on the replacement is necessary, replace a counterbalance
rod at all times. Damage to the surface of the rod can valve with a new part.
cause seal failure. 13. Lubricate the counterbalance valve (11) and the
pilot-operated check valve (12) with clean, filtered
hydraulic oil. Using new oiled o-rings, thread the
valves into the tube (9). Torque to 30-35 lb-ft
(41-47 Nm).
8.158 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
f. Outrigger Cylinder Installation g. Outrigger Cylinder Circuit Test

1. Lubricate the outrigger cylinder pins with multi- 1. Lower the outrigger cylinder to the ground.
purpose lithium-based grease. 2. Apply full down pressure until the front wheels lift off
2. Use a sling and hoist or other suitable lifting device the ground.
to help install the cylinder. Orient the cylinder with 3. Watch for any drifting.
the cylinder eyelet on top and the rod eyelet on the
bottom. 4. If drifting occurs, raise and lower the outriggers
several times and repeat Steps 1 and 4 until no
3. Install the upper cylinder pin. Drive the lubricated drifting occurs.
cylinder pin through the outrigger frame mount and
the cylinder eyelet, aligning the mount pin bolt holes
with the outrigger cylinder mount holes. Secure the
outrigger cylinder with the capscrews and nuts.
Torque the capscrews and nuts to specification.
Refer to the fastener torque chart in Section 2.3,
“Torques.” Repeat with the lower cylinder pin.
4. Use new flat-faced oiled o-rings when installing the
upper and lower hydraulic hoses. Install and tighten
the hoses onto the appropriate fittings.
On Model 10054, connect the pressure switches.

5. Start and run the engine at approximately one-third to
one-half throttle for about one minute without moving
the vehicle or operating any hydraulic functions.

fluid in the reservoir. Shut the engine OFF. Add
7. Conduct an outrigger cylinder hydraulic circuit test
following the procedure that follows.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.159

Hydraulic System
8.13.11 Swing Carriage (Optional) 2

The optional swing carriage provides a way to swing the 3
carriage attachment from side-to-side. The swing X
carriage includes two cylinders (1) that operate together
to provide the side-to-side motion.
1 2
4 R
E
MT2450 X
MT1960
a. Swing Carriage Cylinder Removal

1. Level the boom (place the boom in a horizontal to support the cylinders (5). Remove the bolt (6) and
position). nut (7) holding the center mounting pin (8) to the
2. Swing the carriage to the centered position. pivot mount (9). Remove the pin.
3. Lower the boom until the carriage is resting firmly on 11. Remove snap rings (10) and cylinder base end pins
the ground. (11) from the mounting plates on carriage (12).
4. Place the travel select lever in (N) NEUTRAL, place 12. Identify and mark the location of the 1-1/2" I.D.
the neutral lock lever in the (N) NEUTRAL LOCK shims (13) at the base end of the cylinder.
position, engage the park brake switch and shut the 13. Remove the cylinders (5) from the pivot mount (9)
engine OFF. and the mounting plates (12) using a strap sling and
5. Place an Accident Prevention Tag on both the hoist or other suitable lifting equipment. While
ignition key switch and the steering wheel, stating removing the cylinder(s), identify the locations of the
that the vehicle should not be operated. Refer to 2" I.D. shims (14) at the rod end(s) of the cylinder(s).
Section 1.5, “Accident Prevention Tags.” DO NOT lose the bearing(s) (15), which may be
loose, in the cylinder rod end(s).
WARNING: Hot hydraulic fluid can 14. Wipe up any hydraulic fluid spillage in, on, near and
cause severe burns. Wait for hydraulic fluid to around the vehicle. Disconnect and cap all hoses
cool before servicing any hydraulic component. and fittings, etc.
6. Unlock and open the rear door. Allow the hydraulic 9
fluid to cool. 7

death or serious injury. Relieve hydraulic 5 14
15 5 8
component. 14
7. Remove all dirt and grease from the swing carriage 10
cylinders (2) and their hydraulic lines (3 and 4). 13
8. Label or otherwise mark the hydraulic lines (3 and 4). 15 12
9. Disconnect and cap all hoses and fittings, etc. 14 11
10 MT1970
8.160 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
1 5
6 4
2
3
7
MT1911
For Early Production 4. If the self-aligning bearing (4) requires replacement,

support the rod (5) in a soft-jawed vise or other
b. Swing Carriage Cylinder Disassembly suitable holding device. Carefully press the bearing
out of the rod eyelet.
of the cylinder rod. This additional o-ring may be 5. Extend the rod (5) to access the cylinder base.
discarded, as it served only in a temporarily protective IMPORTANT: Protect the finish on the rod at all times.
role. Damage to the surface of the rod can cause seal failure.
1. Clean the swing carriage cylinder (1) with a suitable 6. Using a pin spanner wrench, unscrew the head
cleaner to remove dirt, debris, grease, etc. gland (6) from the cylinder tube (7). The head gland
IMPORTANT: Avoid using excess force when clamping was originally torqued to 250-300 lb-ft (339-407
the cylinder in a vise. Apply only enough force to hold the Nm), so a considerable amount of force is required.
cylinder securely. Excessive force can damage the cylinder. Carefully slide the head gland down along the rod
toward the eyelet, away from the cylinder tube (7).
2. Secure the swing carriage cylinder in a soft-jawed
vise or other acceptable holding equipment if possible.
damaging the piston (8). Keep the rod centered within the
tube to help prevent binding.
when removing a counterbalance valve or a 7. Carefully pull the rod (5) with all attachments straight
pilot-operated check valve from a cylinder. out of the tube (7).
Escaping hydraulic fluid under pressure can 8. Fasten the rod end in a soft-jawed vise, and put a
penetrate the skin, causing death or serious injury. padded support below and near the threaded end of
3. Slowly remove the 3000 psi (207 bar) counterbalance
cartridge (2) and the 2000 psi (138 bar) direct-acting
relief valve (3) from the swing carriage cylinder.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.161

Hydraulic System
9. Remove the two setscrews (8), with locking inserts 4. If a white, powdery residue is present on threads
(9), from the piston (7). Pry or drill out the setscrews and parts, it can be removed. Clean the residue
as required. DO NOT damage the piston threads. away with a soft brass wire brush prior to reassembly,
New setscrews with locking inserts will be required and wipe with Loctite “T” cleaner before reinstallation.
for reassembly.
d. Swing Carriage Cylinder Inspection
10. Remove the piston (7) from the rod (4).
1. Inspect internal surfaces and all parts for wear,
Note: Loctite Threadlocker #271 (red) and 440-500 lb-ft damage, etc. If the inner surface of the tube (6) does
(597-678 Nm) were applied to the piston (7) when it was not display a smooth finish, or is scored or damaged
installed. It may be necessary to apply heat to break the in any way, replace the tube. Often, dirty hydraulic
bond of the sealant between the piston (7) and the rod fluid causes failure of internal seals and damage to
(4) before the piston can be unthreaded and removed. the smooth surface within the tube.
Some parts of cylinders are sealed with a special organic 2. Remove slight scratches on the piston, rod or inner
sealant and locking compound. surface of the tube with very fine grit emery cloth.
Before attempting to disassemble these parts, remove Use the emery cloth in a rotary motion to polish out
any accessible seals from the area of the bonded joint. and blend the scratch(es) into the surrounding
Wipe off any hydraulic oil and heat the joint uniformly to surface.
break the bond. A temperature of 300-400° F (149-204° C) 3. Clean parts with trichlorethylene after repair.
new rod.
e. Swing Carriage Cylinder Assembly
Breakdown of sealant will leave a white, powdery
residue on threads and parts. Clean the residue away Note: Follow the information in Section 8.13.3, “General
with a soft brass wire brush prior to reassembly, and Cylinder Assembly Instructions.”
wipe with Loctite “T” cleaner before reinstallation. 1. Install the deep Z-seal (19), orienting the edge (24).
11. Remove the piston square seal (10), square ring Install the precision wearbands (18) into the forward
(11) and precision wearband (12) from the piston (7). end of the head gland (5), and at the rear end, install
the rod wiper (20). The wiper lip (23) should be
12. From within the piston, remove the small o-ring (13).
toward the outer end of the head gland and the seal
13. Remove the locking inserts (14) from their lips toward the inner end of the head gland. Use
installation holes in the head gland threads. Pry or tools that will not damage the seals.
drill out the inserts as required. DO NOT damage the
2. Install a new oiled o-ring (17), back-up ring (16) and
head gland threads. New locking inserts will be
oiled o-ring (15) onto the head gland (5).
required for reassembly.
3. Fasten the rod end in a soft-jawed vise and put a
15. Remove the o-ring (15), back-up ring (16) and o-ring the rod to help prevent damage to the rod.
(17) from the head gland (5).
4. Push the head gland (5) onto the rod (4). If
16. From within the head gland (5), remove the precision necessary, use a soft hammer to drive the head
wearbands (18) and the deep Z-seal (19). From the gland onto the rod.
other end, remove the rod wiper (20).
5. Install two new locking inserts (14) into their holes in
the head gland threads.
c. Swing Carriage Cylinder Cleaning
6. Install a new small oiled o-ring (13) into the piston
(7).
swing carriage cylinder (1).
with new items from the complete seal kits (21) to
help ensure proper cylinder function.
8.162 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
1 4
14
5
19
18 22
17
16
15
8 10
11 20
9 13 23
12 14
2
3
24 21
7
9
8
6 MT1911
7. Install a new piston square seal (10), square ring 13. Carefully insert the rod (4) with all attachments
(11) and precision wearband (12) onto the piston (7). straight into the tube (6). Use a pin spanner wrench
8. Apply Loctite Primer “T” and Threadlocker #271 to thread the head gland into the tube. Torque the
(red) to the threads of the piston (7) in accordance head gland to 250-300 lb-ft (339-407 Nm). Remove
with Loctite instructions. Thread the piston (7) onto the compression tool.
the rod (4) and torque to 440-500 ft-lb (597-678 Nm). 14. Using new oiled o-rings, install the counterbalance
valve (2) and direct-acting relief valve (3). Lubricate
9. Install two new setscrews (8) with locking inserts (9)
the cartridge and valve with clean, filtered hydraulic
into their holes in the piston (7). Torque to 85-95 lb-ft
oil. Torque the valves to 35-40 lb-ft (47-54 Nm).
(115-124 Nm).
15. Test the cylinder at low operating pressure (100 psi
or 7 bar). Verify that the piston and rod move freely
in both directions.
cylinder tube (6). 16. Increase the operating pressure to the maximum for
the cylinder (3000 psi or 207 bar). Verify that the
10. Place the cylinder tube (6) in a soft-jawed vise or
piston and rod move freely in both directions.
17. Retract the piston fully and cap the hydraulic hose
11. Lubricate the piston (7), head gland (5) and the ports. Install the cylinder on the carriage.
inside of the tube (6) with clean, filtered hydraulic oil.
18. If the bearing (22) requires replacement, support the
12. Apply a compression sleeve or other suitable tool to rod (4) in a soft-jawed vise or other suitable holding
the head gland (5) in order to compress the o-rings device. Carefully press a new bearing into the rod
(15 and 17). eyelet.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.163

Hydraulic System
22
15
11 13
12 5 4
3 2 6
14 7
15
9
12
10 19 23
11
21
24
19 18
17
8 17
16 16
20 18 MH4330
For Current Production 4. If the self-aligning bearing (4) requires replacement,

support the rod (5) in a soft-jawed vise or other
b. Swing Carriage Cylinder Disassembly suitable holding device. Carefully press the bearing
out of the rod eyelet.
of the cylinder rod. This additional o-ring may be 5. Extend the rod (5) to access the cylinder base.
discarded, as it served only in a temporarily protective IMPORTANT: Protect the finish on the rod at all times.
role. Damage to the surface of the rod can cause seal failure.
1. Clean the swing carriage cylinder (1) with a suitable 6. Remove the lock screw (6) from the flange of the
cleaner to remove dirt, debris, grease, etc. head gland (7).
IMPORTANT: Avoid using excess force when clamping 7. Using a pin spanner wrench, unscrew the head
the cylinder in a vise. Apply only enough force to hold the gland (7) from the cylinder tube (8). The head gland
cylinder securely. Excessive force can damage the cylinder. was originally torqued to 300 ±50 lb-ft (407 ±68 Nm),
2. Secure the swing carriage cylinder in a soft-jawed so a considerable amount of force is required.
vise or other acceptable holding equipment if possible.
toward the eyelet, away from the cylinder tube (8).
WARNING: Significant pressure may be IMPORTANT: When sliding the rod and piston assembly
when removing a counterbalance valve or a damaging the piston (9). Keep the rod centered within the
pilot-operated check valve from a cylinder. tube to help prevent binding.
Escaping hydraulic fluid under pressure can 8. Carefully pull the rod (5) with all attachments straight
penetrate the skin, causing death or serious injury. out of the tube (8).
3. Slowly remove the 3000 psi (207 bar) counterbalance
cartridge (2) and the 2000 psi (138 bar) direct-acting
relief valve (3) from the swing carriage cylinder.
8.164 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
9. Fasten the rod end in a soft-jawed vise, and put a d. Swing Carriage Cylinder Inspection
padded support below and near the threaded end of 1. Inspect internal surfaces and all parts for wear,
the rod to help prevent damage to the rod. damage, etc. If the inner surface of the tube (8) does
10. Remove the precision wear band (10) from the not display a smooth finish, or is scored or damaged
piston (9). in any way, replace the tube. Often, dirty hydraulic
11. Remove the two setscrews (11), and nylon balls fluid causes failure of internal seals and damage to
(12), from the piston (9). Pry or drill out the nylon the smooth surface within the tube.
balls as required. DO NOT damage the piston 2. Remove slight scratches on the piston, rod or inner
threads. New nylon balls will be required for surface of the tube with very fine grit emery cloth.
reassembly. Use the emery cloth in a rotary motion to polish out
12. Remove the piston (9) from the rod (5). The piston and blend the scratch(es) into the surrounding
was originally torqued to 425-500 ft-lb (576-678 Nm) surface.
so a considerable amount of force will be required to 3. Clean parts with trichlorethylene after repair.
remove the piston. 4. Check that the rod (5) is straight. If it is bent, install a
13. Remove the piston square seal (13) and square ring new rod.
(14) from the piston (9).
e. Swing Carriage Cylinder Assembly
14. Remove the small o-ring (15) from the groove in the
end of the rod (5). Note: Follow the information in Section 8.13.3, “General
Cylinder Assembly Instructions.”
1. Install the deep Z-seal (20), orienting the edge (23).
16. Remove the o-ring (16), back-up ring (17) and o-ring Install the precision wearbands (19) into the forward
(18) from the head gland (7). end of the head gland (7), and at the rear end, install
17. From within the head gland (7), remove the precision the rod wiper (21). The wiper lip (24) should be
wearbands (19) and the deep Z-seal (20). From the toward the outer end of the head gland and the seal
other end, remove the rod wiper (21). lips toward the inner end of the head gland. Use
tools that will not damage the seals.
c. Swing Carriage Cylinder Cleaning 2. Install a new oiled o-ring (18), back-up ring (17) and
1. Remove all hydraulic fluid, dirt and debris from the oiled o-ring (16) onto the head gland (7).
swing carriage cylinder (1). 3. Fasten the rod end in a soft-jawed vise and put a
2. Discard all seals, back-up rings and o-rings. Replace padded support below and near the threaded end of
with new items from the complete seal kits (22) to the rod to help prevent damage to the rod.
help ensure proper cylinder function. 4. Push the head gland (7) onto the rod (5). If
3. Clean all metal parts with an approved cleaning necessary, use a soft hammer to drive the head
solvent such as trichlorethylene. Carefully clean gland onto the rod.
cavities, grooves, threads, etc. 5. Install a new small oiled o-ring (15) into the groove in
the end of the rod (5).
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.165

Hydraulic System
2 1
5
6 15
13 7 12
14
9
3
6 4
10
8 11
MH4330
6. Install a new piston square seal (1), square ring (2). 13. Carefully insert the rod (4) with all attachments
7. Apply Loctite #242 (blue) to the threads of the piston straight into the tube (8). Apply Loctite #242 (blue) to
(3). Thread the piston (3) onto the rod (4) and torque the threads of the head gland (9). Use a pin spanner
to 425-500 ft-lb (576-678 Nm). wrench to thread the head gland into the tube.
Torque the head gland to 300 ±50 lb-ft (407 ±68
8. Apply Loctite #242 (blue) to the threads of the two Nm).
setscrews (5). Install two setscrews (5) with nylon
14. Apply Loctite #242 (blue) to the threads of the lock
balls (6) into their holes in the piston (3). Tighten
screw (12). Thread the lock screw into the flange of
until the nylon balls are deformed into the threads of
the head gland (9) and torque to 3-4 lb-ft (4-5 Nm).
the rod.
15. Using new oiled o-rings, install the counterbalance
9. Install the precision wearband (7) onto the piston (3).
valve (13) and direct-acting relief valve (14).
IMPORTANT: Avoid using excess force when clamping Lubricate the cartridge and valve with clean, filtered
the cylinder in a vise. Apply only enough force to hold the hydraulic oil. Torque the valves to 30-35 lb-ft (41-
cylinder securely. Excessive force can damage the 47 Nm).
cylinder tube (8).
16. Test the cylinder at low operating pressure (100 psi
10. Place the cylinder tube (8) in a soft-jawed vise or or 7 bar). Verify that the piston and rod move freely
other acceptable holding equipment if possible. in both directions.
11. Lubricate the piston (3), head gland (9) and the 17. Increase the operating pressure to the maximum for
inside of the tube (8) with clean, filtered hydraulic oil. the cylinder (3000 psi or 207 bar). Verify that the
12. Apply a compression sleeve or other suitable tool to piston and rod move freely in both directions.
the head gland (9) in order to compress the o-rings 18. Retract the piston fully and cap the hydraulic hose
(10 and 11). ports. Install the cylinder on the carriage.
IMPORTANT: When sliding the rod and piston assembly 19. If the bearing (15) requires replacement, support the
into the tube, prevent the threaded end of the tube from rod (4) in a soft-jawed vise or other suitable holding
damaging the piston (3). Keep the rod centered within device. Carefully press a new bearing into the rod
the tube to help prevent binding. eyelet.
8.166 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
f. Swing Carriage Cylinder Installation g. Swing Carriage Cylinder Pressure Checking and
Circuit Bleeding
1. Install the swing carriage cylinder(s) (16) on the pivot
mount (20). Secure the rod ends to the pivot mount 1. Attach a 4000 psi (276 bar) gauge to the test fitting
using the shims (25) and bearings (26). Insert the on the main control valve to test the system
pin (19) and secure with the bolt (17) and nut (18). pressure. Pressure readings should be 3000 ±100
20 System Testing.” To check the cylinder pressure,
18 consult the factory.
2. Center the swing carriage cylinders.
3. Swing the carriage fully left. Hold the joystick at full
swing left for several seconds, then swing the
16 25 17 carriage fully right and hold the joystick at full swing
26 16 right for several seconds. Observe the readings on
19
25 the gauge during the carriage swinging operations.
21
4. Center the carriage. While centering the carriage,
24 check the pressure reading on the gauge.
26 23 5. Repeat Steps 3 and 4 five times.
25 22
21 MT1970
2. Secure the tube end to the mount plates (23) using the
shims (24) and pins (22). Secure with snap rings (21).
3. Lubricate the tube ends with multi-purpose, lithium-
based grease.

4. Remove all plugs and caps from the hydraulic lines,
and securely tighten the lines to the cylinder(s).

5. Start the engine.
6. Swing the carriage five times through its full range or
until the operation of the swing carriage is normal
(no jerks or spongy feel).
7. Shut the engine OFF. Check the hydraulic level and
fill as required.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.167

Hydraulic System
8.13.12 Side Tilt Carriage Cylinder (Optional) a. Side Tilt Carriage (Optional) Removal
The optional side tilt carriage cylinder (1) provides a way 1. Level the boom (place the boom in a horizontal
to tilt the carriage attachment from side-to-side. The side position).
tilt carriage includes a cylinder that operates to provide 2. Tilt the carriage (2) to fully retract the side tilt
the side tilt motion. carriage cylinder (3).
3. Use suitable blocks to support the side tilt carriage
(2) in this position.
4. Engage the park brake switch, place the travel select
1 the (N) NEUTRAL LOCK position and shut the engine
OFF.
MT2440

fluid to cool.

component.
7. Remove all dirt and grease from the side tilt carriage
cylinder (3) and the auxiliary hydraulics lines (4).
8. Label or otherwise mark the auxiliary hydraulics
assemblies (4).
10. Remove the snap rings (5) and cylinder base pin (6)
and rod pin (7) from the mounting plates on the
carriage (2) and pivot base (8).
11. Remove the cylinder (3) using a sling and hoist or
other suitable lifting equipment.
around the vehicle.
8.168 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
4
2
5
7
3
5
5
MT1950
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.169

Hydraulic System
2
6
9 20
1 19
7
12
11
10
18
14
17
8
13 9
16
5 15
4
2
5
MT1921
b. Side Tilt Carriage Cylinder Disassembly

when removing a pilot-operated check valve
from a cylinder. Escaping hydraulic fluid under
role.
pressure can penetrate the skin, causing death
1. Clean the side tilt carriage cylinder (1) with a suitable or serious injury.
cleaner to remove dirt, debris, grease, etc.
5. Slowly remove both pilot check valves (5) from the
2. If necessary, remove both grease fittings (2) from the side tilt carriage cylinder.
cylinder tube end and the rod end.
6. Extend the rod (6) to allow access to the base of the
3. If necessary, press the self-aligning bearings (3) cylinder.
from the cylinder tube and rod ends.
IMPORTANT: Avoid using excess force when clamping Damage to the surface of the rod can cause seal failure.
7. Using a pin spanner wrench, unscrew the head
gland (7) from the tube (4). The head gland was
cylinder tube (4).
originally torqued to 300-400 lb-ft (407-542 Nm), so
4. Place the side tilt carriage cylinder (1) in a soft-jawed a considerable amount of force is required.
vise or other acceptable holding equipment if
8. Carefully slide the head gland down along the rod
possible. toward the eyelet end, away from the cylinder tube
(4).
8.170 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
IMPORTANT: When sliding the rod and piston assembly Note: Loctite Threadlocker #271 (red) and 550-650 lb-ft
into the tube, prevent the threaded end of the tube from (746-881 Nm) of torque were applied to the locknut when
damaging the piston (8). Keep the rod centered within it was installed. It may be necessary to apply heat to
the tube to help prevent binding. break the bond of the sealant between the locknut (16)
9. Carefully pull the rod (6) with all attachments straight and the rod (6) before the parts can be removed. Some
out of the tube (4). parts of cylinders are sealed with a special organic
sealant and locking compound.
10. Fasten the rod end in a soft-jawed vise, and put a
padded support below and near the threaded end of Before attempting to disassemble these parts, remove
the rod, to help prevent damage to the rod. any accessible seals from the area of the bonded joint.
11. Remove the locking inserts (9) from their holes in the
head gland threads. Pry or drill out the insert as
New locking inserts will be required for reassembly.
12. Remove the o-ring (10), back-up ring (11) and o-ring
(12) from the head gland (7). Breakdown of sealant will leave a white, powdery
residue on threads and parts. Clean the residue away
13. Remove the precision wearband (13) and capped T- with a soft brass wire brush prior to reassembly, and
seal (14) from the piston (8). wipe with Loctite “T” cleaner before reinstallation.
Note: The T-seal actually consists of four components: a 5. Remove the piston (8) and head gland (7) from the
wide, flexible inner band, the flexible T-seal band itself, rod (6).
the “T” itself. 6. Remove the small o-ring (17) from inside the piston
(8).
c. Side Tilt Carriage Cylinder Cleaning 7. Remove the precision wearbands (18), deep Z-seal
(19) and rod wiper (20) from the head gland (7).
inner surface of the cylinder tube (4).
d. Side Tilt Carriage Cylinder Inspection
with new items from complete seal kits (15) to help 1. Inspect internal surfaces and all parts for wear,
ensure proper cylinder function. damage, etc. If the inner surface of the tube (4) does
not display a smooth finish, or is scored or damaged
3. Clean all metal parts with an approved cleaning in any way, replace the tube. Often, dirty hydraulic
solvent such as trichlorethylene. Carefully clean fluid causes failure of internal seals and damage to
cavities, grooves, threads, etc. the smooth surface within the tube.
Note: If a white, powdery residue is present on threads 2. Remove slight scratches on the piston, rod or inner
and parts, it can be removed. Clean the residue away surface of the tube with very fine grit emery cloth.
with a soft brass wire brush prior to reassembly, and Use the emery cloth in a rotary motion to polish out
wipe with Loctite T cleaner before reinstallation. and blend the scratch(es) into the surrounding
4. Remove the locknut (16) from the rod (6). surface.
new rod.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.171

Hydraulic System
18 5 20
4
3
8 11
7
10
14
9 6
19 16 18
2
20 12
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 9. Apply Loctite Primer “T” and Threadlocker #271
Section 8.13.3, “General Cylinder Assembly Instructions.” (red) to the threads of the locknut (16) in accordance
with Loctite instructions. Thread the locknut onto the
1. If necessary, press the self-aligning bearings (1) into rod (11) and torque to 550-650 lb-ft (746-881 Nm).
the cylinder tube and rod ends. The bearings should
protrude equally from each side of the eyelet. IMPORTANT: Avoid using excess force when clamping
2. Install the precision wearbands (2) into the rear of cylinder securely. Excessive force can damage the
the head gland (3), and the deep Z-seal (4) and rod cylinder tube (17).
wiper (5) into the front of the head gland (3). Orient
the Z-seal edge (6). The rod wiper lip (7) should be 10. Fasten the cylinder tube (17) in a soft-jawed vise or
toward the outer end of the head gland and the seal other acceptable holding equipment.
lips toward the inner end of the head gland. Use 11. Lubricate the piston (13), head gland (3) and the
tools that will not damage the seals. inside of the tube (17) with clean, filtered hydraulic
3. Install new oiled o-ring (8), back-up ring (9) and oiled oil.
o-ring (10) on the head gland (3). 12. Apply a compression sleeve or other suitable tool to
4. Fasten the rod end in a soft-jawed vise and put a the head gland (3) in order to compress the o-ring
padded support below and near the threaded end of (10), back-up ring (9) and o-ring (8).
5. Carefully slide the head gland (3) onto the rod (11). If
necessary, use a soft hammer to drive the head
gland onto the rod.
6. Install a new small oiled o-ring (12) inside the rod
end of the piston (13).
7. Install the capped T-seal (14) and the precision
wearband (15) on the piston (13).
8.172 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
IMPORTANT: When sliding the rod and piston assembly 16. Test the side tilt cylinder at low operating pressure
in the tube, prevent the threaded end of the tube from (100 psi or 6,9 bar). Verify that the piston and rod
damaging the piston seal (14). Keep the rod centered move freely in both directions.
within the tube to help prevent binding. 17. Increase the operating pressure to the maximum for
13. Carefully insert the rod (11) with all attachments the cylinder (1750 psi or 120 bar). Verify that the
straight into the tube (17). Using a pin spanner piston and rod move freely in both directions.
wrench, begin to thread the head gland into the tube. 18. Retract the piston fully and cap the hydraulic hose
Install new locking inserts (18) into the head gland. ports. Install the cylinder on the carriage. Lubricate
Continue to thread the head gland into the tube and the self-aligning bearing (1) via the grease fittings
torque to 300-400 lb-ft (407-542 Nm). Remove the (20) with multi-purpose grease before operating the
compression tool. side tilt carriage on the vehicle.
14. Install new oiled o-rings and back-up rings on the
pilot check valves (19). Lubricate the valve and rings
with clean, filtered hydraulic oil. Install and torque to
30-35 lb-ft (41-47 Nm).
15. If necessary, install both grease fittings (20) into their
threaded holes in the cylinder tube eyelet.
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.173

Hydraulic System
3
1
4
6
2
4
4
MT1950
f. Side Tilt Carriage Cylinder Installation 3. Remove all plugs and caps from the hydraulic lines
1. Install the side tilt carriage cylinder (2) onto the side (3) and securely tighten the lines to the cylinder.
WARNING:
tilt carriage (1). Secure the rod end to the side tilt
carriage with the cylinder rod pin (6) and snap rings Avoid prolonged engine
(4). Secure the tube end to the pivot base (7) with operation in closed areas with inadequate
the cylinder base pin (5) and snap rings (4). ventilation. Failure to properly ventilate exhaust
2. Lubricate the pivot pins (5 and 6) with multi-purpose
grease. 4. Start the engine and remove any blocking from the
carriage.
WARNING: Escaping hydraulic fluid 5. Tilt the side carriage five times through its full range
under pressure can penetrate the skin, causing or until operation of the side tilt carriage is normal
death or serious injury. (no jerks or spongy feel).
6. Shut the engine OFF. Check the hydraulic level and
fill as required.
8.174 Model 8042, 10042, 10054 Legacy Rev. 10/03

Hydraulic System
g. Side Tilt Carriage Cylinder Pressure Checking 8.13.13 Steering Cylinders

and Circuit Bleeding
The steering cylinders (8 and 9) are secured to the axle
1. Attach a 4000 psi (276 bar) gauge to the test fitting assemblies. Steer cylinders are covered in the
on the main control valve to test the system appropriate manufacturer’s axle literature. For the front
pressure. Pressure readings should be 3000 ±100 steering cylinder (8), refer to the ZF Axle Repair Manual,
psi (207 ±7 bar). Refer to Section 8.7, “Hydraulic Model MS-T 3060 P/N 8990419
System Testing.” To check the cylinder pressure, (ZF P/N 5871 560 002). For the rear steering cylinder (9),
consult the factory. refer to the ZF Axle Repair Manual, Model MS-T 3045 P/N
2. Start with the side tilt carriage cylinder balanced, 8990430 (ZF P/N 5871 550 002).
that is, with the carriage level and centered, not
tilted.
3. Tilt the carriage fully left. Hold the joystick at full tilt 8
left for several seconds, then tilt the carriage fully
right and hold the joystick at full tilt right for several
seconds. Observe the readings on the gauge during
the carriage tilting operations.
4. Center and level the carriage. While levelling the
carriage, check the pressure reading on the gauge. 9
Front
MH3730
Model 8042, 10042, 10054 Legacy Rev. 10/03 8.175

Hydraulic System
8.176 Model 8042, 10042, 10054 Legacy Rev. 10/03

Section 9
Electrical System
Contents

9.1 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
9.1.3 General Overview (Engine Harness) (SN 8042, 18991 - 19987, 10042 19031 - 19987,
10054, 19080 - 19987 And 8042/10042/10054, 0160002332 & After) . . . . . . . . . 9.9
9.1.4 General Overview (ECM Cab Harness) (SN 8042, 18991 - 19987, 10042 19031 - 19987,
10054, 19080 - 19987 And 8042/10042/10054, 0160002332 & After) . . . . . . . . . 9.11
9.2 Service Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
9.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
9.2.2 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
9.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
9.4 Effective Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
9.5 Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
9.5.1 Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
9.5.2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
9.5.3 Cleaning and Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
9.5.4 Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
9.5.5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
9.5.6 Wire Code and Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
9.6 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
9.6.1 Circuit Protection - Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
9.6.2 Fuse and Relay Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
9.7 Electrical System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
9.7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
9.7.3 Troubleshooting with a Digital Multimeter (DMM) . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
9.7.4 Probing Electrical Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
9.7.5 Electrical Symbols Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
9.7.6 8042 Electrical Schematic Legend (SN 13198 Through 18990) . . . . . . . . . . . . . . 9.30
9.7.7 8042 Electrical Schematic (SN 13198 Through 16782, Without Lighting Package) 9.38
9.7.8 8042 Electrical Schematic
(SN 13198 Through 16782, With Lighting Package and SN 16783 Through 18990) 9.40
9.7.9 8042 Cab Harness, Engine Harness & ECM Cab Harness Electrical Schematic Legend
(SN 18991 - 19987 And 0160002332 & After). . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.42
9.7.10 8042 Cab Harness & Engine Harness Electrical Schematic
(SN 18991 - 19987 And 0160002332 & After). . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.50
9.7.11 8042 ECM Cab Harness & Engine Harness
(SN 18991 - 19987 And 0160002332 & After). . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.52
9.7.12 10042 Electrical Schematic Legend (SN 13198 Through 19030) . . . . . . . . . . . . . 9.53
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.1

Electrical System
9.7.13 10042 Electrical Schematic (SN 13198 Through 16782, Without Lighting Package) 9.62
(SN 19031 - 19987 And 0160002332 & After). . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.66
(SN 19031 - 19987 And 0160002332 & After). . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.74
(SN 19031 - 19987 And 0160002332 & After). . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.76
9.7.18 10054 Cab Harness & Engine Harness Electrical Schematic Legend
(SN 13198 Through 19079) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.77
(SN 13198 Through 16782, Without Lighting Package) . . . . . . . . . . . . . . . . . . . . 9.84
9.7.21 10054 Logic Harness & Boom Extend Interlock Harness Electrical Schematic Legend
(SN 13198 Through 19079) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.88
9.7.22 10054 Logic Harness & Boom Extend Interlock Harness Electrical Schematic
(SN 13198 Through 16782, Without Lighting Package) . . . . . . . . . . . . . . . . . . . . 9.92
(SN 19080 - 19987 And 0160002332 & After). . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.95
(SN 19080 - 19987 And 0160002332 & After). . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.102
(SN 19080 - 19987 And 0160002332 & After). . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.104
(SN 19080 - 19987 And 0160002332 & After). . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.105
(SN 19080 - 19987 And 0160002332 & After). . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.107
9.7.30 Wiper/Washer & Heater Harness Electrical Schematic Legend . . . . . . . . . . . . . . 9.108
9.7.31 Wiper/Washer & Heater Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . 9.109
9.7.32 Roadlight Harness Electrical Schematic Legend. . . . . . . . . . . . . . . . . . . . . . . . . . 9.110
9.7.33 Roadlight Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.111
9.7.34 Worklight Harness Electrical Schematic Legend. . . . . . . . . . . . . . . . . . . . . . . . . . 9.112
9.7.35 Worklight Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.113
9.7.36 Engine Start Circuit and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.114
9.7.37 Electronic Throttle Circuit and Troubleshooting (SN 8042, 18991 - 19987,
10042 19031 - 19987, 10054, 19080 - 19987 And 8042/10042/
10054, 0160002332 & After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.120
9.7.38 Charging Circuit and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.122
9.7.39 Front Steer Circuit and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.124
9.7.40 Four-Wheel Steer Circuit and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.126
9.7.41 Crab Steer Circuit and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.128
9.7.42 10042 Outrigger Circuit and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.130
9.7.43 10054 Outrigger Circuit and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.132
9.7.44 Front Windshield Wiper Circuit and Troubleshooting (Option) . . . . . . . . . . . . . . . . 9.134
9.7.45 Skylight Wiper Circuit and Troubleshooting (Option) . . . . . . . . . . . . . . . . . . . . . . . 9.136
9.7.46 Front Windshield & Skylight Washer Circuit and Troubleshooting (Option) . . . . . . 9.138
9.2 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
9.7.47 Heater Circuit and Troubleshooting (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.140

9.7.48 Roadlights Main Beam Circuit and Troubleshooting (Option) . . . . . . . . . . . . . . . . 9.142
9.7.49 Roadlights Hazard Lights Circuit and Troubleshooting (Option) . . . . . . . . . . . . . . 9.144
9.7.50 Roadlights Turn Signals Circuit and Troubleshooting (Option) . . . . . . . . . . . . . . . 9.146
9.7.51 Roadlights Side & Dipped Beam Lights Circuit and Troubleshooting (Option) . . . 9.148
9.7.52 Roadlights Brake Lights Circuit and Troubleshooting (Option) . . . . . . . . . . . . . . . 9.150
9.7.53 Roadlights w/Worklights Circuit and Troubleshooting (Option) . . . . . . . . . . . . . . . 9.152
9.7.54 Worklight (Without Roadlights) Circuit and Troubleshooting (Option) . . . . . . . . . . 9.154
9.8 Transmission Gear Selection Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.156
9.8.1 Transmission, Forward First Gear Circuit,
(SN 8042, 13198 - 18990, 10042 13198 - 19030). . . . . . . . . . . . . . . . . . . . . . . . . 9.157
9.8.2 Transmission, Forward First Gear Circuit, (SN 10054, 13198 - 19079) . . . . . . . . . 9.158
9.8.3 Transmission, Forward First Gear Circuit, (SN 8042, 18991 - 19987,
10042, 19031 - 19987 And 8042/10042, 0160002332 & After). . . . . . . . . . . . . . . 9.159
(SN 10054, 19080 - 19987 And 0160002332 & After). . . . . . . . . . . . . . . . . . . . . . 9.160
9.8.5 Transmission, Forward Second Gear Circuit,
(SN 8042, 13198 - 18990, 10042 13198 - 19030). . . . . . . . . . . . . . . . . . . . . . . . . 9.161
9.8.6 Transmission, Forward Second Gear Circuit, (SN 10054, 13198 - 19079) . . . . . . 9.162
9.8.7 Transmission, Forward Second Gear Circuit, (SN 8042, 18991 - 19987,
10042, 19031 - 19987 And 8042/10042, 0160002332 & After). . . . . . . . . . . . . . . 9.163
(SN 10054, 19080 - 19987 And 0160002332 & After). . . . . . . . . . . . . . . . . . . . . . 9.164
9.8.9 Transmission, Forward Third Gear Circuit,
(SN 8042, 13198 - 18990, 10042 13198 - 19030). . . . . . . . . . . . . . . . . . . . . . . . . 9.165
9.8.10 Transmission, Forward Third Gear Circuit, (SN 10054, 13198 - 19079) . . . . . . . . 9.166
9.8.11 Transmission, Forward Third Gear Circuit, (SN 8042, 18991 - 19987,
10042, 19031 - 19987 And 8042/10042, 0160002332 & After). . . . . . . . . . . . . . . 9.167
(SN 10054, 19080 - 19987 And 0160002332 & After). . . . . . . . . . . . . . . . . . . . . . 9.168
9.8.13 Transmission, Forward Fourth Gear Circuit,
(SN 8042, 13198 - 18990, 10042 13198 - 19030). . . . . . . . . . . . . . . . . . . . . . . . . 9.169
9.8.14 Transmission, Forward Fourth Gear Circuit, (SN 10054, 13198 - 19079) . . . . . . . 9.170
9.8.15 Transmission, Forward Fourth Gear Circuit, (SN 8042, 18991 - 19987,
10042, 19031 - 19987 And 8042/10042, 0160002332 & After). . . . . . . . . . . . . . . 9.171
(SN 10054, 19080 - 19987 And 0160002332 & After). . . . . . . . . . . . . . . . . . . . . . 9.172
9.8.17 Transmission, Reverse First Gear Circuit,
(SN 8042, 13198 - 18990, 10042 13198 - 19030). . . . . . . . . . . . . . . . . . . . . . . . . 9.173
9.8.18 Transmission, Reverse First Gear Circuit, (SN 10054, 13198 - 19079). . . . . . . . . 9.174
9.8.19 Transmission, Reverse First Gear Circuit, (SN 8042, 18991 - 19987,
10042, 19031 - 19987 And 8042/10042, 0160002332 & After). . . . . . . . . . . . . . . 9.175
(SN 10054, 19080 - 19987 And 0160002332 & After). . . . . . . . . . . . . . . . . . . . . . 9.176
9.8.21 Transmission, Reverse Second Gear Circuit,
(SN 8042, 13198 - 18990, 10042 13198 - 19030). . . . . . . . . . . . . . . . . . . . . . . . . 9.177
9.8.22 Transmission, Reverse Second Gear Circuit, (SN 10054, 13198 - 19079) . . . . . . 9.178
9.8.23 Transmission, Reverse Second Gear Circuit, (SN 8042, 18991 - 19987,
10042, 19031 - 19987 And 8042/10042, 0160002332 & After). . . . . . . . . . . . . . . 9.179
(SN 10054, 19080 - 19987 And 0160002332 & After). . . . . . . . . . . . . . . . . . . . . . 9.180
9.8.25 Transmission, Reverse Third Gear Circuit,
(SN 8042, 13198 - 18990, 10042 13198 - 19030). . . . . . . . . . . . . . . . . . . . . . . . . 9.181
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.3
Electrical System
9.8.26 Transmission, Reverse Third Gear Circuit, (SN 10054, 13198 - 19079) . . . . . . . . 9.182
9.8.27 Transmission, Reverse Third Gear Circuit, (SN 8042, 18991 - 19987,
10042, 19031 - 19987 And 8042/10042, 0160002332 & After) . . . . . . . . . . . . . . . 9.183
(SN 10054, 19080 - 19987 And 0160002332 & After). . . . . . . . . . . . . . . . . . . . . . 9.184
9.8.29 Dash Panel Warning Indicator Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . 9.185
9.8.30 Engine Alternator Charging Warning Indicator Troubleshooting . . . . . . . . . . . . . . 9.186
9.8.31 Engine Coolant Temperature Warning Indicator Troubleshooting . . . . . . . . . . . . . 9.187
9.8.32 Transmission Temperature Warning Indicator Troubleshooting . . . . . . . . . . . . . . . 9.188
9.8.33 Hydraulic Oil Temperature Warning Indicator Troubleshooting . . . . . . . . . . . . . . . 9.189
9.8.34 Park Brake Warning Indicator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.190
9.8.35 Engine Oil Pressure Warning Indicator Troubleshooting . . . . . . . . . . . . . . . . . . . . 9.191
9.8.36 Fuel Level Indicator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.192
9.8.37 Hourmeter Indicator Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.193
9.8.38 Stabil-TRAK™ Indicator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.194
9.9 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.195
9.9.1 Starting Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.195
9.9.2 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.196
9.10 Charging Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.199
9.10.1 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.201
9.10.2 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.204
9.11 Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.208
9.11.1 Warning Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.208
9.11.2 Back-up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.209
9.11.3 Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.210
9.12 Window Wiper/Washer (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.213
9.12.1 Windshield Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.213
9.12.2 Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.214
9.12.3 Skylight Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.215
9.12.4 Skylight Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.216
9.12.5 Windshield/Skylight Washer Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.217
9.12.6 Windshield/Skylight Washer Reservoir and Pump . . . . . . . . . . . . . . . . . . . . . . . . 9.218
9.13 Cab Heater and Fan (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.219
9.13.1 Cab Heater Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.219
9.14 Switches and Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.220
9.14.1 Ignition Key Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.220
9.14.2 Fuel Shut-off Solenoid (SN 8042, 13198 - 18990, 10042, 13198 - 19030,
10054, 13198 - 19079) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.222
9.14.3 Hydraulic Oil Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.223
9.14.4 Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.225
9.14.5 Outrigger Switches (10042/10054 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.227
9.14.6 Transmission Shift Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.228
9.14.7 Transmission Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.229
9.14.8 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.234
9.14.9 Steer Select Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.236
9.14.10 Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.237
9.14.11 Engine Low Oil Pressure Sender. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.238
9.14.12 Engine Coolant High Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.239
9.14.13 Transmission Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.240
9.14.14 Engine Block Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.241
9.4 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
9.14.15 Fuel Level Indicator and Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.244

9.14.16 Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.246
9.14.17 Boom Angle Sensor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 9.246
9.14.18 Boom Extend Interlock Sensor Removal/Replacement (10054 Only) . . . . . . . . . . 9.247
9.14.19 Service Brake Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.248
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.5

Electrical System
9.6 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
9.1 ELECTRICAL COMPONENT

TERMINOLOGY
To understand the safety, operation, and service
location of the electrical components of the vehicle. The
9.1.1 General Overview (Cab Harness)

Logic
Harness Cab/Chassis
Connectors Harness
Ignition
Instrument (10054 Only) Connectors
Connectors
Panel Connectors Grounds
Transmission
Shifter Connector
Steer Select
Switch Brake
Connector
Fuse Box Fuse Power
Brake Power
Horn
Outrigger
Wiper/Washer
(Option)
Brake Pedal
Switch
Connector Light Package
(Option)
Roadlights
Package
Park Brake (Option)
Connector
MH5560
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.7

Electrical System
9.1.2 General Overview (Engine Harness)

(SN 8042, 13198 - 18990, 10042 13198 - 19030, 10054, 13198 - 19079)
Tie Strap
Back-up Alarm
Boom Angle Fuel Shut-off

Sensor Solenoid
Connector Connector
Engine Block
Heater Water
Temperature Water
Engine Low
Hyd. Oil Sensor Temperature
Oil Pressure
Tank Sender Sensor
Connector
Oil Pressure
Switch Connector
Fuel
Tank
Trans.
Hyd. Temp.
Temp. Switch
Conn. Alternator
Starter Connectors
Upper Trans. Conn.
Fuel Connector
Sender Boom Angle
Conn. Sensor
Boom Extend
Trans. Logic
Sensor Conn.
Temp. Conn. Lower Trans. Harness
(10054 Only)
Connector (10054 Only)
Steer Boom Extend
Mode Sensor
Conn. Diodes (10054 Only)
Secondary Stabil-
Function TRAK™
Manifold Conn.
Conn. Negative (-)
Battery
Cable
Horn
Connector Trans.
Ground Positive (+)
Battery
Cable
Battery MH6090
Horn
Cab/Chassis
Battery Battery
Logic Harness Harness
Cover Hold-down
Connector Connectors
Plate Bolt
(10054 Only)
9.8 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
10054, 19080 - 19987 And 8042/10042/10054, 0160002332 & After)
Back-up Alarm
Boom Angle
Sensor Water
Connector Temperature
Sensor
Engine Low Water

Hyd. Oil Oil Pressure Temperature
Tank Sender Sensor
Connector
Oil Pressure
Switch Connector
Fuel Engine Harness
Tank Continued.
Trans.
See Page 9.10
Hyd. Temp.
Temp. Switch
Conn. Engine Block
Upper Trans. Heater
Fuel Connector
Sender
Conn.
Boom Extend
Trans.
Sensor
Temp. Conn. Lower Trans. Connector
Steer Connector (10054 Only)
Mode
Conn. Diodes Stabil-TRAK™
Connector
Secondary
Function Boom Angle
Manifold Sensor
Conn.
Trans. Logic
Ground Boom Extend Harness
Horn
Sensor (10054 Only)
Connector
(10054 Only)
Cab ECM
Harness
Connector MH5570
Horn
Cab/Chassis
Logic Harness Harness
Connector Connectors
(10054 Only)
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.9

Electrical System
10054, 19080 - 19987 And 8042/10042/10054, 0160002332 & After) (Continued)
Batteries
Frame
Ground
Stud
To
Engine
Starter
Engine
Grid
Heater
Engine Engine
Starter Alternator
Cold Start Grid

ECM Heater Fuses
Fuses
Engine
Harness
Continued.
See
Grid
Page 9.9
Heater
Relays
Ground Diode VesPaks

Buss Bar Diagnostic Terminating
Connector Resistor
MH5590
ECM
Connectors
Terminating
Resistor
9.10 Model 8042, 10042, 10054 Legacy Rev. 10/03

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)
Engine
Function
Indicator
Lights
A
Throttle
Sensor
Connectors
Fuse Block
A Engine
Connectors
Function
Indicator
Lights
Engine
Air-Intake
Heater
Indicator Light
MH5600
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.11

Electrical System
9.2 SERVICE WARNINGS

CAUTION: DO NOT disconnect the
battery while the engine is running. This will
9.2.1 General cause a voltage surge in the alternator
charging system that will immediately ruin
CAUTION: DO NOT disconnect any internal components.
wiring without first stopping the engine, turning
all electrical switches to the OFF position an
disconnecting the battery ground (-) cable from CAUTION: DO NOT connect a battery
the battery. Failure to remove the negative (-) into the system without checking for correct
battery cable will result in damage to vehicle polarity and voltage.
electronic systems.
Applies To Serial Numbers:
CAUTION: DO NOT cause a short circuit
8042, 18991 - 19987, 10042 19031 - 19987,
10054, 19080 - 19987 And
by connecting leads to incorrect terminals.
8042/10042/10054, 0160002332 & After
Always identify a lead and its correct terminal.
A short circuit or wrong connection creating
reverse polarity will immediately and CAUTION: When doing welding
permanently ruin internal components within anywhere on the vehicle disconnect the wire
the electrical system. harness (1 and 2) from the Engine Control
Module (ECM) (3) on the engine.
CAUTION: DO NOT momentarily or

“flash” connect a terminal to check for current
flow. No matter how brief the contact, the
transistors may be ruined.
1
9.2.2 Battery
WARNING: All lead-acid batteries

generate hydrogen gas, which is highly
flammable. If ignited by a spark or flame, the
3
gas may explode violently, causing spraying of
acid, fragmentation of the battery and possible
severe personal injuries, particularly to the
eyes. Wear safety glasses when working near 2
the battery. MU5510
WARNING: Avoid battery acid. Battery

9.3 SPECIFICATIONS
acid can cause chemical burns or other Electrical system specifications are listed in Section 2,
serious injury. In case of contact with battery “General Information and Specifications.”
acid, flush area immediately with water.
WARNING: Charge the battery in a

well-ventilated area only. Always turn battery
chargers OFF before connecting to or
disconnecting from a battery.
9.12 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
9.4 EFFECTIVE GROUND CONNECTIONS 9.5 WIRING HARNESSES

1. Effective ground connections are essential to the For Serial Numbers 8042, 13198-18990,
efficient operation of electrical components. If an 10042, 13198-19030 & 10054 13189-19079; wiring on
inadequate ground is suspected or determined, the vehicle is contained within two separate wiring
establishing another ground may be desired. Also, in harnesses, an engine harness and a cab harness.
the event a factory-authorized accessory is being For Serial Numbers 8042, 18991 - 19987,
installed, it is necessary to follow the proper 10042 19031 - 19987, 10054, 19080 - 19987 And
sequence for providing an electrical ground. The 8042/10042/10054, 0160002332 & After; wiring on the
sequence for installing or attaching a component to vehicle is contained within three separate wiring
an electrical ground to a stud, bolt or capscrew (4) is harnesses, an engine harness, ECM cab harness and a
to provide a clean surface by eliminating paint and cab harness.
rust from the area around the base of the stud (5).
Install a tooth type lockwasher (6), electrical wire A harness consists of black-nylon woven braiding,
connector (7), flat washer (8), tooth or slot-type providing a protective cover to bundle numerous wiring
lockwasher (9) and hex nut or locknut (10). groups, splices, terminals, connectors and (where
applicable) diodes. Each harness is identified with a part
number when the vehicle leaves the factory.
10
9 Each wire is identified by a wire number on each end of
8 the individual wire and by the color and gauge size of the
7 wire. The wire numbers are also identified on the
appropriate electrical schematic. All circuits have been
6 electrically tested for continuity, and all diodes have been
5 tested for correct biasing. Where several individual
4
connectors appear, the wiring leading to a particular
connector can help identify the specific circuit. For some
MA0871 circuits, a colored band (tie wrap) is present, and is
affixed to the connector wiring and used as a color-code
2. When an electrical component (11) is to be indicator. If wiring needs to be replaced, use the correct
grounded, eliminate paint and rust from around the gauge size wiring. NEVER replace a wire with a smaller
stud, bolt or capscrew (12), install a flat washer (13), gauge wire.
tooth type or slot-type lockwasher, or locking nut with
slotted type lockwasher (14) and hex nut or 9.5.1 Removal and Replacement
locknut (15).
Remove a wiring harness only if damaged or unusable.
15 Install a new harness one terminal at a time, as the old
harness is removed. Label or tag the terminal locations of
14 all wires, harness clips, tie wraps and conduit, as the old
13 harness is removed, to allow correct installation of the
new harness.
12 11
9.5.2 Disassembly
Disassembly of the wiring harness is not recommended
MA0881 due to the precise arrangement of wires and splice
requirements. If it becomes necessary to replace wires,
use the correct gauge size wiring, and NEVER replace a
wire with a smaller gauge wire.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.13

Electrical System
9.5.3 Cleaning and Drying 9.5.6 Wire Code and Color

Clean a wire harness with a natural bristle brush and the The chart below indicates the wire code abbreviation and
same detergent used to clean the vehicle. Allow the color as used on the electrical schematics.
harness to air dry. DO NOT allow surface temperatures
Wire Code Color
to exceed 300° F (149° C).
BLK Black
9.5.4 Inspection and Repair BLU Blue
Replace a harness only if it is damaged or unusable. If a BRN Brown
splice or repair must be made to a wire, always use rosin DK BLU Dark Blue
core solder to bond wires together. Use heat-shrink
tubing or insulating electrical tape to cover all splices or DK GRN Dark Green
bare wires. GRN Green
GRY Gray
9.5.5 Installation
LT BLU Light Blue
The wiring harnesses are held securely in place by wire
LT GRN Light Green
tie wraps, clips or other devices that help prevent chafing
or wearing of the insulation and entanglement with ORG Orange
moving parts. Sections of ribbed plastic conduit have PNK Pink
been installed where wiring or harnesses pass through
PUR Purple
openings in the vehicle frame. Always install tie wraps,
clips, conduit, etc., in their original locations to help RED Red
prevent damage to the wiring or harnesses. TAN Tan
YEL Yellow
VIO Violet
WHT White
9.14 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
9.6 FUSES AND RELAYS 9.6.1 Circuit Protection - Fuses

The fuse is the most common method used for protecting
Fuses and relays help to protect the electrical system. In
wiring circuits. A good fuse (3) will have the center
general, a blown fuse is a symptom of another electrical
element connected to both sides of the fuse. Whenever
problem. Address the true problem, not just the symptom.
there is an excessive amount of current flowing through a
Simply replacing the fuse often will not solve the problem.
circuit, the fusible element will melt (4) and create an
Blown fuses are usually due to simple causes, including
open or incomplete circuit.
loose or corroded connections, or a defective relay.
There are two main causes of blown fuses: a shorted or
grounded wire in the applicable circuit, or a defective
electrical component. Visually check the condition of the
fuse, wires, connections and components in the involved
circuit before replacing a fuse. Check the circuit for
shorts, grounding or defective electrical components.
Keep in mind that many parts in the electrical system
work with components of the hydraulic system; a careful
inspection of the related hydraulic components may help 3 4 MT0420
in solving problems.
Fuses are a one time protection device and must be
For access to the fuse and relay panel, remove the four
replaced each time the circuit is overloaded. To
screws (1) securing the right side console access
determine if a fuse is open (4), remove the suspected
panel (2) to the cab. The fuses and sealed 12-volt relays
fuse and examine the element in the fuse for an open
are mounted under the right side console access panel.
(break). If not broken, also check for continuity using a
The fuse and relay panels are part of the cab harness.
DMM or a continuity tester. If the element is open or
continuity is suspect, replace the fuse with one of an
equal current rating.
Fuse Types
Current Rating Amperes Color
Auto Fuses, Mini Fuses
1 Black
2 Gray
3 Violet
5 Tan
1
7.5 Brown
2 10 Red
OH2430 15 Blue
20 Yellow
25 White
30 Green
Maxi Fuses
20 Yellow
30 Light Green
40 Orange or Amber
50 Red
60 Blue
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.15

Electrical System
9.6.2 Fuse and Relay Locations
a. Fuse Block Fuse Locations

SN 8042/10042, 13198 - 16782 Without Lighting SN 10054, 13198 - 16782 Without Lighting Package
Package
10
10 9
11 7.5 7.5
11 7.5 7.5
20 10 8
20 10 9
10
10 8 7
10
10 7 10 6
10
6 10 4
10 4 7.5 7.5
3
7.5 3 40 7.5
13
40 2 2 14
MH4820
1 1 MH4830
SN 8042/10042, 13198 - 16782 With Lighting Package, SN 10054, 13198 - 16782 With Lighting Package,
16783 - 19987 And 0160002332 & After 16783 - 19987 And 0160002332 & After
10 10
11 7.5 7.5
11 7.5 7.5
9
20 10 9 20 10
8
10 8 10
7
10 7 10
15
6 15 6
10 5 10 5
2
7.5 7.5
7.5 3 3
1 40 7.5
40 2 13
1 12 14
12 40
40 MH4870 MH4860
No. Amp Circuit Protected

1 40 Amp Main
2 7.5 Amp Light Switch Relay
3 10 Amp Instrument Cluster
4 10 Amp Horn/Heater (SN 13198 through 16782)
5 15 Amp Horn/Heater (SN 16783 through 19987 and 0160002332 & After)
6 10 Amp Steer Select Switch
7 10 Amp Stabilizer
8 10 Amp Optional Washer/Wiper
9 7.5 Amp Outriggers & ECM Indicator Light
10 7.5 Amp Transmission
11 20 Amp Optional Lights
12 40 Amp Optional Road/Work Lights (SN 16783 through 19987 and 0160002332 & After)
13 7.5 Amp Boom/Outrigger Interlock (10054 Only)
14 7.5 Amp Boom/Outrigger Interlock (10054 Only)
9.16 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
b. Engine Compartment Fuse Locations ECM Fuses

(SN 8042, 18991 - 19987, 10042 19031 - 19987,
The three fuse holders (16) that protect the ECM and
10054, 19080 - 19987 And
diagnostic system are located inside the engine
8042/10042/10054, 0160002332 & After)
compartment and are tie wrapped to the wire harness on
Cold Start Grid Heater Fuses the top of the engine bell housing. One holder contains
one 7.5 amp fuse, one holder contains three 7.5 amp
The two 125 amp fuses (15) that protect the cold start grid
fuses and the other holder contains three 10 amp fuses.
heater are located inside the engine compartment and
are mounted on a bracket mounted on the left side of the
frame rail.
16
MH4930
15
MH4910
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.17

Electrical System
c. Fuse Block Relay Locations
8042/10042 10054
1 1 8 11
2 5 9 12
2 5
3 6 10 13
3 6
4 7 14
4 7 15
MH4840 MH4850
No. Volt Circuit Protected

1 12 Volt Optional Headlight Switch Relay
2 12 Volt Light Switch Relay
3 12 Volt Stabilizer Lock Relay
4 12 Volt Boom Switch Relay
5 12 Volt Park Brake Disengage Relay
6 12 Volt Neutral Start Relay
7 12 Volt Back Up Relay
8 12 Volt Park Brake Interlock Relay (10054 Only)
9 12 Volt Boom Extend Relay (10054 Only)
Outrigger Lockout Relay (SN 13198 through 17984)
10 12 Volt
Blank (SN 17985 & After) (10054 Only)
11 12 Volt Stabil-TRAK Interlock Relay (10054 Only)
12 12 Volt Stabil-TRAK Lock Up Relay (10054 Only)
13 12 Volt Boom Extend Interlock Relay (10054 Only)
14 12 Volt Right Outrigger Lock Relay (10054 Only)
15 12 Volt Left Outrigger Lock Relay (10054 Only)
9.18 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
d. Engine Compartment Relay Locations There is an engine fuel relay (17), mounted on the right
(SN 8042, 18991 - 19987, 10042 19031 - 19987, frame rail next to the engine.This relay is part of the
10054, 19080 - 19987 And Cummins engine harness and also part of the ECM
8042/10042/10054, 0160002332 & After) Diagnostic System. If there is a problem with the relay it
will trigger a diagnostic code through that system. Refer
There are two relays located inside the engine
to Section 9.7.2, “ECM Diagnostic System
compartment, mounted on a bracket mounted to the left
(8042, 18991 - 19987, 10042 19031 - 19987,
frame rail. The relays (16) control the engine grid heater.
10054, 19080 - 19987 And 8042/10042/
10054, 0160002332 & After).”
17
16
MH4920
MH4910
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.19

Electrical System
9.6.3 Fuse and Relay Replacement b. Engine Compartment Fuse Replacement

(SN 8042, 18991 - 19987, 10042 19031 - 19987,
WARNING: DO NOT perform service or
10054, 19080 - 19987 And
8042/10042/10054, 0160002332 & After)
maintenance on the vehicle with the engine
running, with the exception of the transmission
Cold Start Grid Heater Fuses
level check. Contact with moving parts can
cause death or serious personal injury. 1. To access the fuses (5) open the protective
covers (6) from the engine panel side. Allow the
Shut off the engine and disconnect the negative (-) battery covers to rotate on the tethers on the engine side of
cable(s) at the negative (-) battery terminal(s) before the holder (7).
checking the electrical system fuses or relays.
2. Remove the two hex nuts (8) and lockwashers (9)
securing the fuse (5) and wires to the fuse
holder (7). Remove the fuse and replace with a new
fuse.
3. Place the new fuse and then the wires onto the studs
of the holder. Secure the fuse and wires in place with
the lockwashers (9) and hex nuts (8). Torque the hex
nuts to 7-9 lb-ft (10-12 Nm).
4. Snap the protective cover (6) back in place. Be sure
the cover snaps securely in place on the holder.
1
MH4890
2
9 8
1. Unlock and open the rear engine door.
2. If the vehicle has one battery, disconnect the 9
negative (-) battery cable at the negative (-) battery
terminal (1). 5
If the vehicle has dual batteries, disconnect both
negative battery cables from both negative (-) battery 7
terminals (2). 6
a. Fuse Block Fuse or Relay Replacement

Remove a suspect fuse (3) or relay (4) (Refer to Section
9.6.2, “Fuse and Relay Locations,” for locations of fuses
and relays) from the fuse and relay panel by pulling the
fuse or relay straight out and away. ALWAYS install the
correct amp rated fuse or relay.
MH4900
MH4880
9.20 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
ECM Fuses c. Engine Compartment Relay Replacement

(SN 8042, 18991 - 19987, 10042 19031 - 19987,
1. Locate the three fuse holders. Remove the clear
10054, 19080 - 19987 And
plastic protective cover (10) from the holder (11).
8042/10042/10054, 0160002332 & After)
2. Remove the failed fuse from the holder and replace
with a new fuse. To remove the relays (12) from inside the engine
compartment, remove the mounting screws and
3. Reassemble the plastic cover onto the fuse holder washers (13). When re-installing the relays torque the
and securely snap the cover in place. Replace any mounting hardware to 5 - 9 lb-ft (7 - 12,5 Nm).
tie wraps that were removed, securing the fuse
holders to the wire harness.
13
10
12
11 MH4930
MH4910
d. After Fuse or Relay Service

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).
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.21

Electrical System
9.7 ELECTRICAL SYSTEM flow charts. Keep in mind that the various systems on the
TROUBLESHOOTING vehicle include both electrical and hydraulic components.
What at first may appear to be an electrical problem, may
turn out to be a hydraulic problem.
9.7.1 Introduction
Note: All of the main electrical schematics in this
The electrical system produces, stores and distributes section are shown in the OFF position. The individual
electricity in the operation of the vehicle. circuit diagrams are shown in the ON position.
An engine-driven, 12-volt, 65-amp alternator, equipped
with an internal, solid-state voltage regulator, produces 9.7.2 ECM Diagnostic System
electricity. Current from the alternator charges the battery (8042, 18991 - 19987,
and powers electrical system components. 10042 19031 - 19987,
The battery provides power for starting the engine and 10054, 19080 - 19987 And
supplements the output of the alternator during periods of 8042/10042/10054, 0160002332 &
peak demand. After)
For Serial Numbers 8042, 13198-18990, Advanced diagnostics are included to make this
10042, 13198-19030 & 10054 13189-19079; wiring on Cummins engine straightforward to repair and service.
the vehicle is contained within two separate wiring Diagnostic examination of a fault or maintenance
harnesses, an engine harness and a cab harness. condition can occur through onboard or offboard
Several multiple or “bulkhead” connectors at the end of systems.
each harness joins the two together.
Onboard Diagnostics
For Serial Numbers 8042, 18991 - 19987,
10042 19031 - 19987, 10054, 19080 - 19987 and • Extensive fault detection fault capability within the
8042/10042/10054, 0160002332 & After; wiring on the ECM
vehicle is contained within three separate wiring
• Flash-out of fault codes
harnesses, an engine harness ECM cab harness and a
cab harness. Several multiple or “bulkhead” connector at • Engine function indicator light located on the left side
the end of each harness joins the harnesses together. of the dash to indicate warning/stop
Each wire within a harness has color-coded insulation • Maintenance lamp
which is marked with a number to aid in identifying and
tracing each circuit and in making proper connections. Offboard Diagnostics
Fuses and relays are included with the cab harness to
help protect the electrical system and its components. • INSITE™, a Windows®-based reporting program
used as a service tool for this engine. It is used to
The main wiring diagrams in this section indicate help troubleshoot and repair the engine. This tool is
electrical circuits and components respective of their capable of doing diagnostics and programming. This
approximate locations on the vehicle. tool is available from your local Cummins Distributor.
The information in this section has been developed from Call the Cummins Customer Assistance Center at
the perspective that all wires are connected and routed 1-800-343-7357.
as they were when the vehicle left the factory. Take into
account any disconnected or rerouted wires before Onboard Diagnostics
beginning to diagnose a circuit. Refer to the wiring
diagrams to test circuits for continuity or for shorts using a. Fault Detection
a digital multimeter, analog multimeter, test light, Faults are detected while the key switch is in the RUN
ohmmeter or low-reading voltmeter. position, during the operation of the vehicle itself. If a fault
The text discusses each circuit and component, as well becomes active (currently detected) at this time, a fault is
as component function and replacement. Many of the logged in memory and a snapshot of engine parameters
circuits have a separate diagram specific to that circuit’s is logged. In addition, certain faults may illuminate the
function which can be used for troubleshooting purposes. warning lamp (amber) or the stop lamp (red) depending
Those same circuits also have their own troubleshooting upon the severity of the active fault.
9.22 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
b. Flash-Out of Fault Codes Offboard Diagnostics

Fault flash-out mode can be entered through the use of a INSITE™, is the Windows®-based PC service/
diagnostic switch or the accelerator pedal. To enter the programming/diagnostic tool for 944E-42 engine. It is
fault flash-out mode, the key switch must be in the RUN used to help troubleshoot and repair the engine with
position with the engine not running. extended fault diagnostics and processing power.
INSITE™ allows the user to view active and inactive
When a diagnostic switch is used to enter the fault faults and clear the inactive faults. It provides a monitor
flash-out mode, the ECM will automatically flash the first function that allows the service technician to monitor
fault code after the switch is turned to the RUN position. measured parameters, actuator status and some
The diagnostic increment/decrement is used to sequence calculated values. It also provides the technician with the
forward or backwards through the active faults. capability to turn on certain drivers such as the grid
To enter fault flash-out mode using the accelerator pedal, heaters and lift pump as well as running diagnostic tests
fully depress and release the pedal 3 times. Once in such as single cylinder cutout.
diagnostic mode, cycling the accelerator pedal will
sequence forward through the active faults. The following 9.7.3 Troubleshooting with a Digital
graphic depicts the pattern of the fault code flash-out Multimeter (DMM)
scheme as indicated by the stop lamp. IMPORTANT: Circuits which include any solid-state
Stop Lamp (1) - The stop lamp provides critical operator control modules should only be tested with a ten
messages. These messages require immediate and megohm or higher impedance digital multimeter or
decisive operator response. The stop lamp is also used damage could occur to the module.
to diagnose flash-out fault codes. A DMM should be used instead of a test lamp in order to
Warning Lamp (2) - The warning lamp provides test for voltage in high impedance circuits. While a test
important operator messages. These messages require lamp shows whether voltage is present, a DMM indicates
timely operator attention. The warning lamp is also used how much voltage is present.
to delineate diagnostic fault codes. The ohmmeter function on a DMM shows how much
There is a laminated Wiring Diagram and Fault Code resistance exists between two points along a circuit. Low
Information Chart available from your local Cummins resistance in a circuit means good continuity.
Distributor. Call the Cummins Customer Assistance IMPORTANT: Disconnect the power feed from the
Center at 1-800-343-7357. suspect circuit when measuring resistance with a DMM;
this prevents incorrect readings. DMM’s apply such a
Example Fault Code Sequences small voltage to measure resistance that the presence of
Fault Code 244: P = Pause voltages can upset a resistance reading.
Diodes and solid-state components in a circuit can cause
a DMM to display a false reading. To find out if a
component is affecting a measurement, take a reading
once, then reverse the leads and take a second reading.
1 Blink 2 Blinks 4 Blinks 4 Blinks 1 Blink If the readings differ, the solid-state component is
Fault Code 112: affecting the measurement.
The following are examples of the various methods of
1 connecting the DMM to the circuit to be tested:
• Backprobe both ends of the connector, and either
2
hold the leads in place while manipulating the
1 Blink 1 Blink 1 Blink 2 Blinks 1 Blink
MU5440
connector or tape the leads to the harness for
continuous monitoring while you perform other
operations or test-driving.
• Disconnect the harness at both ends of the
suspected circuit where it connects either to a
component or to other harnesses.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.23

Electrical System
9.7.4 Probing Electrical Connectors (POWER ON AT ALL TIMES)
1 FUSE
a. Front Probe BLOCK
Disconnect the connector and probe the terminals from

the mating side (front) of the connector. RED
Note: DO NOT insert test equipment probes into any (+) SWITCH
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 (-) DMM
in system failures. Always use a connector test adapter BLK
kit or a flat wire probe adapter kit (usually supplied with a
DMM) when front probing terminals. DO NOT use paper SOLENOID
clips or other substitutes as they can damage terminals
and cause incorrect measurements. 2
b. Back Probe
MT0410
DO NOT disconnect the connector and probe the

terminals from the harness side (back) of the connector. Figure 9-1 Measuring Voltage Drop
• Back probe connector terminals only when 1. Set the rotary dial of the DMM to the V (DC) position.
specifically required in diagnostic procedures. 2. Connect the (+) positive lead (1) of the DMM to one
• DO NOT back probe a sealed connector or a flat point of the circuit to be tested.
wire connector. 3. Connect the (-) negative lead (2) of the DMM to the
other point of the circuit.
• Back probing can be a source of damage to
connector terminals. Use care in order to avoid 4. Operate the circuit.
deforming the terminal, either by forcing the test 5. The DMM displays the difference in voltage between
probe too far into the cavity or by using too large of a the two points.
test probe.
• After back probing any connector, inspect for Testing for Continuity
terminal damage. If terminal damage is suspected, The following procedures verify good continuity in a circuit.
test for proper terminal contact.
With a DMM
c. Measuring and Testing Voltage 1. Set the rotary dial of the DMM to the Ohm position.
2. Disconnect the power feed (i.e. fuse, control module)
Testing for Voltage Drop
from the suspect circuit.
This test checks for voltage being lost along a wire, or 3. Disconnect the load.
through a connection or switch.
4. Press the MIN MAX button on the DMM.
1. Connect the positive lead of a DMM to the end of the
wire (or to one side of the connection or switch) 5. Connect one lead of the DMM to one end of the
which ever is closer to the battery. circuit to be tested.
2. Connect the negative lead to the other end of the 6. Connect the other lead of the DMM to the other end
wire (or the other side of the connection or switch). of the circuit.
3. Operate the circuit. 7. If the DMM displays low or no resistance and a tone
is heard, the circuit has good continuity.
4. Voltage through the wire should be displayed.
Measuring Voltage Drop

The following test determines the difference in voltage
potential between two points.
9.24 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
With a Test Lamp Testing a Fuse Powering Several Loads

IMPORTANT: Only use the test lamp procedure on low 1. Review the system schematic and locate the fuse
impedance power and ground circuits. that is open.
1. Remove the power feed (i.e. fuse, control module) 2. Open the first connector or switch leading from the
from the suspect circuit. fuse to each load.
2. Disconnect the load. 3. Connect a DMM across the fuse terminals (be sure
3. Connect one lead of the test lamp to one end of the that the fuse is powered).
circuit to be tested. • When the DMM displays voltage, the short is in
4. Connect the other lead of the test lamp to battery the wiring leading to the first connector or switch.
positive voltage. • If the DMM does not display voltage, refer to the
5. Connect the other end of the circuit to ground. next step.
6. If the test lamp illuminates (full intensity), then the 4. Close each connector or switch until the DMM or
circuit has good continuity. analog tester displays voltage, in order to find which
circuit is shorted.
Testing for Short to Ground
Testing for Electrical Intermittence
The following procedures test for a short to ground in a
circuit. Perform the following procedure while wiggling the
harness from side to side. If possible, continue this at
With a DMM
6-inch intervals while watching the test equipment.
1. Remove the power feed (i.e. fuse, control module)
• Testing for Short to Ground
• Testing for Continuity
2. Disconnect the load.
3. Set the rotary dial of the DMM to the Ohm position. Testing Relays from the Fuse Block
4. Connect one lead of the DMM to one end of the Relays are used to control a large amount of current by
circuit to be tested. using a small amount of control current flowing through
5. Connect the other lead of the DMM to a good the relay coil.
ground.
6. If the DMM does NOT display infinite resistance WARNING: DO NOT perform service or
(OL), there is a short to ground in the circuit. maintenance on the vehicle with the engine
running, with the exception of the transmission
With a Test Lamp
level check. Contact with moving parts can
1. Remove the power feed (i.e. fuse, control module) cause death or serious personal injury.
2. Disconnect the load. 1. Be sure that the vehicle is on a level surface, the
implement grounded, park brake engaged, ignition
3. Connect one lead of the test lamp to one end of the switch is in the OFF position.
circuit to be tested.
4. Connect the other lead of the test lamp to battery
positive voltage.
5. Connect the other end of the circuit to ground.
6. If the lamp illuminates (full intensity), then the circuit
has good continuity.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.25

Electrical System
3. If the vehicle has one battery, disconnect the 5. Remove the suspect relay (5) from the fuse block.
terminal (1).
negative battery cables from both negative (-) battery 5
terminals (2).
MH4880
6. Apply the proper voltage to the relay coil at

1 terminal 86 (6 and 8) and attach the ground (-) probe
MH4890
2 to terminal 85 (7 and 9), ground. An audible click
should be heard indicating that the relay is
4. The fuse block relays (5) are located in the fuse functioning properly.
block and is mounted behind the right side console
access panel (3). To gain access, remove the
screws (4) that secure the right side panel in place. 6
87
86
87A 7
85
30
MN1820
4
3 87A
30
OH2430
87
85 86
9 8
MT3140
9.26 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
7. When reassembling the right side console access

panel (3), torque the screws (4) to 3 - 5 lb-ft
12
(13 - 22 Nm). 10
8. If the vehicle has one battery, connect the 10
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).
Testing Relays located in the Engine Compartment

1. Be sure the vehicle is on a level surface, the
implement grounded, parking brake engaged,
ignition switch is in the OFF position
2. Unlock and open the rear engine door. 11
3. If the vehicle has one battery, disconnect the

terminal (1).
negative battery cables from both negative (-) battery
terminals (2).
4. To remove the relays from inside the engine
compartment, label and remove all the wires
connected to the suspect relay. MH4910
To access the terminal nuts and washers on the grid

heater relays, lift the protective cover (10) and slide it
along the wire, away from the mounting hardware.
Save the terminal nuts and washers (11) for later
reassembly.
5. Remove the mounting hardware (12) from the
mounting bracket on the relay. Remove the relay
from the engine compartment.
6. Inspect the general condition of the relay casing and
terminals. Replace the relay if it is cracked or
damaged in any way.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.27

Electrical System
7. To test the operation of the relays, connect a 12-volt Testing Diodes

DC positive lead to the positive terminal (1). Connect
To test diodes in the electrical system, set the DMM dial
the negative lead to the mounting bracket or
on R x1 setting and connect one lead to each side (9) of
negative post (2), listening for a “click” sound as the
the diode. Note the reading on the DMM. Reverse the
contacts close. Replace the relay if the contacts do
leads and note reading. The DMM should indicate a high
not close.
or infinite resistance (no meter movement) when
connected one way and a low reading when connected to
4
the other. If both readings are high or infinite, the diode is
open. If both readings are low, the diode is shorted.
Repeat test on remaining diodes. If any diodes are
shorted or open, replace the diode board (10). Note the
3 orientation of the board when removing it for
replacement. Replace diode board in the same
orientation as it was when it was removed.
2 1
10
5
MH4940
8
8. When reassembling the relays to the mounting

bracket, torque the relay mounting hardware (3) to
5 - 9 lb-ft (7 - 12,5 Nm).
9. When reassembling the wires to the relay, torque the MU6020
terminal nuts (4) to a maximum of 95 lb-in (11 Nm).

Torque the other terminal nuts (5), to a maximum of
40 lb-in (4,5 Nm).
10. If the vehicle has one battery, connect the
terminal (6).
terminals (7).
6
MH4890
7
9.28 Model 8042, 10042, 10054 Legacy Rev. 10/03

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.
Fuse
Solenoid
(Coil)
Relay coil Relay contacts
Suppression diode
Relay resistor
TRG6
Wire name 2
Splice
+ -
30
Proximity switch
Battery +
Fuel level sender
-
1 In-line bulkhead
Lamp or switch
connector pin
Diode
Temperature activated
switch
Momentary type
switches
Pressure activated
switch
Alarm/Buzzer
Motor
Horn
M
MH6130
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.29

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
9.38 or
2BB 18 BLK Splice 20 (Ground) to Back-up Alarm Relay (Pin 85)
9.40
9.39 or
2C 16 BLK Splice 20 (Ground) to Steer Select Valve Solenoid (Crab) (–)
9.41
9.38 or
2CC 18 BLK Splice 20 (Ground) to Stabilizer Lock Relay (Pin 85)
9.40
9.39 or
2D 16 BLK Splice 20 (Ground) to Diode VESPAK (Pin F)
9.41
9.38 or
18 BLK Splice 20 (Ground) to Light Switch Relay (Pin 85) (Cab Harness)
9.40
2DD
9.39 or
16 BLK Splice 20 (Ground) to Diode VESPAK (Pin F) (Engine Harness)
9.41
9.39 or
2E 16 BLK Splice 20 (Ground) to Secondary Function Manifold Park Brake Solenoid (PB A) (Pin B)
9.41
9.38 or
2EE 18 BLK Splice 20 (Ground) to Park Brake Disconnect Relay (Pin 85)
9.40
9.39 or
2F 16 BLK Splice 20 (Ground) to Secondary Function Manifold Park Brake Solenoid (PB B) (Pin B)
9.41
9.38 or
2FF 18 BLK Splice 20 (Ground) to Neutral Start Relay (Pin 85)
9.40
9.39 or
2G 16 BLK Splice 20 (Ground) to Transmission Ground
9.41
9.38 or
2GG 16 BLK Splice 20 (Ground) to Instrument Panel Connector (Pin J5)
9.40
9.39 or
2H 18 BLK Splice 20 (Ground) to Lower Transmission Connector (Pin 7, Solenoid Y4, Y5 & Y6)
9.41
9.38 or
2HH 18 BLK Splice 20 (Ground) to Park Brake Switch Connector (Pin 7)
9.40
9.39 or
2J 18 BLK Splice 20 (Ground) to Upper Transmission Connector (Pin 7, Solenoid Y1, Y2 & Y3)
9.41
9.38 or
2JJ 18 BLK Splice 20 (Ground) to Steer Select Switch (Pin 7)
9.40
9.39 or
2K 16 BLK Splice 20 (Ground) to Stabil-TRAK™ Cylinder Solenoid (SOL 3) (–)
9.41
9.38 or
2KK 18 BLK Splice 20 (Ground) to Headlight Switch Relay (Pin 85)
9.40
9.39 or
2L 16 BLK Splice 20 (Ground) to Stabil-TRAK™ Cylinder Solenoid (SOL 12A) (–)
9.41
9.39 or
2M 16 BLK Splice 20 (Ground) to Stabil-TRAK™ Cylinder Solenoid (SOL 4A) (–)
9.41
9.39 or
2N 16 BLK Splice 20 (Ground) to Stabil-TRAK™ Cylinder Solenoid (SOL 4B) (–)
9.41
9.39 or
2P 16 BLK Splice 20 (Ground) to Stabil-TRAK™ Cylinder Solenoid (SOL 12B) (–)
9.41
9.39 or
2R 18 BLK Not Used
9.41
9.39 or
2S 16 BLK Splice 20 (Ground) to Fuel Shut-off Solenoid Connector (Pin C)
9.41
† SN 13198 through 16782 w/o Lighting Package
§ SN 13198 through 16782 w/Lighting Package and SN 16783 through 18990
9.30 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

9.39 or
2T 16 BLK Splice 20 (Ground) to Boom Sensor Connector (Pin C)
9.41
9.39 or
2W 16 BLK Splice 20 (Ground) to Alternator (GND)
9.41
9.39 or
2X 16 BLK Splice 20 (Ground) to Back-up Alarm (–)
9.41
3 9.38 10 PUR † Ignition Switch 5-Way Connector (Pin B) to Fuse Buss Bar
9.38 † Fuse Buss Bar to Transmission Fuse to Option Connector
3A 10 PUR
9.40 § Fuse Buss Bar to Transmission Fuse
3B 9.40 10 PUR § Open Fuse to Option Connector
3C 9.40 10 PUR § Ignition Switch 5-Way Connector (Pin B) to Fuse Buss Bar
9.39 or
5 10 RED Starter (Pin 30) to Alternator (B+)
9.41
9.38 or Instrument Panel Connector (Pin J8)
18 YEL
9.40 to Cab/Chassis Female Connector (Pin C1) (Cab Harness)
6
9.39 or
18 YEL Cab/Chassis Male Connector (Pin C1) to Alternator (D+) (Engine Harness)
9.41
9.38 or
7 16 BRN Stabilizer Fuse to Jumper Wire 157
9.40
9.38 or Steer Select Switch (Pin 1)
16 GRN/WHT
8
9.39 or Cab/Chassis Male Connector (Pin C2)
16 LT GRN/WHT
9.41 to Steer Select Valve Solenoid (Crab) (+) (Engine Harness)
16 GRN/BLK
9
16 LT GRN/BLK
9.41 to Steer Select Valve Solenoid (4-Wheel) (+) (Engine Harness)
9.38 or Boom Switch Relay (Pin 86)
16 TAN
10
9.39 or
16 TAN Cab/Chassis Male Connector (Pin C4) to Boom Sensor Connector (Pin B) (Engine Harness)
9.41
Steer Select Switch Relay Fuse to Steer Select Switch Connector (Pin 2)
11 9.38 16 LT GRN/BLU †
Steer Select Switch Connector Jumper (Pin 2) to (Pin 8)
11A 9.40 16 LT GRN/BLU § Steer Select Switch Relay Fuse to Steer Select Switch Connector (Pin 2)
11B 9.40 16 LT GRN/BLU § Steer Select Switch Connector Jumper (Pin 2) to (Pin 8)
9.38 or
12 18 DK BLU Light Switch Relay Fuse to Light Switch Relay (Pin 86)
9.40
9.38 † Light Switch Relay (Pin 87) to Splice 12A to Road/Worklights Connector (Option)
12A 12 DK BLU
9.40 § Light Switch Relay (Pin 87) to Splice 12A
12AA 9.40 12 DK BLU § Splice 12A to Road/Worklights Connector (Option)
9.38 † Splice 12A to Headlight Switch Relay (Pin 30)
12B 12 DK BLU
9.40 § Splice 12A to Option Connector
9.38 † Splice 27 to Roadlights Connector (Option) (Hazards)
12C 16 DK BLU
9.40 § Optional Lights Fuse (Lights 1) to Roadlights Connector (Option) (Hazards)
18 LT BLU
9.40 to Cab/Chassis Male Connector (Pin A1) (Cab Harness)
15
9.39 or
18 LT BLU Cab/Chassis Female Connector (Pin A1) to Water Temperature Switch (Engine Harness)
9.41
18 BRN
16
9.39 or
18 BRN Cab/Chassis Male Connector (Pin C5) to Oil Pressure Switch (Engine Harness)
9.41
18 GRY
17
9.39 or
16 GRY Cab/Chassis Female Connector (Pin A2) to Fuel Level Sender (Engine Harness)
9.41
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.31

Electrical System

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
9.39 or
12 BLK Cab/Chassis Female Connector (Pin A3) to Splice 20 (Ground) (Engine Harness)
9.41
9.38 or
21C 16 RED Headlight Switch Relay (Pin 86) to Roadlights Connector (Option) (Main Beam)
9.40
9.38 or
22 16 WHT Instrument Panel Fuse to Inline Diode to Instrument Panel Connector (Pin J1)
9.40
9.38 or Headlight Switch Relay (Pin 87)
16 GRN
9.40 to Roadlights Connector (Option) (Main Beam) (Cab Harness)
23
9.39 or
16 ORG/GRN Not Used (Engine Harness)
9.41
9.38 or
24 14 ORG/GRN Horn/Heater Fuse to Back-Up Alarm Relay (Pin 30)
9.40
9.38 or Back-Up Alarm Relay (Pin 30)
14 ORG/GRN
24A
9.39 or
16 ORG/BLK Cab/Chassis Male Connector (Pin B2) to Horn Connector (+) (Engine Harness)
9.41
9.38 † Main Fuse to Ignition Switch 3-Way Connector (Pin A)
26 10 RED
9.40 § Ignition Switch 3-Way Connector (Pin A) to Splice 26
26A 10 RED
26B 9.40 10 RED § Splice 26 to Main Fuse
9.38 or
10 RED Main Fuse to Splice 100 (Cab Harness)
9.40
27
9.39 or
10 RED Splice 27 to Starter (Pin 30) (Engine Harness)
9.41
9.38 † Optional Lights Fuse to Splice 27 to Light Switch Relay (Pin 30)
27A 12 RED
9.40 § Optional Lights Fuse (Lights 1) to Headlight Switch Relay (Pin 30)
9.38 † Optional Lights Fuse to Main Fuse
27B 12 RED
9.40 § Optional Lights Fuse (Lights 1) to Splice 100
9.38 or
12 RED Splice 100 to Cab/Chassis Male Connector (Pin A4) (Cab Harness)
9.40
27C
9.39 or
12 RED Cab/Chassis Female Connector (Pin A4) to Splice 27 (Engine Harness)
9.41
9.38 or
12 RED Splice 100 to Cab/Chassis Male Connector (Pin B5) (Cab Harness)
9.40
27D
9.39 or
12 RED Cab/Chassis Female Connector (Pin B5) to Splice 27 (Engine Harness)
9.41
27F 9.40 12 RED § Splice 100 to Optional Road/Worklights Fuse (Lights 2)
16 PUR/WHT
28
9.39 or
16 PUR/WHT Cab/Chassis Male Connector (Pin B3) to Splice 28 (Engine Harness)
9.41
9.39 or
28A 16 PUR/WHT Splice 28 to Stabil-TRAK™ Cylinder (SOL 12A) (+)
9.41
9.39 or
28B 16 PUR/WHT Splice 28 to Stabil-TRAK™ Cylinder (SOL 12B) (+)
9.41
29 9.40 12 RED § Optional Road/Worklights Fuse (Lights 2) to Light Switch Relay (Pin 30)
9.32 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

9.38 or Back-up Alarm Relay (Pin 87)
16 ORG/RED
31
9.39 or
16 ORG/RED Cab/Chassis Female Connector (Pin A5) to Back-up Alarm (+) (Engine Harness)
9.41
9.38 or
32 14 GRY/WHT Option Fuse to Wiper/Washer Connector (Option)
9.40
9.38 or Ignition Switch 5-Way Connector (Pin C)
16 RED/BLK
9.40 to Cab/Chassis Male Connector (Pin B1) (Cab Harness)
34
9.39 or Cab/Chassis Female Connector (Pin B1)
16 RED/BLK
9.41 to Fuel Shut-off Solenoid Connector (Pin A) (Engine Harness)
9.38 or
16 BRN/WHT Jumper Wire 157 to Cab/Chassis Female Connector (Pin B4) (Cab Harness)
9.40
35
9.39 or
16 BRN/WHT Cab/Chassis Male Connector (Pin B4) to Boom Sensor Connector (Pin A) (Engine Harness)
9.41
16 ORG
38
9.39 or
16 ORG Cab/Chassis Male Connector (Pin B5) to Alternator (D+) (Engine Harness)
9.41
9.38 or
39 16 RED/GRY Stabilizer Fuse to Boom Switch Relay (Pin 30)
9.40
9.38 or
16 BRN/BLK Splice 40 to Cab/Chassis Female Connector (Pin A1) (Cab Harness)
9.40
40
9.39 or
16 BRN/BLK Cab/Chassis Male Connector (Pin A1) to Stabil-TRAK™ Cylinder (SOL 3) (+) (Engine Harness)
9.41
9.38 or
40A 16 BRN/BLK Splice 40 to Stabilizer Lock Relay (Pin 87)
9.40
9.38 or
40B 16 BRN/BLK Splice 40 to Instrument Panel Connector (Pin J11)
9.40
Park Brake Switch Connector (Pin 1)
9.38 DK BLU/WHT † to Splice 41 to Male Connector (Cab Harness)
41 16 Female Connector to Cab/Chassis Female Connector (Pin A2) (Cab Harness)
9.39 or
BLU/WHT Cab/Chassis Male Connector (Pin A2) to Splice 41 (Engine Harness)
9.41
9.40 DK BLU/WHT § Female Connector to Cab/Chassis Female Connector (Pin A2) (Cab Harness)
41A 9.39 or 16
BLU/WHT Splice 41 to Secondary Function Manifold Park Brake Solenoid (PB A) (Pin A) (Engine Harness)
9.41
9.40 DK BLU/WHT § Park Brake Switch Connector (Pin 1) to Splice 41 (Cab Harness)
41B 9.39 or 16
BLU/WHT Splice 41 to Secondary Function Manifold Park Brake Solenoid (PB B) (Pin A) (Engine Harness)
9.41
41C 9.40 16 DK BLU/WHT § Splice 41 to Male Connector
Instrument Panel Fuse to Park Brake Switch Connector (Pin 2)
42 9.38 18 TAN †
Park Brake Switch Connector Jumper (Pin 2) to (Pin 8)
42A 9.40 18 TAN § Instrument Panel Fuse to Park Brake Switch Connector (Pin 2)
42B 9.40 18 TAN § Park Brake Switch Connector Jumper (Pin 2) to (Pin 8)
9.38 or
45 16 DK BLU/ORG Splice 45 to Splice 114
9.40
45A 9.38 16 DK BLU/ORG † Splice 45 to Inline Diode to Splice 152
45A2 9.40 16 DK BLU/ORG § Splice 45 to Inline Diode to Splice 152B
9.38 or
45B 16 DK BLU/ORG Splice 45 to Brake Pedal Switch (Pin 1)
9.40
9.38 or
46 16 WHT/ORG Steer Select Switch Relay Fuse to Brake Pedal Switch (Pin 2)
9.40
9.38 or Stabilizer Lock Relay (Pin 87A)
16 ORG/WHT
9.40 to Cab/Chassis Female Connector (Pin A3) (Cab Harness)
47
9.39 or
16 ORG/WHT Cab/Chassis Male Connector (Pin A3) to Splice 47 (Engine Harness)
9.41
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.33

Electrical System

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
49 16 RED/BLU Not Used
9.41
9.38 or
50 16 WHT/YEL Option Fuse to Option Connector
9.40
9.38 or
51 16 WHT/RED Option Fuse to Option Connector
9.40
9.38 or
52 12 ORG Horn/Heater Fuse to Heater Connector (Option)
9.40
9.38 or
16 BRN Shifter Connector (Pin 5) to Cab/Chassis Male Connector (Pin C1) (Cab Harness)
9.40
101
9.39 or
16 BRN Cab/Chassis Female Connector (Pin C1) to Splice 101 (Engine Harness)
9.41
9.39 or
101A 16 BRN Splice 101 to Diode VESPAK (Pin B)
9.41
9.39 or
101B 18 BRN Splice 101 to Lower Transmission Connector (Pin 5, Solenoid Y5)
9.41
9.38 or
16 PNK Splice 102 to Cab/Chassis Male Connector (Pin C2) (Cab Harness)
9.40
102
9.39 or
16 PNK Cab/Chassis Female Connector (Pin C2) to Splice 102 (Engine Harness)
9.41
9.38 or
16 PNK Splice 102 to Shifter Connector (Pin 3) (Cab Harness)
9.40
102A
9.39 or
16 PNK Splice 102 to Diode VESPAK (Pin E) (Engine Harness)
9.41
9.38 or
16 PNK Splice 102 to Back-Up Alarm Relay (Pin 86) (Cab Harness)
9.40
102B
9.39 or
18 PNK Splice 102 to Upper Transmission Connector (Pin 2, Solenoid Y2) (Engine Harness)
9.41
9.38 or
16 BLU Shifter Connector (Pin 7) to Cab/Chassis Male Connector (Pin C3) (Cab Harness)
9.40
103
9.39 or
16 BLU Cab/Chassis Female Connector (Pin C3) to Splice 103 (Engine Harness)
9.41
9.39 or
103A 16 BLU Splice 103 to Diode VESPAK (Pin A)
9.41
9.39 or
103B 18 BLU Splice 103 to Upper Transmission Connector (Pin 3, Solenoid Y3)
9.41
9.38 or
16 YEL Shifter Connector (Pin 2) to Cab/Chassis Male Connector (Pin C4) (Cab Harness)
9.40
104
9.39 or
16 YEL Cab/Chassis Female Connector (Pin C4) to Splice 104 (Engine Harness)
9.41
9.39 or
104A 16 YEL Splice 104 to Diode VESPAK (Pin E)
9.41
9.39 or
104B 18 YEL Splice 104 to Upper Transmission Connector (Pin 1, Solenoid Y1)
9.41
9.38 or
16 GRN Shifter Connector (Pin 6) to Cab/Chassis Male Connector (Pin C5) (Cab Harness)
9.40
105
9.39 or
16 GRN Cab/Chassis Female Connector (Pin C5) to Splice 105 (Engine Harness)
9.41
9.39 or
105A 16 GRN Splice 105 to Diode VESPAK (Pin B)
9.41
9.34 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

9.39 or
105B 18 GRN Splice 105 to Lower Transmission Connector (Pin 4, Solenoid Y4)
9.41
9.38 or
12 BLU/ORG Neutral Start Relay (Pin 87) to Cab/Chassis Male Connector (Pin B2) (Cab Harness)
9.40
106
9.39 or
12 BLU/ORG Cab/Chassis Female Connector (Pin B2) to Starter (Pin 50) (Engine Harness)
9.41
Splice 41 to Female Connector
107 9.38 18 BLU †
Male Connector to Park Brake Disconnect Relay (Pin 86)
107A 9.40 18 BLU § Splice 41 to Female Connector
107B 9.40 18 BLU § Male Connector to Park Brake Disconnect Relay (Pin 86)
9.38 or
111 12 RED Park Brake Switch (Pin 6) to Splice 111
9.40
9.38 or
111A 12 RED Splice 111 to Neutral Start Relay (Pin 30)
9.40
9.38 or
112 16 GRY Shifter Connector (Pin 4) to Splice 112
9.40
9.38 or
112A 16 GRY Splice 112 to Neutral Start Relay (Pin 86)
9.40
9.38 or
113 16 RED Shifter Connector (Pin 1) to Splice 113
9.40
9.38 or
113A 16 RED Splice 113 to Inline Diode to Splice 111
9.40
9.38 or
113B 16 RED Splice 113 to Park Brake Disconnect Relay (Pin 87)
9.40
9.38 or
114A 16 BLU/ORG Splice 112 to Inline Diode to Splice 114
9.40
9.38 or
114B 16 BLU/ORG Splice 114 to Stabilizer Lock Relay (Pin 86)
9.40
9.38 or
16 VIO Shifter Connector (Pin 8) to Cab/Chassis Male Connector (Pin B3) (Cab Harness)
9.40
150
9.39 or
16 VIO Cab/Chassis Female Connector (Pin B3) to Splice 150 (Engine Harness)
9.41
9.39 or
150A 16 VIO Splice 150 to Diode VESPAK (Pin A)
9.41
9.39 or
150B 18 VIO Splice 150 to Lower Transmission Connector (Pin 6, Solenoid Y6)
9.41
16 YEL/GRN
151
9.39 or
16 YEL/GRN Cab/Chassis Female Connector (Pin B4) to Hydraulic Temperature Switch (Engine Harness)
9.41
Park Brake Switch Connector (Pin 3) to Splice 152 to Male (Cab Harness)
9.38 16 BLK/WHT † Female Connector to Inline Diode
152 to Instrument Panel Connector (Pin J7) (Cab Harness)
9.39 or
10 RED Starter (Pin M) to Fuel Shut-off Solenoid Connector (Pin B) (Engine Harness)
9.41
152A 9.38 16 BLK/WHT † Not Used
152A1 9.40 16 BLK/WHT § Female Connector to Inline Diode to Splice 152A
152A2 9.40 16 BLK/WHT § Not Used
152A3 9.40 16 BLK/WHT § Splice 152A to Instrument Panel Connector (Pin J7)
152B1 9.40 16 BLK/WHT § Male Connector to Splice 152B
152B2 9.40 16 BLK/WHT § Splice 152B to Park Brake Switch Connector (Pin 3)
9.38 or
153 16 GRY/WHT Park Brake Disconnect Relay (Pin 30) to Shifter Connector (Pin 9)
9.40
9.38 or
153A 16 GRY/WHT Transmission Fuse to Park Brake Disconnect Relay (Pin 30)
9.40
9.38 or
154 16 BLU/WHT Instrument Panel Connector (Pin J14) to Roadlights Connector (Option) (Main Beam)
9.40
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.35

Electrical System

9.38 or
155 16 GRN/RED Instrument Panel Connector (Pin J15) to Roadlights Connector (Option) (Turn Signals)
9.40
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
9.39 or
16 WHT Cab/Chassis Male Connector (Pin A5) to Horn Connector (–) (Engine Harness)
9.41
9.36 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.37

Electrical System
9.7.7 8042 Electrical Schematic (SN 13198 Through 16782, Without Lighting Package)
INSTRUMENT PANEL
TURN SIGNALS
HYD. OIL TEMP.
TRANS. TEMP.
WATER TEMP.
HOURMETER
FUEL GAUGE
STABIL-TRAK
ALTERNAT0R
PARK BRAKE
BACK LIGHT
(OPTIONAL)
(OPTIONAL)
(OPTIONAL)
ENGINE OIL
HIGH BEAM
ROADLIGHTS
GROUND
OPTION
POWER
CONNECTORS CAB
HAZARDS HIGH BEAM HARNESS
J1 J5 J14 J15 J7 J2 J10 J3 J12 J11 J8 J9 J6 J4 FEMALE
CONNECTOR
23 47
12C 22 154 155 152 156 38 40B 16 17 A3
21C 152A
ROAD/ 28
2GG 151 18 6 15 B3
WORKLIGHT
OPTION
40
A1
NOT
12A USED
12B 3
12A 40
21C 12B 12A 26A 34 STEER 40B
SELECT 40
30 A B C D E
86 SWITCH 40A
HEADLIGHT A B C D E 2GG
SWITCH 7 8
18
RELAY 20 B1
85
2JJ 1 11
87A 87 1
S 11 D 8
2KK 23 19 P 2
R
58
11 16
C5
IGNITION
O
S E 3
27A 9
27 SWITCH P
R 24A
15 B2
27A O
30
3A 12 27A
S
158
P
HORN A5
R
7.5 BUTTON
OPEN
50 OPTION 30 50
86 LIGHT
O 35
B4
51 OPTION SWITCH
RELAY A B C 10
85 C4
87A 87
10.0
32 WIPER/
OPTION WASHER 2DD 12A 2KK 1
WIPER/
WASHER 2DD 26 38
20 B5
7 157 35
7 6
10.0 C1
STABILIZER 39
8
11 C2
41
10.0 A2
STEER SELECT
46 9
SWITCH C3
15.0
HORN/HEATER 24 114B 48 10 39
52 52 HEATER 30 30
10.0 86 STABIL. 86 BOOM
42
INSTR. PANEL LOCK SWITCH
22 RELAY RELAY 15
LIGHT 7.5 85 85 A1
SWITCH RELAY
12 87A 87 87A 87
17
3 A2
2CC 40A 2AA 48 28
27B 27C
40.0 47
MAIN
27 27 27D
100
3A 26
20 20
A3
26A
3A 153A 2CC 2AA 20
7.5 CAB
TRANSMISSION 27B 2HH GROUND STUD
20 20 20 20 20
27A 151
20.0 B4
LIGHTS 27C
A4
27D
B5
42 1 2HH
8 7
3A 111 24A
6 153A 111 102B
PARK 24
E 2 107 153 113A
BRAKE 111
OPTION 1 SWITCH 30 112A 111A 86
30
86 PARK BACK-UP
5
D BRAKE ALARM
45A 30
RELAY
4 DIS. 86 NEUTRAL
42 152 152 RELAY 85
E 3
85 START 87A 87
152 87A 87 RELAY
113A 85 2BB 31
42
2 87A 87 31
D 41 113B A5
41 41 2EE 113
1 106 106
113 2FF B2
107 107
2EE 2BB
20 20
9 9
34
BRAKE B1
B+ 153
PEDAL
SWITCH 8
GEAR 8
150 104
C4
45A
7 7 103
45B 46 GEAR 103 C3
45 1 2
6 6 102
45 GEAR 105 C2
5 5
GEAR 101
F 112A
1 4 4 105
2 NEUTRAL 112 112 114A C5
112 102B
3 N
3 3
4 REVERSE 102A 102A 102 101
R 102 C1
SHIFTER 2 2
ZF TRANSMISSION FORWARD 104 150
B3
1 1
B+ 113
CAB
114B HARNESS
MALE
45 114A CONNECTOR
114
MH42401
9.38 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
8042 (13198 - 16782, w/oLighting Package)
BATTERY
+ -

47 47B
47
47A
ENGINE 28 28B
28
HARNESS 28A BOOM
MALE 2K 2P 2N SENSOR BATTERY
CONNECTOR GRND
40 28B 47B + -
47 + - + - + - 27C
A3
+ - + - + - 27D 27 106
27 30 50
28 5
B3 M
BRN
3 12B 4B
BLU
152
40
A1
STABIL-TRAK BLK
GND
CYLINDER SOLENOIDS
4A 12A STARTER
A B C
A B C
+ - + -
+ - + - 35 2T
18 10
B1 47A 28A
2M 2L
16
C5 34
RED
A A
152
24A 24A + WHT
B2
+ -
+ -
BLK B B
2S
158 158 - C C
A5
HORN FUEL
35 SHUTOFF
B4 SOLENOID
10
C4
5
38 38
B5
B+
D+
6 6 GND
C1
41 41A (-) 2W
41
8 8 2C 41B 2E ALTERNATOR
C2
+ - AB
41
A2 AB
+ -
9
C3 4-WHEEL PB B
+ - + - TRANS. TEMP
+ - + -
CRAB PB A SWITCH
18
+ - STEER AB SECONDARY
SELECT A B
FUNCTION
+ -
VALVE MANIFOLD WATER TEMP
9 2B SOLENOIDS 41B 2F SOLENOIDS SWITCH
15 15
A1
17
A2
FUEL 2L 2P 16
LEVEL 2M 2N 2K
SENDER OIL PRESSURE 2T
2B SWITCH
2A 2C 20 2E 2W
20 2S
A3 20 20 20 20
2R
2DD 2G 2H 2X
2D 2J
151 151
B4
27C
A4 NOT
27D HYDR. OIL USED
B5
TEMP SWITCH
B A
49
23 2X
2R
-
C B A BACK-UP
ALARM
+
NOT USED
31
31
A5
106
B2
34
B1 2J 7 7
104 104B Y1 Y3 Y2
C4 104 1 1
E E E
103 103B Y1 Y3 Y2
C3 103 3 3
102 102B 2 2
C2 102
UPPER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
105 105B 4
C5 105 4
101 101B
C1 101 5 5 Y6 Y5 Y4
150 150B E E E
B3 150 6 6
102A 103A 105A 2H
ENGINE 7 7 Y6 Y5 Y4
2DD 101A 150A 104A 2D
HARNESS
FEMALE F E B A A B E F
CONNECTOR 2G
LOWER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
TRANS.
DIODE PACK DIODE PACK GRND
MH42402
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.39

Electrical System

(SN 13198 Through 16782, With Lighting Package and SN 16783 Through 18990)
INSTRUMENT PANEL
TURN SIGNALS
HYD. OIL TEMP.
TRANS. TEMP.
WATER TEMP.
HOURMETER
FUEL GAUGE
STABIL-TRAK
ALTERNAT0R
PARK BRAKE
BACK LIGHT
(OPTIONAL)
(OPTIONAL)
(OPTIONAL)
ENGINE OIL
HIGH BEAM
ROADLIGHTS
GROUND
OPTION
POWER
CONNECTOR CAB
HIGH BEAM HARNESS
CONNECTOR
23 47
22 154 155 152A3 156 38 40B 16 17 A3
21C 152A2
ROAD/ 28
2GG 152A 151 18 6 15 B3
WORKLIGHT
OPTION OPTION 152A1 40
A1
NOT
12B 12AA USED
12B 3C
12A 40
21C 27A 12A 26A 34 STEER 40B
SELECT 40
30 A B C D E
86 SWITCH 40A
HEADLIGHT A B C D E 2GG
SWITCH 7 8 11B 18
RELAY 20 B1
85
2JJ 1
87A 87 1
S 11B D 8
P 2
2KK 23 19
R 11A
11 16
OPTION 58 C5
IGNITION
O
S E 3
9
SWITCH P
R 24A
3B 15 B2
O
30
3A 12 29
S
158
P
HORN A5
R
7.5 BUTTON
OPEN
50 OPTION 30 50
86 LIGHT
O 35
B4
51 OPTION SWITCH
RELAY A B C 10
85 C4
87A 87
10.0
32 WIPER/
OPTION WASHER 2DD 12A 2KK 1
WIPER/
WASHER 2DD 26 38
20 B5
7 157 35
7 6
10.0 C1
STABILIZER 39
8
11A C2
41A
10.0 A2
STEER SELECT
46 9
SWITCH C3
15.0
HORN/HEATER 24 114B 48 10 39
52 52 HEATER 30 30
42A
INSTR. PANEL LOCK SWITCH
22 RELAY RELAY 15
LIGHT 7.5 85 85 A1
SWITCH RELAY
12 87A 87 87A 87
17
3C A2
29 2CC 40A 2AA 48 28
40.0
LIGHTS 2 27F 27C
40.0 47
MAIN
27 27 27D
100
26B 27B
26 20 20
A3
26 26A
3A 153A 2CC 2AA 20
7.5 CAB
TRANSMISSION 27B 2HH GROUND STUD
20 20 20 20 20
27A 151
20.0 B4
LIGHTS 1 27C
A4
12C 27D
7 B5
1 2HH
42B 8
111 24A
6
153A 111
HAZARDS 102B 24
PARK 153 113A
ROADLIGHTS E BRAKE 107B 111
OPTION 30
1 2 SWITCH 30 112A 111A 86
CONNECTOR 86 PARK BACK-UP
5 4
D 45A2 BRAKE 30 ALARM
DIS. 86 NEUTRAL RELAY
42B 152B1 152A1 RELAY 85
E
152B2 85 START 87A 87
3 152B 87A 87
113A RELAY
42A 85 2BB 31
2 41
87A 87 31
D
41B 41C 41A 113B A5
2EE 113
1 106 106
113 2FF B2
107A 107B
2EE 2BB
20 20
9 9
34
B1
BRAKE B+ 153
PEDAL 8 8
SWITCH GEAR 150 104
C4
45A2 7 7 103
45
GEAR 103 C3
45B 46 102
1 2 6 6
GEAR 105 C2
45
5 5
GEAR 101
F 112A
1 4 4 105
2 NEUTRAL 112 112 114A C5
112 102B
3 N
3 3
4 REVERSE 102A 102A 102 101
R 102 C1
SHIFTER 2 2
B3
1 1
B+ 113
CAB
114B HARNESS
MALE
45 114A CONNECTOR
114
MA78621
9.40 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
8042 (13198 - 16782, w/Light Package & 16783 -18990)
BATTERY
+ -
§
47 47B
47
47A
ENGINE 28 28B
28
HARNESS 28A BOOM
MALE 2K 2P 2N SENSOR BATTERY
CONNECTOR GRND
40 28B 47B + -
47 + - + - + - 27C
A3
+ - + - + - 27D 27 106
27 30 50
28 5
B3 M
BRN
3 12B 4B
BLU
152
40
A1
STABIL-TRAK BLK
GND
CYLINDER SOLENOIDS
4A 12A STARTER
A B C
A B C
+ - + -
+ - + - 35 2T
18 10
B1 47A 28A
2M 2L
16
C5 34
RED
A A
152
24A 24A + WHT
B2 B B
+ -
+ -
BLK
C C
2S
158 158 -
A5
HORN FUEL
SHUTOFF
35 SOLENOID
B4
10
C4
5
38 38
B5
B+
D+
6 6 GND
C1
41 41A (-) 2W
41
8 8 2C 41B 2E ALTERNATOR
C2 + - AB
41
A2 + - AB
9
C3 4-WHEEL PB B
+ - + - TRANS. TEMP
+ - + -
CRAB PB A SWITCH
18
+ - STEER AB SECONDARY
SELECT AB
FUNCTION
+ -
VALVE MANIFOLD WATER TEMP
9 2B SOLENOIDS 41B 2F SOLENOIDS SWITCH
15 15
A1
17
A2
FUEL 2L 2P 16
LEVEL 2M 2N 2K
SENDER OIL PRESSURE 2T
2B SWITCH
2A 2C 20 2E 2W
20 2S
A3 20 20 20 20
2R
2DD 2G 2H 2X
2D 2J
151 151
B4
27C
A4 NOT
27D HYDR. OIL USED
B5
TEMP SWITCH
B A
49
23 2X
2R
-
C B A BACK-UP
ALARM
+
NOT USED
31
31
A5
106
B2
34
B1 2J 7 7
104 104B Y1 Y3 Y2
C4 104 1 1
E E E
103 103B Y1 Y3 Y2
C3 103 3 3
102 102B 2 2
C2 102
UPPER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
105 105B 4
C5 105 4
101 101B
C1 101 5 5 Y6 Y5 Y4
150 150B E E E
B3 150 6 6
102A 103A 105A 2H Y6 Y5 Y4
ENGINE 7 7
2DD 101A 150A 104A 2D
HARNESS
FEMALE
F E B A A B E F
CONNECTOR 2G
LOWER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
TRANS.
MA78622
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.41

Electrical System
(SN 18991 - 19987 And 0160002332 & After)
1 9.50 10 WHT Ignition Switch 3-Way Connector (Pin B) to Park Brake Switch Connector (Pin 5)
2A 9.51 16 BLK Splice 20 (Ground) to Fuel Level Sender
2AA 9.50 18 BLK Splice 20 (Ground) to Boom Switch Relay (Pin 85)
2B 9.51 16 BLK Splice 20A (Ground) to Steer Select Valve Solenoid (4-Wheel) (Pin B)
2BB 9.50 18 BLK Splice 20A (Ground) to Back-up Alarm Relay (Pin 85)
2C 9.51 16 BLK Splice 20A (Ground) to Steer Select Valve Solenoid (Crab) (Pin B)
2CC 9.50 18 BLK Splice 20 (Ground) to Stabilizer Lock Relay (Pin 85)
2D 9.51 16 BLK Splice 20 (Ground) to Diode VESPAK VP2 (Pin F) (Engine Harness)
9.50 18 BLK Splice 20 (Ground) to Light Switch Relay (Pin 85) (Cab Harness)
2DD
9.51 16 BLK Splice 20 (Ground) to Diode VESPAK VP1 (Pin F) (Engine Harness)
Splice 20A (Ground)
2E 9.51 18 BLK
to Secondary Function Manifold Park Brake Solenoid (PB A) (Pin B)
2EE 9.50 18 BLK Splice 20A (Ground) to Park Brake Disconnect Relay (Pin 85)
Splice 20A (Ground)
2F 9.51 18 BLK
to Secondary Function Manifold Park Brake Solenoid (PB B) (Pin B)
2FF 9.50 18 BLK Splice 20 (Ground) to Neutral Start Relay (Pin 85)
2G 9.51 16 BLK Splice 20 (Ground) to Transmission Ground (Engine Harness)
2GG 9.50 16 BLK Splice 20A (Ground) to Instrument Panel Connector (Pin J5)
2H 9.51 18 BLK Splice 20 (Ground) to Lower Transmission Connector (Pin 7, Solenoid Y4, Y5 & Y6)
2HH 9.50 18 BLK Splice 20A (Ground) to Park Brake Switch Connector (Pin 7)
2J 9.51 18 BLK Splice 20 (Ground) to Upper Transmission Connector (Pin 7, Solenoid Y1, Y2 & Y3)
2JJ 9.50 18 BLK Splice 20A (Ground) to Steer Select Switch (Pin 7)
2K 9.51 18 BLK Splice 20D (Ground) to Stabil-TRAK™ Cylinder Solenoid (SOL 3) (Pin B)
2KK 9.50 18 BLK Splice 20 (Ground) to Headlight Switch Relay (Pin 85)
2L 9.51 18 BLK Splice 20D (Ground) to Stabil-TRAK™ Cylinder Solenoid (SOL 12A) (Pin B)
2LL 9.50 12 BLK Splice 20 (Ground) to Cab Ground Stud
2M 9.51 18 BLK Splice 20D (Ground) to Stabil-TRAK™ Cylinder Solenoid (SOL 4A) (Pin B)
2MM 9.50 12 BLK Splice 20A (Ground) to Cab Ground Stud
2N 9.51 18 BLK Splice 20D (Ground) to Stabil-TRAK™ Cylinder Solenoid (SOL 4B) (Pin B)
2P 9.51 18 BLK Splice 20D (Ground) to Stabil-TRAK™ Cylinder Solenoid (SOL 12B) (Pin B)
2R 9.51 16 BLK Not Used
2T 9.51 16 BLK Splice 20B (Ground) to Boom Sensor Connector (Pin C)
2X 9.51 16 BLK Splice 20B (Ground) to Back-up Alarm (–)
3A 9.50 10 PUR Fuse Buss Bar to Transmission Fuse
3B 9.50 10 PUR Open Fuse to Female Option Connector
3C 9.50 10 PUR Ignition Switch 5-Way Connector (Pin B) to Fuse Buss Bar
Instrument Panel Connector (Pin J8)
9.50 18 YEL
to Cab/Chassis Female Connector (Pin C1) (Cab Harness)
6
9.51 &
9.52
7 9.50 16 BRN Stabilizer Fuse to Female Connector
Steer Select Switch (Pin 1)
9.50 16 GRN/WHT
8
Cab/Chassis Male Connector (Pin C2)
9.51 16 LT GRN/WHT
to Steer Select Valve Solenoid (Crab) (A) (Engine Harness)
9.50 16 GRN/BLK
9
9.51 16 LT GRN/BLK
to Steer Select Valve Solenoid (4-Wheel) (A) (Engine Harness)
Boom Switch Relay (Pin 86)
9.50 16 TAN
10 to Cab/Chassis Female Connector (Pin C4) (Cab Harness)
9.51 16 TAN Cab/Chassis Male Connector (Pin C4) to Boom Sensor Connector (Pin B) (Engine Harness)
These wires are not part of a wire harness. Refer to the appropriate Parts Manual for part number information.
9.42 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

11A 9.50 16 LT GRN/BLU Steer Select Switch Relay Fuse to Steer Select Switch Connector (Pin 2)
11B 9.50 16 LT GRN/BLU Steer Select Switch Connector Jumper (Pin 2) to (Pin 8)
12 9.50 18 DK BLU Light Switch Relay Fuse to Light Switch Relay (Pin 86)
12A 9.50 12 DK BLU Light Switch Relay (Pin 87) to Splice 12A
12AA 9.50 12 DK BLU Splice 12A to Road/Worklights Connector (Option)
12B 9.50 12 DK BLU Splice 12A to Female Option Connector
12C 9.50 16 DK BLU Optional Lights Fuse (Lights 1) to Roadlights Connector (Option) (Hazards)
9.50 18 LT BLU
15 to Cab/Chassis Male Connector (Pin A1) (Cab Harness)
9.51 16 LT BLU Cab/Chassis Female Connector (Pin A1) to Water Temperature Switch (Engine Harness)
9.50 18 BRN
9.51 16 BRN Cab/Chassis Male Connector (Pin C5) to Oil Pressure Switch (Engine Harness)
9.50 18 GRY
9.51 16 GRY Cab/Chassis Female Connector (Pin A2) to Fuel Level Sender (Engine Harness)
9.50 18 GRN
18 to Cab/Chassis Female Connector (Pin B1) (Cab Harness)
9.51 16 GRN Cab/Chassis Male Connector (Pin B1) to Transmission Temperature Switch (Engine Harness)
9.50 12 BLK Cab Ground Stud to Cab/Chassis Male Connector (Pin A3) (Cab Harness)
20
9.51 12 BLK Cab/Chassis Female Connector (Pin A3) to Splice 20 (Ground) (Engine Harness)
9.50 12 BLK Splice 20A (Ground) to Cab/Chassis Female Connector (Pin A4) (Cab Harness)
20A
9.51 12 BLK Cab/Chassis Male Connector (Pin A4) to Splice 20A (Ground) (Engine Harness)
20B 9.51 12 BLK Splice 20A (Ground) to 20B (Ground)
20C 9.51 12 BLK Splice 20B (Ground) to Engine Ground Buss Bar
20D 9.51 12 BLK Splice 20 (Ground) to 20D (Ground)
20E 9.51 12 BLK Splice 20D (Ground) to Engine Ground Buss Bar
21C 9.50 16 RED Headlight Switch Relay (Pin 86) to Roadlights Female Connector (Option) (Main Beam)
22 9.50 16 WHT Instrument Panel Fuse to Inline Diode to Instrument Panel Connector (Pin J1)
Headlight Switch Relay (Pin 87)
9.50 16 GRN
23 to Roadlights Female Connector (Option) (Main Beam) (Cab Harness)
9.51 16 ORG/GRN Not Used (Engine Harness)
24 9.50 14 ORG/GRN Horn/Heater Fuse to Back-Up Alarm Relay (Pin 30)
Back-Up Alarm Relay (Pin 30)
9.50 14 ORG/GRN
24A to Cab/Chassis Female Connector (Pin B2) (Cab Harness)
9.51 16 ORG/BLK Cab/Chassis Male Connector (Pin B2) to Horn Connector (B) (Engine Harness)
26 9.50 10 RED Ignition Switch 3-Way Connector (Pin A) to Splice 26
26A 9.50 10 RED Ignition Switch 5-Way Connector (Pin A) to Splice 26
26B 9.50 10 RED Splice 26 to Main Fuse
27 9.50 10 RED Main Fuse to Splice 100
27A 9.50 12 RED Optional Lights Fuse (Lights 1) to Headlight Switch Relay (Pin 30)
27B 9.50 12 RED Optional Lights Fuse (Lights 1) to Splice 100
9.50 12 RED Splice 100 to Cab/Chassis Male Connector (Pin A4) (Cab Harness)
27C
9.51 12 RED Cab/Chassis Female Connector (Pin A4) to 12V Buss Bar (Engine Harness)
9.50 12 RED Splice 100 to Cab/Chassis Male Connector (Pin B5) (Cab Harness)
27D
9.51 12 RED Cab/Chassis Female Connector (Pin B5) to 12V Buss Bar (Engine Harness)
27F 9.50 12 RED Splice 100 to Optional Road/Worklights Fuse (Lights 2)
9.50 16 PUR/WHT
9.51 16 PUR/WHT Cab/Chassis Male Connector (Pin B3) to Splice 28 (Engine Harness)
28A 9.51 18 PUR/WHT Splice 28 to Stabil-TRAK™ Cylinder (SOL 12A) (A)
28B 9.51 18 PUR/WHT Splice 28 to Stabil-TRAK™ Cylinder (SOL 12B) (A)
29 9.50 12 RED Optional Road/Worklights Fuse (Lights 2) to Light Switch Relay (Pin 30)
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.43

Electrical System

Back-up Alarm Relay (Pin 87)
9.50 16 ORG/RED
9.51 16 ORG/RED Cab/Chassis Female Connector (Pin A5) to Back-up Alarm (+) (Engine Harness)
32 9.50 14 GRY/WHT Option Fuse to Wiper/Washer Female Connector (Option)
Ignition Switch 5-Way Connector (Pin C)
9.50 16 RED/BLK
to Cab/Chassis Male Connector (Pin B1) (Cab Harness)
34
Cab/Chassis Female Connector (Pin B1)
9.51 16 RED/BLK
to 7.5 amp Mini Fuse VESPAK Connector P9 (Pin E) (Engine Harness)
9.51 & 7.5 amp Mini Fuse VESPAK Connector P9 (Pin F)
34A 16 RED/WHT
9.52 to Engine Control Module Connector P1 (Pin A)
9.50 16 BRN/WHT Female Connector to Cab/Chassis Female Connector (Pin B4) (Cab Harness)
35
9.51 16 BRN/WHT Cab/Chassis Male Connector (Pin B4) to Boom Sensor Connector (Pin A) (Engine Harness)
9.50 16 ORG
to Cab/Chassis Female Connector (Pin B5) (Cab Harness)
38
9.51 &
9.52
39 9.50 16 RED/GRY Stabilizer Fuse to Boom Switch Relay (Pin 30)
9.50 16 BRN/BLK Splice 40 to Cab/Chassis Female Connector (Pin A1) (Cab Harness)
40
9.51 18 BRN/BLK Cab/Chassis Male Connector (Pin A1) to Stabil-TRAK™ Cylinder (SOL 3) (A) (Engine Harness)
40A 9.50 16 BRN/BLK Splice 40 to Stabilizer Lock Relay (Pin 87)
40B 9.50 16 BRN/BLK Splice 40 to Instrument Panel Connector (Pin J11)
41 9.51 16 BLU/WHT Cab/Chassis Male Connector (Pin A2) to Splice 41
Female Connector
9.50 16 DK BLU/WHT
41A to Cab/Chassis Female Connector (Pin A2) (Cab Harness)
9.51 18 BLU/WHT Splice 41 to Secondary Function Manifold Park Brake Solenoid (PB A) (Pin A) (Engine Harness)
9.50 16 DK BLU/WHT Park Brake Switch Connector (Pin 1) to Male Connector (Cab Harness)
41B
9.51 18 BLU/WHT Splice 41 to Secondary Function Manifold Park Brake Solenoid (PB B) (Pin A) (Engine Harness)
42A 9.50 18 TAN Instrument Panel Fuse to Park Brake Switch Connector (Pin 2)
42B 9.50 18 TAN Park Brake Switch Connector Jumper (Pin 2) to (Pin 8)
45 9.50 16 DK BLU/ORG Splice 45 to Splice 114
45A2 9.50 16 DK BLU/ORG Splice 45 to Inline Diode to Park Brake Switch Connector (Pin 3)
45B 9.50 16 DK BLU/ORG Splice 45 to Brake Pedal Switch (Pin 1)
46 9.50 16 WHT/ORG Steer Select Switch Relay Fuse to Brake Pedal Switch (Pin 2)
Stabilizer Lock Relay (Pin 87A)
9.50 16 ORG/WHT
47 to Cab/Chassis Female Connector (Pin A3) (Cab Harness)
9.51 16 ORG/WHT Cab/Chassis Male Connector (Pin A3) to Splice 47 (Engine Harness)
47A 9.51 18 ORG/WHT Splice 47 to Stabil-TRAK™ Cylinder (SOL 4A) (A)
47B 9.51 18 ORG/WHT Splice 47 to Stabil-TRAK™ Cylinder (SOL 4B) (A)
48 9.50 16 PUR/BLK Stabilizer Lock Relay (Pin 30) to Boom Switch Relay (Pin 87A)
49 9.51 16 RED/BLU Not Used
50 9.50 16 WHT/YEL Option Fuse to Female Option Connector
51 9.50 16 WHT/RED Option Fuse to Female Option Connector
52 9.50 12 ORG Horn/Heater Fuse to Heater Connector (Option)
9.50 16 BRN Shifter Connector (Pin 5) to Cab/Chassis Male Connector (Pin C1) (Cab Harness)
101
9.51 16 BRN Cab/Chassis Female Connector (Pin C1) to Splice 101 (Engine Harness)
101A 9.51 16 BRN Splice 101 to Diode VESPAK VP1 (Pin B)
101B 9.51 18 BRN Splice 101 to Lower Transmission Connector (Pin 5, Solenoid Y5)
9.50 16 PNK Splice 102 to Cab/Chassis Male Connector (Pin C2) (Cab Harness)
102
9.51 16 PNK Cab/Chassis Female Connector (Pin C2) to Splice 102 (Engine Harness)
9.50 16 PNK Splice 102 to Shifter Connector (Pin 3) (Cab Harness)
102A
9.51 16 PNK Splice 102 to Diode VESPAK VP1 (Pin C) (Engine Harness)
9.50 16 PNK Splice 102 to Back-Up Alarm Relay (Pin 86) (Cab Harness)
102B
9.51 18 PNK Splice 102 to Upper Transmission Connector (Pin 2, Solenoid Y2) (Engine Harness)
9.44 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

9.50 16 BLU Shifter Connector (Pin 7) to Cab/Chassis Male Connector (Pin C3) (Cab Harness)
103
9.51 16 BLU Cab/Chassis Female Connector (Pin C3) to Splice 103 (Engine Harness)
103A 9.51 16 BLU Splice 103 to Diode VESPAK VP1 (Pin A)
103B 9.51 18 BLU Splice 103 to Upper Transmission Connector (Pin 3, Solenoid Y3)
9.50 16 YEL Shifter Connector (Pin 2) to Cab/Chassis Male Connector (Pin C4) (Cab Harness)
104
9.51 16 YEL Cab/Chassis Female Connector (Pin C4) to Splice 104 (Engine Harness)
104A 9.51 16 YEL Splice 104 to Diode VESPAK VP2 (Pin C)
104B 9.51 18 YEL Splice 104 to Upper Transmission Connector (Pin 1, Solenoid Y1)
9.50 16 GRN Shifter Connector (Pin 6) to Cab/Chassis Male Connector (Pin C5) (Cab Harness)
105
9.51 16 GRN Cab/Chassis Female Connector (Pin C5) to Splice 105 (Engine Harness)
105A 9.51 16 GRN Splice 105 to Diode VESPAK VP2 (Pin B)
105B 9.51 18 GRN Splice 105 to Lower Transmission Connector (Pin 4, Solenoid Y4)
9.50 12 BLU/ORG Neutral Start Relay (Pin 87) to Cab/Chassis Male Connector (Pin B2) (Cab Harness)
106 9.51 &
12 BLU/ORG Cab/Chassis Female Connector (Pin B2) to Starter Solenoid (Engine Harness)
9.52
107A 9.50 18 BLU Park Brake Switch Connector (Pin 1) to Female Connector
107B 9.50 18 BLU Male Connector to Park Brake Disconnect Relay (Pin 86)
111 9.50 12 RED Park Brake Switch (Pin 6) to Splice 111
111A 9.50 12 RED Splice 111 to Neutral Start Relay (Pin 30)
112 9.50 16 GRY Shifter Connector (Pin 4) to Splice 112
112A 9.50 16 GRY Splice 112 to Neutral Start Relay (Pin 86)
113 9.50 16 RED Shifter Connector (Pin 1) to Splice 113
113A 9.50 16 RED Splice 113 to Inline Diode to Splice 111
113B 9.50 16 RED Splice 113 to Park Brake Disconnect Relay (Pin 87)
114A 9.50 16 BLU/ORG Splice 112 to Inline Diode to Splice 114
114B 9.50 16 BLU/ORG Splice 114 to Stabilizer Lock Relay (Pin 86)
9.50 16 PUR Shifter Connector (Pin 8) to Cab/Chassis Male Connector (Pin B3) (Cab Harness)
150
9.51 16 PUR Cab/Chassis Female Connector (Pin B3) to Splice 150 (Engine Harness)
150A 9.51 16 PUR Splice 150 to Diode VESPAK VP2 (Pin A)
150B 9.51 18 PUR Splice 150 to Lower Transmission Connector (Pin 6, Solenoid Y6)
9.50 16 YEL/GRN
151 to Cab/Chassis Male Connector (Pin B4) (Cab Harness)
9.51 16 YEL/GRN Cab/Chassis Female Connector (Pin B4) to Hydraulic Temperature Switch (Engine Harness)
152A1 9.50 16 BLK/WHT Female Connector to Inline Diode to Splice 152A
152A2 9.50 16 BLK/WHT Not Used
152A3 9.50 16 BLK/WHT Splice 152A to Instrument Panel Connector (Pin J7)
152B 9.50 16 BLK/WHT Park Brake Switch Connector (Pin 3) to Male Connector
153 9.50 16 GRY/WHT Park Brake Disconnect Relay (Pin 30) to Shifter Connector (Pin 9)
153A 9.50 16 GRY/WHT Transmission Fuse to Park Brake Disconnect Relay (Pin 30)
154 9.50 16 BLU/WHT Instrument Panel Connector (Pin J14) to Roadlights Connector (Option) (Main Beam)
155 9.50 16 GRN/RED Instrument Panel Connector (Pin J15) to Roadlights Connector (Option) (Turn Signals)
156 9.50 16 RED/WHT
to Roadlights Connector (Option) (Instrument Panel Backlight)
157 9.50 16 BRN Jumper Wire (Wire 7 to Wire 35)
9.50 16 BLK Horn Button to Cab/Chassis Female Connector (Pin A5)
158
9.51 16 WHT Cab/Chassis Male Connector (Pin A5) to Horn Connector (Pin A) (Engine Harness)
A 9.52 6 RED Battery 2, Positive (+) Terminal to 125 Amp Fuse
AB1 9.52 10 RED Alternator (Pin B+) to 12V Buss Bar
AG1 9.52 10 BLK Alternator (Pin GND) to Ground Buss Bar
B 9.52 6 RED Battery 2, Positive (+) Terminal to 125 Amp Fuse
BN 9.52 16 BLK Battery 2, Negative (-) Terminal to Engine Control Module, Male Diagnostic Connector, P7 (Pin A)
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.45

Electrical System

BNE 9.52 16 BLK Battery 2, Negative (-) Terminal to Engine Control Module, Female Engine Connector, P1 (Pin E)
BNF 9.52 16 BLK Battery 2, Negative (-) Terminal to Engine Control Module, Female Engine Connector, P1 (Pin F)
BNH 9.52 16 BLK Battery 2, Negative (-) Terminal to Engine Control Module, Female Engine Connector, P1 (Pin H)
BNP 9.52 14 BLK Battery 2, Negative (-) Terminal to Engine Control Module, Female Engine Connector, P1 (Pin P)
BNW 9.52 14 BLK Battery 2, Negative (-) Terminal to Engine Control Module, Female Engine Connector, P1 (Pin W)
10 amp Mini Fuse VESPAK Connector P6 (Pin F)
BP 9.52 16 RED/GRN
to Engine Control Module, Male Diagnostic Connector, P7 (Pin B)
BP1 9.52 16 RED/GRN Battery 2, Positive (+) Terminal to 10 amp Mini Fuse VESPAK Connector P6 (Pin E)
7.5 amp Mini Fuse VESPAK Connector P5 (Pin B)
BPB 9.52 16 RED/WHT
to Engine Control Module, Female Engine Connector, P1 (Pin B)
BPB1 9.52 16 RED/WHT Battery 2, Positive (+) Terminal to 7.5 amp Mini Fuse VESPAK Connector P5 (Pin A)
7.5 amp Mini Fuse VESPAK Connector P5 (Pin D)
BPC 9.52 16 RED/WHT
to Engine Control Module, Female Engine Connector, P1 (Pin C)
BPC1 9.52 16 RED/WHT Battery 2, Positive (+) Terminal to 7.5 amp Mini Fuse VESPAK Connector P5 (Pin C)
7.5 amp Mini Fuse VESPAK Connector P5 (Pin F)
BPD 9.52 16 RED/WHT
to Engine Control Module, Female Engine Connector, P1 (Pin D)
BPD1 9.52 16 RED/WHT Battery 2, Positive (+) Terminal to 7.5 amp Mini Fuse VESPAK Connector P5 (Pin E)
10 amp Mini Fuse VESPAK Connector P6 (Pin B)
BPM 9.52 14 RED/GRN
to Engine Control Module, Female Engine Connector, P1 (Pin M)
BPM1 9.52 14 RED/GRN Battery 2, Positive (+) Terminal to 10 amp Mini Fuse VESPAK Connector P6 (Pin A)
10 amp Mini Fuse VESPAK Connector P6 (Pin D)
BPS 9.52 14 RED/GRN
to Engine Control Module, Female Engine Connector, P1 (Pin S)
BPS1 9.52 14 RED/GRN Battery 2, Positive (+) Terminal to 10 amp Mini Fuse VESPAK Connector P6 (Pin C)
C 9.52 6 RED 125 Amp Fuse to Grid Heater Relay 2 (Pin 2)
CG1 9.52 16 BLK Preheat Indicator Light, Female Connector, P15 (Pin 1B-) to Cab Ground Stud
CNH 9.52 18 YEL Splice 1 to Engine, Female Connector, P3 (Pin A)
CNH1 9.52 18 YEL Splice 1 to Resistor, Female Connector, P4 (Pin A)
CNH2 9.52 18 YEL Splice 4 to Engine Control Module, Male Diagnostic Connector, P7 (Pin C)
CNH4 9.52 18 YEL Splice 1 to Splice 4
CNL 9.52 18 GRN Splice 2 to Engine, Female Connector, P3 (Pin B)
CNL1 9.52 18 GRN Splice 2 to Resistor, Female Connector, P4 (Pin B)
CNL2 9.52 18 GRN Splice 5 to Engine Control Module, Male Diagnostic Connector, P7 (Pin D)
CNL4 9.52 18 GRN Splice 2 to Splice 5
CNS 9.52 18 DRAIN Splice 3 to Engine, Female Connector, P3 (Pin C)
CNS1 9.52 18 DRAIN Splice 3 to Resistor, Female Connector, P4 (Pin C)
CNS2 9.52 18 DRAIN Splice 6 to Engine Control Module, Male Diagnostic Connector, P7 (Pin E)
CNS4 9.52 18 DRAIN Splice 3 to Splice 6
CNS5 9.52 18 BLK Splice 3 to Engine Block
D 9.52 6 RED 125 Amp Fuse to Grid Heater Relay 1 (Pin 2)
Engine Control Module Bulkhead, Female Connector (Pin N)
DD 9.52 18 BLK
to Engine Control Module, Female Engine Connector, P2 (Pin 36)
Engine Control Module Bulkhead, Female Connector (Pin M)
DI 9.52 18 BLK
DLP 9.52 16 WHT/RED Splice 6 to Male Connector
DLP1 9.52 16 WHT/RED Engine Function Indicator Light, Female Connector, P15 (Pin 1A+) to Splice 6
DLP3 9.52 16 WHT/RED Splice 6 to Female Connector
Engine Control Module Bulkhead, Female Connector (Pin L)
DS 9.52 18 BLK
E 9.52 6 RED Grid Heater Relay 1 (Pin 1) to Engine Grid Heater (Pin 1)
9.46 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

F 9.52 6 RED 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 9.52 18 BLK Splice 8 to Engine Control Module, Female Engine Connector, P2 (Pin 41)
GH1A 9.52 16 BLK Splice 8 to Diode VESPAK Connector P10 (Pin A)
GH1B 9.52 16 BLK Splice 8 to Grid Heater Relay 1 (Pin 3)
GH2A 9.52 16 BLK Splice 9 to Diode VESPAK Connector P10 (Pin B)
GH3 9.52 16 BLK Grid Heater Relay 1 (Pin 1) to Diode VESPAK Connector P11 (Pin A)
GH4 9.52 16 BLK Grid Heater Relay 2 (Pin 1) to Diode VESPAK Connector P11 (Pin F)
GHG 9.52 16 BLK Splice 7 to Diode VESPAK Connector P10 (Pin F)
GHG1 9.52 16 BLK Splice 7 to Grid Heater Relay 1 (Pin 4)
GHG3 9.52 16 BLK Battery 2, Negative (-) Terminal to Splice 7
H 9.52 1/0 RED Battery 1, Positive (+) Terminal to Battery 2, Positive (+) Terminal
J 9.52 1 BLK Battery 2, Negative (-) Terminal to Frame Ground
Engine Control Module, Female Engine Connector, P2 (Pin 49)
J87H 9.52 18 RED
to Engine Control Module, Male Diagnostic Connector, P7 (Pin F)
J87L 9.52 18 BLK
to Engine Control Module, Male Diagnostic Connector, P7 (Pin G)
K 9.52 1/0 BLK Battery 1, Negative (-) Terminal to Battery 2, Negative (-) Terminal
L 9.52 1/0 BLK Battery 1, Negative (-) Terminal to Starter Ground Stud
Engine Control Module Bulkhead, Female Connector (Pin F)
ML 9.52 18 BLK
Engine Control Module Bulkhead, Female Connector (Pin H)
9.52 18 BLK
to Engine Control Module, Female Engine Connector, P2 (Pin 25) (Engine Harness)
OFF1
Engine Control Module Bulkhead, Male Connector (Pin H)
9.52 18 ORG
to Idle Validation Switch, Male Connector, P16 (Pin C) (ECM Cab Harness)
Engine Control Module Bulkhead, Female Connector (Pin J)
9.52 18 BLK
ON1
Engine Control Module Bulkhead, Male Connector (Pin J)
9.52 18 VIO
to Idle Validation Switch, Male Connector, P16 (Pin B) (ECM Cab Harness)
Engine Control Module Bulkhead, Male Connector (Pin P)
PH1 9.52 18 BLU
to Preheat Indicator Light, Female Connector, P19 (Pin 1A+)
Engine Control Module Bulkhead, Female Connector (Pin P)
PH1A 9.52 16 PNK/BLU
to Diode VESPAK Connector P11 (Pin B)
Engine Control Module Bulkhead, Female Connector (Pin O)
RTS 9.52 18 BLK
Engine Control Module Bulkhead, Female Connector (Pin D)
SL 9.52 18 BLK
Engine Control Module Bulkhead, Male Connector (Pin D)
SL1 9.52 18 GRN
to Engine Function Indicator Light, Female Connector, P15 (Pin 1B-)
Engine Control Module Bulkhead, Female Connector (Pin K)
9.52 18 BLK
SWR
Engine Control Module Bulkhead, Male Connector (Pin K)
9.52 18 YEL
to Idle Validation Switch, Male Connector, P16 (Pin A) (ECM Cab Harness)
Engine Control Module Bulkhead, Female Connector (Pin A)
THG 9.52 18 BLK
Engine Control Module Bulkhead, Male Connector (Pin A)
THG1 9.52 18 BLK
to Throttle Sensor, Female Connector, P14 (Pin A)
Engine Control Module Bulkhead, Female Connector (Pin B)
THP 9.52 18 RED
Engine Control Module Bulkhead, Male Connector (Pin B)
THP1 9.52 18 RED
to Throttle Sensor, Female Connector, P14 (Pin C)
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.47

Electrical System

Engine Control Module Bulkhead, Female Connector (Pin C)
THS 9.52 18 WHT
Engine Control Module Bulkhead, Male Connector (Pin C)
THS1 9.52 18 WHT
to Throttle Sensor, Female Connector, P14 (Pin B)
Engine Control Module Bulkhead, Female Connector (Pin E)
WL 9.52 18 BLK
Engine Control Module Bulkhead, Male Connector (Pin E)
WL1 9.52 18 BRN
Engine Control Module Bulkhead, Female Connector (Pin G)
WSL 9.52 18 BLK
9.48 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.49

Electrical System

(SN 18991 - 19987 And 0160002332 & After)
INSTRUMENT PANEL
TURN SIGNALS
HYD. OIL TEMP.
TRANS. TEMP.
WATER TEMP.
HOURMETER
FUEL GAUGE
STABIL-TRAK
ALTERNAT0R
PARK BRAKE
BACK LIGHT
(OPTIONAL)
(OPTIONAL)
(OPTIONAL)
ENGINE OIL
HIGH BEAM
ROADLIGHTS
GROUND
OPTION
POWER
CONNECTOR CAB
HIGH BEAM HARNESS
CONNECTOR
23 47
22 154 155 152A3 156 38 40B 16 17 A3
21C 152A2
ROAD/ 28
2GG 152A 151 18 6 15 B3
WORKLIGHT
A1
NOT 40
12B 12AA USED
40B
40
12B 3C 40A
12A
STEER
21C 27A 12A 26A 34 SELECT
A B C D E SWITCH
30 2GG
86 HEADLIGHT A B C D E 11B
20A 7 8
SWITCH 2JJ 1
85 RELAY 18
87A 87 1 B1
11B D 8
S 2
2KK 23 19 P 11A
R 16
OPTION IGNITION
58 E 3 C5
O
S
9
SWITCH P
R 24A
15 B2
3B O
30 S
3A 12 29 P CAB 158 158
HORN A5
7.5 R GROUND
OUTRIGGERS
50 OPTION 86
30 LIGHT 50
STUD BUTTON
O 35
SWITCH B4
51 OPTION 85 RELAY
A B C
87A 87 10
2MM C4
10.0
32 WIPER/ 2KK 20A
OPTION WASHER 2DD 12A 1 20A 20A
20A A4
WIPER/ 2DD
WASHER 20 38
26 B5
7 157 35 6
7 C1
10.0
STABILIZER 39 8
C2
41A
11A A2
9
C3
10.0 114B 48 10 39
STEER SELECT
46
SWITCH 30 30
86 STABIL. 86 BOOM
LOCK SWITCH
15.0 RELAY RELAY
HORN/HEATER 24 85
87A 87
85
87A 87
52 52 HEATER
10.0 40A 28
INSTR. PANEL
42A
47 48
22
7.5
LIGHT SWITCH 12 2CC 2AA
RELAY
3C 20
29
40.0 20
LIGHTS 2 27F 27C
40.0 15
27 27 27D A1
MAIN 100 17
26B 27B A2
26
26 26A CAB
GROUND 2LL 20
3A 153A STUD 20 A3
7.5
TRANSMISSION 27B 2FF
27A
20.0 151
LIGHTS 1 B4
12C 27C
A4
27D
7 B5
1 2HH 2HH
42B 8 20A
HAZARDS 111 24A
6
153A 153 111
ROADLIGHTS 102B 24
PARK 113A
OPTION E BRAKE 107B 111
CONNECTOR SWITCH 30
1 2 30 PARK 112A 111A 86 BACK-UP
86
5
D 4 BRAKE ALARM
45A2 DIS. 30 85 RELAY
85 86 NEUTRAL 87A 87
42B 152A1 87A 87 RELAY START
152B
E 3 85 RELAY
113A 87A 87
42A 2EE 113B 2BB 31
2 31
D A5
41B 41A 113 2FF
1 106 106
113 B2
107A 107B
2EE 2BB
20A
9 9
34
B1
BRAKE B+ 153
PEDAL 8 8
SWITCH GEAR 150 104
C4
45A2 7 7 103
45
GEAR 103 C3
45B 46 102
1 2 6 6
GEAR 105 C2
45
5 5
GEAR 101
F 112A
1 4 4 105
2 NEUTRAL 112 112 114A C5
112 102B
3 N
3 3
4 REVERSE 102A 102A 102 101
R 102 C1
SHIFTER 2 2
B3
1 1
B+ 113
CAB
114B HARNESS
MALE
45 114A CONNECTOR
114
MH48101
9.50 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
8042 (18991 & After)
47 47B
47
47A
STARTER 12V BUSS BAR
28 28B
28 +
ENGINE 28B 47B
HARNESS 28A BOOM
GND (-)
2K 2P 2N 106
MALE 40 SENSOR
CONNECTOR A B A B A B
+ -
AB AB AB 27D
47
A3
AB2 27C
28 AB1 STARTER
3 12B 4B
B3
STABIL-TRAK BRN
BLU 38
See
40 CYLINDER SOLENOIDS
A1
4A 12A
BLK 6 D+ B+
AG1 Page 9.52
GND (-)
AG2
A B C W
AB AB
A B C ALTERNATOR
A B A B
47A 2L 35 2T
28A
2M 10
18
B1
16
C5
24A +
B2 B B
A A
158 - 18
A5
HORN
35 8 2C TRANS. TEMP
B4
41A SWITCH
A B
10 2E
C4 AB SECONDARY
20A FUNCTION
4-WHEEL
MANIFOLD AB
16
A4 + -
38 + - SOLENOIDS AB
B5 CRAB OIL PRESSURE
A B STEER PB B SWITCH
6 + -
C1
AB
SELECT + -
8 VALVE PB A
C2
9 2B SOLENOIDS AB
41
A2 AB
9
C3
41A 41B
41 P9
41 2F
IGNITION
SWITCH
2E 2C FUSE
2B See Page 9.52
F
34A
20A 20B 7.5
20A 20A 20A E
34
D
C
B
15 15 A
A1
17 2A 2M 2N 2K
A2
FUEL LEVEL 2L 2P WATER TEMP
2A SWITCH
SENDER 2T
20
20 20 20D
A3 20 20D
20B 20C
2DD 20E 20B
2D 2G 2H 2J 2R
151 151 2X
B4
27C
A4
27D HYDR. OIL NOT
B5 TEMP SWITCH USED
B A
2X
49
23 -
2R BACK-UP
ALARM
C B A +
31
NOT USED
31
A5
106
B2
34
B1 2J 7 7
104 104B Y1 Y3 Y2
C4 104 1 1
E E E
103 103B Y1 Y3 Y2
C3 103 3 3
102 102B 2 2
C2 102
UPPER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
105 105B 4
C5 105 4
101 101B
C1 101 5 5 Y6 Y5 Y4
150 150B E E E
B3 150 6 6
102A 103A 105A 2D 2H 7 7 Y6 Y5 Y4

ENGINE
HARNESS 2DD 101A 150A 104A
FEMALE
F C B A A B C F
CONNECTOR 2G
LOWER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
TRANS. 20E 20C

VP1 VP2
ENGINE GROUND BUSS BAR
MH48102
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.51

Electrical System
9.7.11 8042 ECM Cab Harness & Engine Harness (SN 18991 - 19987 And 0160002332 & After)

+
106 BPB1
GND (-)
See Page 9.51 38
+
BPC1
6 BATTERY BPD1
1
BPM1
7.5 50 DLP CNS4 CNS3
OPEN AB2 BPS1
-
6
CNS2 STARTER ENGINE BP1
51 AB1 BLOCK
OPTION
CNS4
ENGINE G J87L
10.0 CNS5 CNS1 D+ B+
OPTION BLOCK 3 F J87H AG1
GND (-)
WIPER/ CNS CNS2 CNL4
+
E AG2
WASHER
D CNL2 W BATTERY
5 BNE
C CNH2 2
CNL3 ALTERNATOR
BNF
10.0 CNL4 B BP
STABILIZER A CNH BNH
A BN
B
C
CNL
CNS
CNL
2
CNL1
P7
DIAGNOSTIC
P8
RESISTOR
FEMALE
BNP
BNW
-
10.0 P3 CNH PLUG
CNH2 CONNECTOR
STEER SELECT FEMALE BN
SWITCH
CONNECTOR CNH4 CNH4 CNS3 C GHG3
1 4
125
CNH1 CNH3 CNL3 B Amp
15.0 Fuse
HORN/HEATER P6 CNH3 A
ENGINE
A CNH1 CONTROL
MODULE FRAME
10.0 B CNL1 GROUND
INSTR. PANEL FUSES
C CNS1
BP
7.5 P4 10 F
LIGHT SWITCH BP1
RELAY RESISTOR E
FEMALE D
BPS
10
CONNECTOR BPS1
C
See Page 9.50 10 B
BPM
BNW W
A
BPM1
BPS S
BNP P
P5 BPM M
CAB DLP ENGINE
GROUND BNH H
CONTROL
STUD DLP3 OPTION MODULE BNF F
6
FUSES BNE E
DLP1
CG1 BPD BPD D
7.5 F
DLP2
1B- 2B- E
BPD1 BPC C
P19 1A+ 2A+ BPC BPB B
PREHEAT P15 7.5 D
1
INDICATOR ENGINE C
BPC1 34A A
LIGHT
1 2 FUNCTION BPB
INDICATOR 7.5 B P1
1A+ 2A+ BPB1
LIGHT A ENGINE
1B- 2B-
CONTROL
PH1 MODULE
WL1
23 PIN FEMALE
SL1
See Page 9.51 34A
CONNECTOR
PH1 P P PH1A
O O RTS
N N DD
M M DI
L L DS J87L 50
1
A A SWR SWR K K SWR J87H 49
2
B B ON1 ON1 J J ON1 RTS 45
3
C C OFF1 OFF1 H H OFF1 GH1 41
G G WSL DS 37
P16
IDLE F F ML DD 36
VALIDATION WL1 E E WL DI 35
SWITCH
SL1 D D SL GH2 31
THS1 C C THS THS 30
C C THP1 THP1 B B THP THP 29
B B THS1 THG1 A A THG ON1 26
A A THG1 OFF1 25
ECM ECM
BULKHEAD BULKHEAD SWR 20
P14
THROTTLE MALE FEMALE THG 19
SENSOR CONNECTOR CONNECTOR
WSL 11
ML 4
WL 3
SL 1
ENGINE GRID
HEATER RELAY 2 P2
GH4 GH4 ENGINE
F
1 2
CONTROL
MODULE
E 50 PIN FEMALE
PH1A GH2B CONNECTOR
3
B
GH3
A 4
ENGINE COMPARTMENT
P11 GHG2
DIODE PACK
GH1
125
GH1B Amp
Fuse
VEHICLE CAB
GH1A GH1A GH2B

A
GH2A GH2A GH2
B 9
GHG2
C
GHG GHG GHG3
F 7
P10 GHG1 ENGINE GRID
DIODE PACK HEATER RELAY 1 GH1B
GH3
1 2
ENGINE GRID
HEATER 3 AG2
ENGINE 2 4
BLOCK 1
AG1
GHG1

MH4740
9.52 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
9.7.12 10042 Electrical Schematic Legend (SN 13198 Through 19030)

9.62 or
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
9.64
9.63 or
16 BLK Splice 20 (Ground) to Steer Select Valve Solenoid (4-Wheel) (–) (Engine Harness)
9.65
2B
9.62 or
16 BLK Splice 2 to Right Outrigger Switch Connector (Pin 7) (Outrigger Harness)
9.64
9.62 or
9.64
9.63 or
9.65
9.62 or
9.64
9.63 or
9.65
9.62,
2D
9.63,
16 BLK Splice 2 to Outrigger Valve Solenoid (Left Down) (–) (Outrigger Harness)
9.64 or
9.65
9.62 or
9.64
2DD
9.63 or
9.65
9.63 or Splice 20 (Ground)
16 BLK
9.65 to Secondary Function Manifold Park Brake Solenoid (PB A) (Pin B) (Engine Harness)
9.62,
2E
9.63,
16 BLK Splice 2 to Outrigger Valve Solenoid (Left Up) (–) (Outrigger Harness)
9.64 or
9.65
9.62 or
9.64
9.63 or Splice 20 (Ground)
16 BLK
9.65 to Secondary Function Manifold Park Brake Solenoid (PB B) (Pin B) (Engine Harness)
9.62,
2F
9.63,
16 BLK Splice 2 to Outrigger Valve Solenoid (Right Down) (–) (Outrigger Harness)
9.64 or
9.65
9.62 or
9.64
9.63 or
16 BLK Splice 20 (Ground) to Transmission Ground (Engine Harness)
9.65
9.62,
2G
9.63,
16 BLK Splice 2 to Outrigger Valve Solenoid (Right Up) (–) (Outrigger Harness)
9.64 or
9.65
9.62 or
9.64
9.63 or
9.65
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.53

Electrical System

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
2R 18 BLK Not Used
9.65
9.63 or
9.65
9.63 or
9.65
9.63 or
9.65
9.63 or
9.65
3A 10 PUR
3B 9.64 10 PUR § Outrigger Fuse to Option Connector
9.63 or
9.65
18 YEL
6
9.63 or
9.65
9.62 or
7 16 BRN Stabilizer Fuse to Jumper Wire 157
9.64
16 GRN/WHT
8
16 LT GRN/WHT
16 GRN/BLK
9
16 LT GRN/BLK
16 TAN
10
9.63 or
9.65
11 9.62 16 LT GRN/BLU †
9.54 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

9.62 or
9.64
12A 12 DK BLU
12B 12 DK BLU
12C 16 DK BLU
18 LT BLU
15
9.63 or
9.65
18 BRN
16
9.63 or
9.65
18 GRY
17
9.63 or
9.65
18 GRN
18
9.63 or
9.65
9.62 or
14 BLK Splice 20 (Ground) to Cab Ground Stud (Cab Harness)
9.64
9.62 or
12 BLK Cab Ground Stud to Cab/Chassis Male Connector (PinA3) (Cab Harness)
9.64
20
9.63 or
9.65
9.62 or
14 BLK Splice 2 to Cab Ground Stud (Outrigger Harness)
9.64
9.62 or
9.64
9.62 or
9.64
16 GRN
23
9.63 or
16 ORG/GRN Not Used (Engine Harness)
9.65
9.62 or
9.64
14 ORG/GRN
24A
9.63 or
9.65
26 10 RED
26A 10 RED
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.55

Electrical System

9.62 or
9.64
27
9.63 or
9.65
27A 12 RED
9.64 § Optional Lights Fuse (Lights 1) to Splice 27 to Headlight Switch Relay (Pin 30)
27B 12 RED
9.62 or
9.64
27C
9.63 or
9.65
9.62 or
9.64
27D
9.63 or
9.65
16 PUR/WHT
28
9.63 or
9.65
9.63 or
9.65
9.63 or
9.65
16 ORG/RED
31
9.63 or
9.65
9.62 or
9.64
16 RED/BLK
34
16 RED/BLK
9.62 or
16 BRN/WHT Jumper Wire 157 to Cab/Chassis Female Connector (Pin B4) (Cab Harness)
9.64
35
9.63 or
9.65
16 ORG
38
9.63 or
9.65
9.62 or
9.64
9.62 or
9.64
40
9.63 or
9.65
9.62 or
9.64
9.62 or
9.64
9.56 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

Park Brake Switch Connector (Pin 1) to Splice 41
9.62 DK BLU/WHT † to Male Connector (Cab Harness)
41 16 Female Connector to Cab/Chassis Female Connector (Pin A2) (Cab Harness)
9.63 or
BLU/WHT Cab/Chassis Male Connector (Pin A2) to Splice 41 (Engine Harness)
9.65
9.64 DK BLU/WHT § Female Connector to Cab/Chassis Female Connector (Pin A2) (Cab Harness)
41A 9.63 or 16
BLU/WHT Splice 41 to Secondary Function Manifold Park Brake Solenoid (PB A) (Pin A) (Engine Harness)
9.65
41B 9.63 or 16
BLU/WHT Splice 41 to Secondary Function Manifold Park Brake Solenoid (PB B) (Pin A) (Engine Harness)
9.65
42 9.62 18 TAN †
9.62 or
9.64
9.62 or
9.64
9.62 or
9.64
16 ORG/WHT
47
9.63 or
9.65
9.63 or
9.65
9.63 or
9.65
9.62 or
9.64
9.63 or
49 16 RED/BLU Not Used
9.65
9.62 or
50 16 WHT/YEL Outrigger Fuse to Female Option Connector to Wire 60E
9.64
9.62 or
9.64
9.62 or
9.64
9.62 or
60A 16 YEL Splice 60 to Right Outrigger Switch Connector (Pin 2)
9.64
9.62 or
60B 16 YEL Splice 60 to Right Outrigger Switch Connector (Pin 8)
9.64
9.62 or
60C 16 YEL Splice 60 to Left Outrigger Switch Connector (Pin 2)
9.64
9.62 or
60D 16 YEL Splice 60 to Left Outrigger Switch Connector (Pin 8)
9.64
9.62 or
60E 16 YEL Splice 60 to Male Connector
9.64
9.62,
9.63,
61 16 RED/GRY Right Outrigger Switch Connector (Pin 1) to Outrigger Valve Solenoid (Right Up) (+)
9.64 or
9.65
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.57

Electrical System

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
9.62 or
9.64
101
9.63 or
9.65
9.63 or
9.65
9.63 or
9.65
9.62 or
9.64
102
9.63 or
9.65
9.62 or
9.64
102A
9.63 or
9.65
9.62 or
9.64
102B
9.63 or
9.65
9.62 or
9.64
103
9.63 or
9.65
9.63 or
9.65
9.63 or
9.65
9.62 or
9.64
104
9.63 or
9.65
9.63 or
9.65
9.63 or
9.65
9.62 or
9.64
105
9.63 or
9.65
9.63 or
9.65
9.63 or
9.65
9.58 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

9.62 or
9.64
106
9.63 or
9.65
Splice 41 to Female Connector
107 9.62 18 BLU †
107A 9.64 18 BLU § Splice 41 to Female Connector
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
150
9.63 or
9.65
9.63 or
9.65
9.63 or
9.65
16 YEL/GRN
151
9.63 or
9.65
Park Brake Switch Connector (Pin 3) to Splice 152 to Male (Cab Harness)
9.62 16 BLK/WHT † Female Connector to Inline Diode
152 to Instrument Panel Connector (Pin J7) (Cab Harness)
9.63 or
9.65
152A 9.62 16 BLK/WHT † Not Used
152A2 9.64 16 BLK/WHT § Not Used
9.62 or
9.64
9.62 or
9.64
9.62 or
9.64
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.59

Electrical System

9.62 or
9.64
156 16 RED/WHT
9.62 or
157 16 BRN Jumper Wire (Wire 7 to Wire 35)
9.64
9.62 or
9.64
158
9.63 or
9.65
9.60 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.61

Electrical System
9.7.13 10042 Electrical Schematic (SN 13198 Through 16782, Without Lighting Package)
INSTRUMENT PANEL
TURN SIGNALS
HYD. OIL TEMP.
TRANS. TEMP.
WATER TEMP.
HOURMETER
FUEL GAUGE
STABIL-TRAK
ALTERNAT0R
PARK BRAKE
BACK LIGHT
(OPTIONAL)
(OPTIONAL)
(OPTIONAL)
ENGINE OIL
HIGH BEAM
ROADLIGHTS
GROUND
OPTION
POWER
CONNECTORS CAB
HAZARDS HIGH BEAM HARNESS
CONNECTOR
23 47
12C 154 155 152 156 38 40B 16 17 A3
21C 22 152A
ROAD/ 28
2GG 151 18 6 15 B3
For additional information WORKLIGHT
OPTION
40
on the 10042 Outrigger NOT 40
A1
12A 40B
Circuit, refer to Section 12B 3
USED
40
12A 40A
9.7.42, “10042 Outrigger 21C 12B 12A 26A 34 STEER
SELECT
Circuit and 86
30
HEADLIGHT
A B C D E
2GG
SWITCH
A B C D E
Troubleshooting.” SWITCH
RELAY 20
2JJ
7
1
8
11 18
85 B1
87A 87 1
S 11 D 8
2KK 23 19 P 2
R
58
11 16
C5
27A IGNITION O
E 3
S
27 SWITCH P 9
27A R 24A
15 B2
O
30
3A 12 27A
S
158
P
HORN A5
R
7.5 BUTTON
OUTRIGGERS
50 60E 30 50
86 LIGHT
O 35
B4
51 OPTION SWITCH
RELAY A B C 10
85 C4
87A 87
10.0
32 WIPER/ 60
OPTION WASHER 2KK 60E
WIPER/ 2DD 12A 1
WASHER 2DD LEFT RIGHT 38
20 26 B5
7 157 35 OUTRIGGER 60D OUTRIGGER 60B
SWITCH SWITCH 6
7 C1
10.0 7 8 7 8
39 8
STABILIZER 2A 1 2B 1 C2
UP 1 63 UP 1 61 41
11 2 2 A2
60C 60A 9
C3
10.0
STEER SELECT
46 DOWN 3 DOWN 3
SWITCH
64 62 61
62
15.0 63
HORN/HEATER 24
64
52 52 HEATER 2B
10.0 2E
INSTR. PANEL
42 2A
2 2D
22 114B 48 10 39
7.5 2F OUTRIGGER
LIGHT SWITCH 12 HARNESS
RELAY
3 30 30 20 2G
86 STABIL. 86 BOOM
LOCK SWITCH
27B 27C RELAY RELAY
40.0 15
27 27 27D 85 85 A1
MAIN 100 87A 87 87A 87 17
A2
3A 26 2CC 40A 2AA 48
26A 28 20
47
20 20
3A 153A A3
7.5
TRANSMISSION 27B 2CC 2AA 20 CAB
27A 2HH GROUND STUD
20.0 20 20 20 20 20
151
LIGHTS B4
27C
A4
42 1 2HH 27D
B5
8 7
3A 111
6
24A
2 PARK 153A 111
E BRAKE 102B 24
OPTION 1 SWITCH 107 153 113A
111
30
5 30 112A 111A 86
D 45A 86 PARK BACK-UP
4 BRAKE ALARM
42 30
152 152 DIS. 86 NEUTRAL RELAY
E 3 152 85
85
RELAY START 87A 87
42 87A 87 RELAY
2 113A 85 2BB 31
D 41
41 41 87A 87 31
1 113B A5
2EE 113
107 107 106 106
113 2FF B2
2EE 2BB
20 20
BRAKE 34
9 9 B1
PEDAL B+ 153
SWITCH 8 8
45A GEAR 150 104
C4
45B 46 7 7 103
45 1 2 GEAR 103 C3
45 6 6 102
GEAR 105 C2
5 5
GEAR 101
F 112A
1 4 4 105
2 NEUTRAL 112 112 114A C5
112 102B
3 N
3 3
4 REVERSE 102A 102A 102 101
R 102 C1
SHIFTER 2 2
B3
1 1
B+ 113
CAB
114B HARNESS
MALE
45 114A CONNECTOR
114
MA78411
9.62 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
10042 (13198 - 16782, w/o Lighting Package)

BATTERY
28 28B
47
47A
47
47B
+ -
ENGINE 28 28B 47B
HARNESS 28A BOOM
MALE 40 2K 2P 2N SENSOR BATTERY
CONNECTOR + - + - + -
GRND
+ -
+ - + - + - 27C
47
A3
27D 27 106
27 30 50
28 3 12B 4B 5
B3 M
BRN
STABIL-TRAK BLU
152
A1 BLK
4A 12A GND
STARTER
A B C
+ - + -
A B C
+ - + -
47A 2L 35 2T
28A
2M 10
18
B1
5
16
C5 34
38 B+ RED
A A
152
24A +
6 D+ WHT
B2 GND
+ -
+ -
BLK B B
8 2C (-) 2W 2S
158 - C C
A5
HORN + - 41A 2E ALTERNATOR FUEL
35 SHUTOFF
+ - AB SOLENOID
B4
4-WHEEL AB
10 + -
C4 + -
CRAB PB B
+ -
+ - STEER + -
PB A
38 SELECT
+ - SECONDARY
B5 VALVE AB
9 2B SOLENOIDS AB
FUNCTION
6 MANIFOLD
C1
8
41A 41B 2F SOLENOIDS
C2
41
41 41 41B
A2
9
C3
61
63 61 18
OUTRIGGER 62 + + LEFT RIGHT + +
HARNESS - - UP UP - -
63 2E 2G
TRANS. TEMP
64 OUTRIGGER VALVE SWITCH
SOLENOIDS
2E 64 62
+ + LEFT RIGHT + +
2D - - DOWN DOWN - -
16
2D 2F
2F
OIL PRESSURE
2G SWITCH
15 15
A1
17 2A 2B 2F 2E 2C 2M 2L 2N 2P 2K
A2
FUEL LEVEL WATER TEMP 2T
SENDER SWITCH 2W
20
20 2S
A3 20 20 20 20
2R
2D 2DD 2G 2H 2J 2X
151 151
B4
27C
A4
27D HYDR. OIL NOT
B5 TEMP SWITCH USED
B A
2X
49
23 -
2R BACK-UP
ALARM
+
C B A
31
NOT USED
31
A5
106
B2
34
B1 2J 7 7
104 104B Y1 Y3 Y2
C4 104 1 1
E E E
103 103B Y1 Y3 Y2
C3 103 3 3
102 102B 2 2
C2 102
UPPER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
105 105B 4
C5 105 4
101 101B
C1 101 5 5 Y6 Y5 Y4
150 150B E E E
B3 150 6 6
102A 103A 105A 2H Y6 Y5 Y4
ENGINE 7 7
2DD 101A 150A 104A 2D
HARNESS
FEMALE
F E B A A B E F
CONNECTOR 2G
LOWER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
TRANS.
MA78412
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.63

Electrical System

INSTRUMENT PANEL
TURN SIGNALS
HYD. OIL TEMP.
TRANS. TEMP.
WATER TEMP.
HOURMETER
FUEL GAUGE
STABIL-TRAK
ALTERNAT0R
PARK BRAKE
BACK LIGHT
(OPTIONAL)
(OPTIONAL)
(OPTIONAL)
ENGINE OIL
HIGH BEAM
ROADLIGHTS
GROUND
OPTION
POWER
CONNECTOR CAB
HIGH BEAM HARNESS
CONNECTOR
23 47
22 154 155 152A3 156 38 40B 16 17 A3
21C 152A2
ROAD/ 28
2GG 152A 151 18 6 15
For additional information OPTION
WORKLIGHT
OPTION
B3
152A1 40
on the 10042 Outrigger NOT 40
A1
12B 12AA USED

Circuit, refer to Section 3C
40B
40
12B 40A
9.7.42, “10042 Outrigger 21C 27A
12A
12A 26A 34 STEER
Circuit and 86
30
HEADLIGHT
A B C D E SELECT
SWITCH
A B C D E 2GG
Troubleshooting.” SWITCH
RELAY 20 7 8 11B
2JJ 1 18
85 B1
87A 87 1
S 11B D 8
2KK 23 19 P 2
R 11A 16
OPTION IGNITION
58 C5
O
S E 3
SWITCH P 9
R 24A
3B 15 B2
O
30
3A 12 29
S
158
P
HORN A5
R
7.5 BUTTON
OUTRIGGERS
50 60E 30 50
86 LIGHT
O 35
B4
51 OPTION SWITCH
RELAY A B C 10
85 C4
87A 87
10.0
32 WIPER/ 60
OPTION WASHER 2KK 60E
WIPER/ 2DD 12A 1
WASHER 2DD LEFT RIGHT 38
20 26 B5
7 157 35 OUTRIGGER 60D OUTRIGGER 60B
SWITCH SWITCH 6
7 C1
10.0 7 8 7 8
39 8
STABILIZER 2A 1 2B 1 C2
UP 1 63 UP 1 61 41A
11A 2 2 A2
60C 60A 9
C3
10.0
STEER SELECT
46 DOWN 3 DOWN 3
SWITCH
64 62 61
62
15.0 63
HORN/HEATER 24
64
52 52 HEATER 2B
10.0 2E
INSTR. PANEL
42A 2A
2 2D
22 114B 48 10 39
7.5 2F OUTRIGGER
LIGHT SWITCH 12 HARNESS
RELAY
3C 30 30 20 2G
86 STABIL. 86 BOOM
29
40.0 LOCK SWITCH
LIGHTS 2 27F 27C RELAY RELAY
40.0 15
27 27 27D 85 85 A1
MAIN 100 87A 87 87A 87 17
26B 27B A2
26 2CC 40A 2AA 48
26 26A 28 20
47
20 20
3A 153A A3
7.5
TRANSMISSION 27B 2CC 2AA 20 CAB
27A 2HH GROUND STUD
20.0 20 20 20 20 20
151
LIGHTS 1 B4
12C 27C
A4
27D
7 B5
1 2HH
42B 8
HAZARDS 111 24A
6
153A 111
ROADLIGHTS 102B 24
PARK 153 113A
CONNECTOR SWITCH 30
1 2 30 112A 111A 86
86 PARK BACK-UP
5 4
D 45A2 BRAKE 30 ALARM
DIS. 86 NEUTRAL RELAY
42B 152B1 152A1 RELAY 85
E
152B2 85 START 87A 87
3 152B 87A 87
113A RELAY
42A 85 2BB 31
2 41
87A 87 31
D
41B 41C 41A 113B A5
2EE 113
1 106 106
113 2FF B2
107A 107B
2EE 2BB
20 20
9 9
34
B1
BRAKE B+ 153
PEDAL 8 8
SWITCH GEAR 150 104
C4
45A2 7 7 103
45
GEAR 103 C3
45B 46 102
1 2 6 6
GEAR 105 C2
45
5 5
GEAR 101
F 112A
1 4 4 105
2 NEUTRAL 112 112 114A C5
112 102B
3 N
3 3
4 REVERSE 102A 102A 102 101
R 102 C1
SHIFTER 2 2
B3
1 1
B+ 113
CAB
114B HARNESS
MALE
45 114A CONNECTOR
114
MH42501
9.64 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
10042 (13198 - 16782, w/Light Package & 16783 -19030)
BATTERY
+ -
§
47 47B
47
47A
28 28B
ENGINE 28 28B 47B
HARNESS 28A BOOM
MALE 40 2K 2P 2N SENSOR BATTERY
CONNECTOR + - + - + -
GRND
+ -
+ - + - + - 27C
47
A3
27D 27 106
27 30 50
28 3 12B 4B 5
B3 M
BRN
STABIL-TRAK BLU
152
A1 BLK
4A 12A GND
STARTER
A B C
+ - + -
A B C
+ - + -
47A 2L 35 2T
28A
2M 10
18
B1
5
16
C5 34
38 B+ RED
A A
152
24A +
6 D+ WHT
B2 GND
+ -
+ -
BLK B B
8 2C (-) 2W 2S
158 - C C
A5
HORN + - 41A 2E ALTERNATOR FUEL
35 SHUTOFF
+ - AB SOLENOID
B4
4-WHEEL AB
10 + -
C4 + -
CRAB PB B
+ -
+ - STEER + -
PB A
38 SELECT
+ - SECONDARY
B5 VALVE AB
9 2B SOLENOIDS AB
FUNCTION
6 MANIFOLD
C1
8
41A 41B 2F SOLENOIDS
C2
41
41 41 41B
A2
9
C3
61
63 61 18
OUTRIGGER 62 + + LEFT RIGHT + +
63 2E 2G
TRANS. TEMP
64 OUTRIGGER VALVE SWITCH
SOLENOIDS
2E 64 62
+ + LEFT RIGHT + +
2D - - DOWN DOWN - -
16
2D 2F
2F
OIL PRESSURE
2G SWITCH
15 15
A1
17 2A 2B 2F 2E 2C 2M 2L 2N 2P 2K
A2
FUEL LEVEL WATER TEMP 2T
SENDER SWITCH 2W
20
20 2S
A3 20 20 20 20
2R
2D 2DD 2G 2H 2J 2X
151 151
B4
27C
A4
27D HYDR. OIL NOT
B5 TEMP SWITCH USED
B A
2X
49
23 -
2R BACK-UP
ALARM
+
C B A
31
NOT USED
31
A5
106
B2
34
B1 2J 7 7
104 104B Y1 Y3 Y2
C4 104 1 1
E E E
103 103B Y1 Y3 Y2
C3 103 3 3
102 102B 2 2
C2 102
UPPER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
105 105B 4
C5 105 4
101 101B
C1 101 5 5 Y6 Y5 Y4
150 150B E E E
B3 150 6 6
102A 103A 105A 2H Y6 Y5 Y4
ENGINE 7 7
2DD 101A 150A 104A 2D
HARNESS
FEMALE
F E B A A B E F
CONNECTOR 2G
LOWER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
TRANS.
MH42502
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.65

Electrical System
(SN 19031 - 19987 And 0160002332 & After)
9.75 16 BLK Splice 20 (Ground) to Fuel Level Sender (Engine Harness)
2A
9.74 16 BLK Splice 2 to Left Outrigger Switch Connector (Pin 7) (Outrigger Harness)
9.75 16 BLK Splice 20A (Ground) to Steer Select Valve Solenoid (4-Wheel) (Pin B) (Engine Harness)
2B
9.74 16 BLK Splice 2 to Right Outrigger Switch Connector (Pin 7) (Outrigger Harness)
2D 9.74 &
16 BLK Splice 2 to Outrigger Valve Solenoid (Left Down) (Pin 2) (Outrigger Harness)
9.75
2DD
Splice 20A (Ground)
9.75 18 BLK
to Secondary Function Manifold Park Brake Solenoid (PB A) (Pin B) (Engine Harness)
2E
9.74 &
16 BLK Splice 2 to Outrigger Valve Solenoid (Left Up) (Pin 2) (Outrigger Harness)
9.75
Splice 20A (Ground)
9.75 18 BLK
to Secondary Function Manifold Park Brake Solenoid (PB B) (Pin B) (Engine Harness)
2F
9.74 &
16 BLK Splice 2 to Outrigger Valve Solenoid (Right Down) (Pin 2) (Outrigger Harness)
9.75
9.75 16 BLK Splice 20 (Ground) to Transmission Ground (Engine Harness)
2G 9.74 &
16 BLK Splice 2 to Outrigger Valve Solenoid (Right Up) (Pin 2) (Outrigger Harness)
9.75
2R 9.75 16 BLK Not Used
3B 9.74 10 PUR Open Fuse to Female Option Connector
9.74 18 YEL
6
9.75 &
9.76
9.66 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

9.74 16 GRN/WHT
8
9.75 16 LT GRN/WHT
9.74 16 GRN/BLK
9
9.75 16 LT GRN/BLK
9.74 16 TAN
12B 9.74 12 DK BLU Splice 12A to Female Option Connector
9.74 18 LT BLU
9.74 18 BRN
9.74 18 GRY
9.74 18 GRN
20 9.75 12 BLK Cab/Chassis Female Connector (Pin A3) to Splice 20 (Ground) (Engine Harness)
9.74 14 BLK Splice 2 to Cab Ground Stud (Outrigger Harness)
20A
9.74 16 GRN
23 to Roadlights Female Connector (Option) (Main Beam) (Cab Harness)
9.75 16 ORG/GRN Not Used (Engine Harness)
9.74 14 ORG/GRN
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.67

Electrical System

27C
27D
9.74 16 PUR/WHT
9.74 16 ORG/RED
9.74 16 RED/BLK
34
9.75 16 RED/BLK
34A 16 RED/WHT
35
9.74 16 ORG
38
9.75 &
9.76
40
41 9.75 16 BLU/WHT Cab/Chassis Male Connector (Pin A2) to Splice 41
Female Connector
9.74 16 DK BLU/WHT
41A to Cab/Chassis Female Connector (Pin A2) (Cab Harness)
9.75 18 BLU/WHT Splice 41 to Secondary Function Manifold Park Brake Solenoid (PB A) (Pin A) (Engine Harness)
41B
9.75 18 BLU/WHT Splice 41 to Secondary Function Manifold Park Brake Solenoid (PB B) (Pin A) (Engine Harness)
9.74 16 ORG/WHT
49 9.75 16 RED/BLU Not Used
60A 9.74 16 YEL Splice 60 to Right Outrigger Switch Connector (Pin 2)
9.68 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

60B 9.74 16 YEL Splice 60 to Right Outrigger Switch Connector (Pin 8)
60C 9.74 16 YEL Splice 60 to Left Outrigger Switch Connector (Pin 2)
60D 9.74 16 YEL Splice 60 to Left Outrigger Switch Connector (Pin 8)
60E 9.74 16 YEL Splice 60 to Male Connector
9.74 &
61 16 RED/GRY Right Outrigger Switch Connector (Pin 1) to Outrigger Valve Solenoid (Right Up) (Pin 1)
9.75
9.74 &
9.75
9.74 &
63 16 BRN/YEL Left Outrigger Switch Connector (Pin 1) to Outrigger Valve Solenoid (Left Up) (Pin 1)
9.75
9.74 &
9.75
101
102
102A
102B
103
104
105
106 9.75 &
9.76
107A 9.74 18 BLU Park Brake Switch Connector (Pin 1) to Female Connector
150
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.69

Electrical System

9.74 16 YEL/GRN
152A2 9.74 16 BLK/WHT Not Used
152B 9.74 16 BLK/WHT Male Connector to Park Brake Switch Connector (Pin 3)
156 9.74 16 RED/WHT
157 9.74 16 BRN Jumper Wire (Wire 7 to Wire 35)
9.74 16 BLK Horn Button to Cab/Chassis Female Connector (Pin A5)
158
BP 9.76 16 RED/GRN
BPB 9.76 16 RED/WHT
BPC 9.76 16 RED/WHT
BPD 9.76 16 RED/WHT
BPM 9.76 14 RED/GRN
BPS 9.76 14 RED/GRN
9.70 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

DD 9.76 18 BLK
DI 9.76 18 BLK
DS 9.76 18 BLK
J87H 9.76 18 RED
J87L 9.76 18 BLK
ML 9.76 18 BLK
9.76 18 BLK
OFF1
9.76 18 ORG
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.71

Electrical System

9.76 18 BLK
ON1
9.76 18 VIO
PH1 9.76 18 BLU
RTS 9.76 18 BLK
SL 9.76 18 BLK
SL1 9.76 18 GRN
9.76 18 BLK
SWR
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 9.76 18 BLK
9.72 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.73

Electrical System

(SN 19031 - 19987 And 0160002332 & After)
INSTRUMENT PANEL
TURN SIGNALS
HYD. OIL TEMP.
TRANS. TEMP.
WATER TEMP.
HOURMETER
FUEL GAUGE
STABIL-TRAK
ALTERNAT0R
PARK BRAKE
BACK LIGHT
(OPTIONAL)
(OPTIONAL)
(OPTIONAL)
ENGINE OIL
HIGH BEAM
ROADLIGHTS
GROUND
OPTION
POWER
CONNECTOR CAB
HIGH BEAM HARNESS
CONNECTOR
23 47
22 154 155 152A3 156 38 40B 16 17 A3
21C 152A2
ROAD/ 28
2GG 152A 151 18 6 15 B3
WORKLIGHT
A1
NOT 40
12B 12AA USED
40B
40
12B 3C 40A
12A
STEER
21C 27A 12A 26A 34 SELECT
A B C D E SWITCH
30 2GG
86 HEADLIGHT A B C D E 11B
20A 7 8
SWITCH 2JJ 1
85 RELAY 18
87A 87 1 B1
11B D 8
S 2
2KK 23 19 P 11A
R 16
OPTION IGNITION
58 E 3 C5
O
S
9
SWITCH P
R 24A
15 B2
3B O
30 S
3A 12 29 P CAB 158 158
HORN A5
7.5 R GROUND
OUTRIGGERS
50 60E 86
30 LIGHT 50
STUD BUTTON
O 35
SWITCH B4
51 OPTION 85 RELAY
A B C
87A 87 10
2MM C4
10.0
32 WIPER/ 2KK 20A
OPTION WASHER 2DD 12A 1 20A 20A
20A 60 A4
WIPER/ 2DD 60E
WASHER 20 38
26 B5
7 157 35 LEFT RIGHT
OUTRIGGER 60D OUTRIGGER 60B 6
7 C1
10.0
39 SWITCH SWITCH 8
STABILIZER C2
7 8 7 8
2A 1 2B 1 41A
11A A2
UP 1 63 UP 1 61 9
2 2
C3
10.0 60C 60A
STEER SELECT
46
SWITCH DOWN 3 DOWN 3
61
64 62 62
15.0 63
HORN/HEATER 24
64
52 52 HEATER
10.0 2E
INSTR. PANEL
42A 2B
2A 2D
22 2
7.5 2F OUTRIGGER
LIGHT SWITCH 12 114B 48 10 39 HARNESS
RELAY
3C 20 2G
29 30 30
LIGHTS 2 27F 27C LOCK SWITCH CAB
40.0 RELAY RELAY 15
85 85 GROUND A1
MAIN
27 27 27D 87A 87 87A 87
27B 100 STUD 17
26B A2
26 40A 28
26
48
26A 2CC 47 2AA
20
3A 153A CAB A3
7.5 20
TRANSMISSION 27B 2LL GROUND
20 20
STUD
27A 2FF
20.0 2HH 151
LIGHTS 1 20A B4
12C 27C
A4
27D
7 B5
1 2HH
42B 8
HAZARDS 111 24A
6
153A 153 111
ROADLIGHTS 102B 24
PARK 113A
CONNECTOR SWITCH 30
1 2 30 PARK 112A 111A 86 BACK-UP
86
5
D 4 BRAKE ALARM
45A2 DIS. 30 85 RELAY
85 86 NEUTRAL 87A 87
42B 152A1 87A 87 RELAY START
152B
E 3 85 RELAY
113A 87A 87
42A 2EE 113B 2BB 31
2 31
D A5
41B 41A 113 2FF
1 106 106
113 B2
107A 107B
2EE 2BB
20A
9 9
34
B1
BRAKE B+ 153
PEDAL 8 8
SWITCH GEAR 150 104
C4
45A2 7 7 103
45
GEAR 103 C3
45B 46 102
1 2 6 6
GEAR 105 C2
45
5 5
GEAR 101
F 112A
1 4 4 105
2 NEUTRAL 112 112 114A C5
112 102B
3 N
3 3
4 REVERSE 102A 102A 102 101
R 102 C1
SHIFTER 2 2
B3
1 1
B+ 113
CAB
114B HARNESS
MALE
45 114A CONNECTOR
114
MH47801
9.74 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
10042 (19031 & After)
47 47B
47
47A
28 28B
28 +
ENGINE 28B 47B
HARNESS 28A BOOM
GND (-)
2K 2P 2N 106
MALE 40 SENSOR
CONNECTOR A B A B A B
+ -
AB AB AB 27D
47
A3
AB2 27C
28 AB1 STARTER
3 12B 4B
B3
STABIL-TRAK BRN
BLU 38 See
A1
4A 12A
BLK 6 D+ B+
GND (-)
AG1 Page 9.76
AG2
A B C W
AB AB
A B C ALTERNATOR
A B A B
47A 2L 35 2T
28A
2M 10
18
B1
16
C5
24A + 8 2C
B2 B B
A A A B
41A
158 -
A5 SECONDARY 2E
HORN AB
FUNCTION AB
35 4-WHEEL MANIFOLD
B4 + - SOLENOIDS AB
+ -
CRAB
10 PB B
C4 + -
A B STEER + -
20A AB
SELECT PB A
A4 VALVE
AB
38 9 2B SOLENOIDS
B5 AB
6 18
41B 2E
C1 20A
20A 41A
8 2C
C2
41 TRANS. TEMP
41 41 41B 2F SWITCH
A2
9 20B
C3 20A
61
63 61 P9
OUTRIGGER 62 1 1 LEFT RIGHT 1 1
IGNITION
HARNESS 2 2 UP UP 2 2 SWITCH
63 2E 2G
FUSE
64 OUTRIGGER VALVE
2E 64
SOLENOIDS
62 7.5 F
34A See Page 9.76
1 1 LEFT RIGHT 1 1 34
2D 2 2 DOWN DOWN 2 2
16 E
2D 2F
2F D
OIL PRESSURE
2G SWITCH C
B
15 15 A
A1
17 2A 2M 2N 2K
A2
FUEL LEVEL 2L 2P WATER TEMP
2A SWITCH
SENDER 2T
20
20 20 20D
A3 20 20D
20B 20C
2DD 20E 20B
2D 2G 2H 2J 2R
151 151 2X
B4
27C
A4
27D HYDR. OIL NOT
B5 TEMP SWITCH USED
B A
2X
49
23 -
2R BACK-UP
ALARM
C B A +
31
NOT USED
31
A5
106
B2
34
B1 2J 7 7
104 104B Y1 Y3 Y2
C4 104 1 1
E E E
103 103B Y1 Y3 Y2
C3 103 3 3
102 102B 2 2
C2 102
UPPER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
105 105B 4
C5 105 4
101 101B
C1 101 5 5 Y6 Y5 Y4
150 150B E E E
B3 150 6 6
102A 103A 105A 2D 2H 7 7 Y6 Y5 Y4

ENGINE
HARNESS 2DD 101A 150A 104A
FEMALE
F C B A A B C F
CONNECTOR 2G
LOWER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
TRANS. 20E 20C

VP1 VP2
MH47802
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.75

Electrical System

+
106 BPB1
GND (-)
See Page 9.75 38
+
BPC1
6 BATTERY BPD1
1
BPM1
OPEN AB2 BPS1
-
6
51 AB1 BLOCK
OPTION
CNS4
ENGINE G J87L
GND (-)
+
E AG2
WASHER
D CNL2 W BATTERY
5 BNE
C CNH2 2
CNL3 ALTERNATOR
BNF
10.0 CNL4 B BP
A BN
B
C
CNL
CNS
CNL
2
CNL1
P7
DIAGNOSTIC
P8
RESISTOR
FEMALE
BNP
BNW
-
10.0 P3 CNH PLUG
CNH2 CONNECTOR
SWITCH
1 4
125
15.0 Fuse
ENGINE
A CNH1 CONTROL
MODULE FRAME
10.0 B CNL1 GROUND
INSTR. PANEL FUSES
C CNS1
BP
7.5 P4 10 F
LIGHT SWITCH BP1
RELAY RESISTOR E
FEMALE D
BPS
10
CONNECTOR BPS1
C
See Page 9.74 10 B
BPM
BNW W
A
BPM1
BPS S
BNP P
P5 BPM M
CAB DLP ENGINE
GROUND BNH H
CONTROL
6
FUSES BNE E
DLP1
CG1 BPD BPD D
7.5 F
DLP2
1B- 2B- E
BPD1 BPC C
PREHEAT P15 7.5 D
1
INDICATOR ENGINE C
BPC1 34A A
LIGHT
1 2 FUNCTION BPB
INDICATOR 7.5 B P1
1A+ 2A+ BPB1
LIGHT A ENGINE
1B- 2B-
CONTROL
PH1 MODULE
WL1
23 PIN FEMALE
SL1
See Page 9.75 34A
CONNECTOR
PH1 P P PH1A
O O RTS
N N DD
M M DI
L L DS J87L 50
1
2
3
G G WSL DS 37
P16
IDLE F F ML DD 36
SWITCH
SL1 D D SL GH2 31
THS1 C C THS THS 30
A A THG1 OFF1 25
ECM ECM
P14
WSL 11
ML 4
WL 3
SL 1
ENGINE GRID
HEATER RELAY 2 P2
GH4 GH4 ENGINE
F
1 2
CONTROL
MODULE
E 50 PIN FEMALE
PH1A GH2B CONNECTOR
3
B
GH3
A 4
ENGINE COMPARTMENT
P11 GHG2
DIODE PACK
GH1
125
GH1B Amp
Fuse
VEHICLE CAB
GH1A GH1A GH2B

A
GH2A GH2A GH2
B 9
GHG2
C
GHG GHG GHG3
F 7
GH3
1 2
ENGINE GRID
HEATER 3 AG2
ENGINE 2 4
BLOCK 1
AG1
GHG1

MH4740
9.76 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
9.7.18 10054 Cab Harness & Engine Harness Electrical Schematic Legend
(SN 13198 Through 19079)
9.84 or
9.86
9.85 or
2A 18 BLK Splice 20 (Ground) to Fuel Level Sender
9.87
9.84 or
9.86
9.85 or
2B 16 BLK Splice 20 (Ground) to Steer Select Valve Solenoid (4-Wheel) (–)
9.87
9.84 or
9.86
9.85 or
9.87
9.84 or
9.86
9.85 or
2D 16 BLK Splice 20 (Ground) to Diode VESPAK (Pin F)
9.87
9.84 or
9.86
2DD
9.85 or
9.87
9.85 or
2E 16 BLK Not Used
9.87
9.85 or
9.87
9.85 or
2F 16 BLK Not Used
9.87
9.84 or
9.86
9.85 or
2G 16 BLK Splice 20 (Ground) to Transmission Ground
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
9.85 or
9.87
9.84 or
9.86
9.85 or
9.87
9.85 or
9.87
9.85 or
9.87
9.85 or
9.87
9.85 or
2R 18 BLK Splice 20 (Ground) to Boom Extend Harness Male Connector (Pin C)
9.87
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.77

Electrical System

9.85 or
9.87
9.85 or
9.87
9.85 or
9.87
9.85 or
9.87
3A 10 PUR
3B 9.86 10 PUR § Open Fuse to Female Connector
9.85 or
9.87
18 YEL
6
9.85 or
9.87
9.84 or
7 16 BRN Stabilizer Fuse to Female Connector
9.86
16 GRN/WHT
8
16 LT GRN/WHT
16 GRN/BLK
9
16 LT GRN/BLK
16 TAN
10
9.85 or
9.87
11 9.84 16 LT GRN/BLU †
9.84 or
9.86
12A 12 DK BLU
12B 12 DK BLU
12C 16 DK BLU
18 LT BLU
15
9.85 or
9.87
18 BRN
16
9.85 or
9.87
9.78 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

18 GRY
17
9.85 or
9.87
18 GRN
18
9.85 or
9.87
9.84 or 14 BLK Splice 20 (Ground) to Cab Ground Stud (Cab Harness)
20
9.85 or
9.87
9.84 or
9.86
9.84 or
9.86
16 GRN
23
9.85 or Logic Harness Female Connector (Pin B)
16 ORG/GRN
9.87 to Boom Extend Harness Male Connector (Pin B) (Engine Harness)
9.84 or
9.86
14 ORG/GRN
24A
9.85 or
9.87
26 10 RED
26A 10 RED
9.84 or
9.86
27
9.85 or
9.87
27A 12 RED
9.86 § Optional Lights Fuse (Lights 1) to Splice 27 to Headlight Switch Relay (Pin 30)
27B 12 RED
9.84 or
9.86
27C
9.85 or
9.87
9.84 or
9.86
27D
9.85 or
9.87
16 PUR/WHT
28
9.85 or
9.87
9.85 or
9.87
9.85 or
9.87
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.79

Electrical System

16 ORG/RED
31
9.85 or
9.87
9.84 or
9.86
16 RED/BLK
34
16 RED/BLK
9.84 or
16 BRN/WHT Female Connector to Cab/Chassis Female Connector (Pin B4) (Cab Harness)
9.86
35
9.85 or
9.87
16 ORG
38
9.85 or
9.87
9.84 or
9.86
9.84 or
9.86
40
9.85 or
9.87
9.84 or
9.86
9.84 or
9.86
9.84 DK BLU/WHT † to Male Connector (Cab Harness)
41 16 Not Used (Cab Harness)
9.85 or
BLU/WHT Not Used (Engine Harness)
9.87
9.86 DK BLU/WHT § Not Used (Cab Harness)
41A 9.85 or 16
9.87
41B 9.85 or 16
9.87
42 9.84 18 TAN †
9.84 or
9.86
9.84 or
9.86
9.84 or
9.86
9.80 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

16 ORG/WHT
47
9.85 or
9.87
9.85 or
9.87
9.85 or
9.87
9.84 or
9.86
9.85 or
49 16 RED/BLU Logic Harness Female Connector (Pin A) to Boom Extend Harness Male Connector (Pin A)
9.87
9.84 or
50 16 WHT/YEL Option Fuse to Option Connector
9.86
9.84 or
9.86
9.84 or
9.86
9.84 or
9.86
101
9.85 or
9.87
9.85 or
9.87
9.85 or
9.87
9.84 or
9.86
102
9.85 or
9.87
9.84 or
9.86
102A
9.85 or
9.87
9.84 or
9.86
102B
9.85 or
9.87
9.84 or
9.86
103
9.85 or
9.87
9.85 or
9.87
9.85 or
9.87
9.84 or
9.86
104
9.85 or
9.87
9.85 or
9.87
9.85 or
9.87
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.81

Electrical System

9.84 or
9.86
105
9.85 or
9.87
9.85 or
9.87
9.85 or
9.87
9.84 or
9.86
106
9.85 or
9.87
Not Used
107 9.84 18 BLU †
107A 9.86 18 BLU § Not Used
9.84 or
9.86
9.84 or
9.86
9.84 or
9.86
9.84 or
9.86
9.84 or
9.86
9.84 or
9.86
9.84 or
9.86
9.84 or
9.86
9.84 or
9.86
9.84 or
9.86
150
9.85 or
9.87
9.85 or
9.87
9.85 or
9.87
16 YEL/GRN
151
9.85 or
9.87
9.84 or to Male Connector (Cab Harness)
16 BLK/WHT †
9.86 Female Connector to Inline Diode
152
to Instrument Panel Connector (Pin J7) (Cab Harness)
9.85 or
9.87
152A 9.84 16 BLK/WHT † Instrument Panel Connector (Pin J7) to Inline Diode to Female Connector
152A2 9.86 16 BLK/WHT § Splice 152A to Inline Diode to Female Connector
9.82 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

9.84 or
9.86
9.84 or
9.86
9.84 or
9.86
9.84 or
9.86
156 16 RED/WHT
9.84 or
9.86
158
9.85 or
9.87
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.83

Electrical System

(SN 13198 Through 16782, Without Lighting Package)
INSTRUMENT PANEL
TURN SIGNALS
HYD. OIL TEMP.
TRANS. TEMP.
WATER TEMP.
HOURMETER
FUEL GAUGE
STABIL-TRAK
ALTERNAT0R
PARK BRAKE
BACK LIGHT
(OPTIONAL)
(OPTIONAL)
(OPTIONAL)
ENGINE OIL
HIGH BEAM
ROADLIGHTS
GROUND
OPTION CAB
POWER
CONNECTORS HARNESS
FEMALE
HAZARDS HIGH BEAM
J1 J5 J14 J15 J7 J2 J10 J3 J12 J11 J8 J9 J6 J4
CONNECTOR
23 47
12C 22 154 155 152 156 38 40B 16 17 A3
152A
21C
ROAD/ 28
2GG 151 18 6 15 B3
WORKLIGHT
OPTION
40
A1
40
12A H 40B
40
12B 3 40A
12A
21C 12B 12A 26A 34 STEER
A B C D E SELECT
30 SWITCH
86 HEADLIGHT A B C D E 2GG
SWITCH 20 7 8
85 RELAY 2JJ 1 11 18
87A 87 B1
1
S 11 D 8
2KK 23 19 P 2
R
58
11 16
C5
IGNITION O
E 3
S
27 SWITCH P 9
27A R 24A
15 B2
O
3A 27A 30 S
158
12 P A5
R
HORN
7.5 BUTTON
OPEN
50 OPTION 86
30 LIGHT 50
O 35
SWITCH B4
51 OPTION 85 RELAY
87A 87 A B C 10
C4
10.0
32 WIPER/ 2KK
OPTION WASHER 2DD 12A 38
WIPER/ 1 B5
WASHER
2DD
20 26 6
7
7 E 35
C1
10.0
STABILIZER 39 8
C2
41
11 A2
10.0 114B 48 10 39 9
STEER SELECT
46 C3
SWITCH 30 30
86 STABIL. 86 BOOM
LOCK SWITCH
15.0
24 85 RELAY 85 RELAY
HORN/HEATER 87A 87 87A 87
52 52 HEATER 2CC 40A 2AA 48

10.0
42 28
INSTR. PANEL 47
22
7.5
LIGHT SWITCH 12
RELAY
3 153
153A
107
27B 27C 15
30 PARK A1
40.0 86
MAIN
27 27 27D BRAKE
100 17
DIS. A2
3A 26 85
87A 87 RELAY
26A
113B 20 20
3A 153A 2EE 2AA
A3
7.5 2CC 20
TRANSMISSION 27B CAB
27A 20 20 20 20 20 20 GROUND STUD
20.0 2HH 151
LIGHTS 113 113A B4
113
27C
A4
42 1 2HH 27D
B5
8 7
3A 111
PARK 6
BRAKE 24A
SWITCH E 2 102B 24
111
D 1
5
D 113A 30
4
45A 111 86 BACK-UP
112A ALARM
42
E 3 152
152 A 152 111A
85
87A 87
RELAY
42 NOT USED 41 86
30
NEUTRAL
2 2BB 31
START
D
1
41
41 B 85
87A 87
RELAY
107 NOT USED 31
A5
2FF 106 106
C 107
20 20
2BB
B2
34
BRAKE 9 9 B1
B+ 153
PEDAL
SWITCH 8 8
GEAR 150
45A 104
C4
7 7
45B 46 GEAR 103 103
45 1 2 C3
45 6 6 102
GEAR 105 C2
5 5
GEAR 101
F 112A
1 4 4 105
2 NEUTRAL 112 112 114A C5
112 102B
3 N
3 3
4 REVERSE 102A 102A 102 101
R 102 C1
SHIFTER 2 2
B3
1 1
B+ 113
CAB
114B HARNESS
MALE
45 114A CONNECTOR
114
= See Page 9.92
MA78211
9.84 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
10054 (13198 - 16782, w/o Lighting Package)
BATTERY
+ -

47 47B
47
ENGINE 47A
28 28B
HARNESS 28 28B 47B
MALE 28A BOOM
CONNECTOR 40 2K 2P 2N SENSOR BATTERY
+ - + - + -
+ -
GRND
+ - + - + - 27C
47
A3
27D 27 106
27 30 50
28 3 12B 4B 5
B3 M
BRN
STABIL-TRAK BLU
152
A1 BLK
4A 12A GND
STARTER
A B C
+ - + -
A B C
+ - + -
47A 2L 35 2T
28A
2M 10
18
B1
16 5
C5
38 B+
24A +
6 D+
B2 GND
+ -
+ -
8 2C (-) 2W
158 -
A5
HORN + - ALTERNATOR
35 + -
B4 NOT USED
4-WHEEL
10 + -
C4 + -
CRAB AB AB
38 + - STEER 41B 2F
B5
SELECT 41A 2E 18
6 + -
VALVE
C1
9 2B SOLENOIDS
TRANS. TEMP
SWITCH
8
C2
41
41 41
A2
9 34
C3
RED
A A
152
WHT
BLK B B
16 C C
2S
FUEL
OIL PRESSURE SHUTOFF
SWITCH SOLENOID
15 15
A1
17 2A 2B 2E 2F 2C 2M 2L 2N 2P 2K
A2 WATER TEMP 2T
FUEL LEVEL SWITCH
SENDER 2A 2W
20 2S
A3 20 20 20 20
2DD 2R
2D 2G 2H 2J 2X
151 151
B4
27C
A4
27D HYDR. OIL
B5 TEMP SWITCH
F
B A
49
23 2X
2R
-
C B A BACK-UP
ALARM
+
G 31
31
A5
106
B2
34
B1
2J 7 7
104 104B Y1 Y3 Y2
C4 104 1 1
E E E
103 103B Y1 Y3 Y2
C3 103 3 3
102 102B 2 2
C2 102
UPPER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
105 105B 4
C5 105 4
101 101B
C1 101 5 5 Y6 Y5 Y4
150 150B E E E
B3 150 6 6
102A 103A 105A 2H 7 7 Y6 Y5 Y4
ENGINE 2DD 101A 150A 104A 2D
HARNESS 2G
FEMALE F E B A A B E F
CONNECTOR LOWER
TRANSMISSION COILS
(VIEWED FROM
TRANS.
= See Page 9.92 FRONT OF VEHICLE)
GRND
DIODE PACK DIODE PACK
MA78212
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.85

Electrical System

INSTRUMENT PANEL
TURN SIGNALS
HYD. OIL TEMP.
TRANS. TEMP.
WATER TEMP.
HOURMETER
FUEL GAUGE
STABIL-TRAK
ALTERNAT0R
PARK BRAKE
BACK LIGHT
(OPTIONAL)
(OPTIONAL)
(OPTIONAL)
ENGINE OIL
HIGH BEAM
ROADLIGHTS
GROUND
OPTION CAB
POWER
CONNECTOR HARNESS
FEMALE
HIGH BEAM
J1 J5 J14 J15 J7 J2 J10 J3 J12 J11 J8 J9 J6 J4
CONNECTOR
23 47
22 154 155 152A3 156 38 40B 16 17 A3
21C 152A2
ROAD/ 28
2GG 152A 151 18 6 15 B3
WORKLIGHT
A1
40
12B 12AA H 40B
40
12B 3C 40A
12A
12A 26A 34 STEER
21C 27A
A B C D E SELECT
30 SWITCH
SWITCH 20 7 8 11B
85 RELAY 2JJ 1 18
87A 87 B1
1
S 11B D 8
2KK 2
D 23 19 P
R
58
11A 16
C5
IGNITION O
E 3
S
SWITCH P 9
R 24A
3B 15 B2
O
30
3A 12 29
S
158
P
HORN A5
R
7.5 BUTTON
OPEN
50 OPTION 86
30 LIGHT 50
O 35
SWITCH B4
51 OPTION 85 RELAY
87A 87 A B C 10
C4
10.0
32 WIPER/ 2KK
OPTION WASHER 2DD 12A 38
WIPER/ 1 B5
WASHER
2DD
20 26 6
7
7 E 35
C1
10.0
STABILIZER 39 8
C2
41A
11A A2
10.0 114B 48 10 39 9
STEER SELECT
46 C3
SWITCH 30 30
86 STABIL. 86 BOOM
LOCK SWITCH
15.0
52 52 HEATER 2CC 40A 2AA

10.0
42A 48 28
INSTR. PANEL 47
22
7.5
LIGHT SWITCH 12
RELAY
3C 153
153A
29 107B
40.0
LIGHTS 2 27F 27C 15
30 PARK A1
40.0 86
MAIN
27 27 27D BRAKE
27B 100 17
26B DIS. A2
26 85
87A 87 RELAY
26 26A
113B 20 20
3A 153A 2EE 2AA
A3
7.5 2CC 20
TRANSMISSION 27B CAB
27A 20 20 20 20 20 20 GROUND STUD
20.0 2HH 151
LIGHTS 1 113 113A B4
113
12C 27C
A4
7
1 2HH 27D
B5
42B 8
111
6
HAZARDS 24A
PARK
OPTION SWITCH 111
CONNECTOR 1 2
5
D 4 113A 30
45A2 111 86 BACK-UP
112A ALARM
42B
E 3
152B2
152B
152B1 A 152A1 111A
85
87A 87
RELAY
42A NOT USED 41A 30
86 NEUTRAL
2 START 2BB 31
D
1
41B
41
41C B 85
87A 87
RELAY
107A NOT USED 31
A5
2FF 106 106
C 107B
2BB
B2
20 20
34
BRAKE 9 9 B1
B+ 153
PEDAL
SWITCH 8 8
GEAR 150
45A2 104
C4
7 7
45B 46 GEAR 103 103
45 1 2 C3
45 6 6 102
GEAR 105 C2
5 5
GEAR 101
F 112A 105
1 4 4 C5
2 NEUTRAL 112 112 114A
112 102B
3 N
3 3 101
4 REVERSE 102A 102A 102 C1
R 102
SHIFTER 2 2 150
ZF TRANSMISSION FORWARD 104 B3
1 1
B+ 113
CAB
114B HARNESS
MALE
45 114A CONNECTOR
114
= See Page 9.93 or 9.94.

MH43601
9.86 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
10054 (13198 - 16782, w/Light Package & 16783 -19079)
BATTERY
+ -
§
47 47B
47
ENGINE 47A
28 28B
HARNESS 28 28B 47B
MALE 28A BOOM
CONNECTOR 40 2K 2P 2N SENSOR BATTERY
+ - + - + -
+ -
GRND
+ - + - + - 27C
47
A3
27D 27 106
27 30 50
28 3 12B 4B 5
B3 M
BRN
STABIL-TRAK BLU
152
A1 BLK
4A 12A GND
STARTER
A B C
+ - + -
A B C
+ - + -
47A 2L 35 2T
28A
2M 10
18
B1
16 5
C5
38 B+
24A +
6 D+
B2 GND
+ -
+ -
8 2C (-) 2W
158 -
A5
HORN + - ALTERNATOR
35 + -
B4 NOT USED
4-WHEEL
10 + -
C4 + -
CRAB AB AB
38 + - STEER 41B 2F
B5
SELECT 41A 2E 18
6 + -
VALVE
C1
9 2B SOLENOIDS
TRANS. TEMP
SWITCH
8
C2
41
41 41
A2
9 34
C3
RED
A A
152
WHT
BLK B B
16 C C
2S
FUEL
OIL PRESSURE SHUTOFF
SWITCH SOLENOID
15 15
A1
17 2A 2B 2E 2F 2C 2M 2L 2N 2P 2K
A2 WATER TEMP 2T
FUEL LEVEL SWITCH
SENDER 2A 2W
20 2S
A3 20 20 20 20
2DD 2R
2D 2G 2H 2J 2X
151 151
B4
27C
A4
27D HYDR. OIL
B5 TEMP SWITCH
F
B A
49
23 2X
2R
-
C B A BACK-UP
ALARM
+
G 31
31
A5
106
B2
34
B1
2J 7 7
104 104B Y1 Y3 Y2
C4 104 1 1
E E E
103 103B Y1 Y3 Y2
C3 103 3 3
102 102B 2 2
C2 102
UPPER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
105 105B 4
C5 105 4
101 101B
C1 101 5 5 Y6 Y5 Y4
150 150B E E E
B3 150 6 6
102A 103A 105A 2D 2H 7 7 Y6 Y5 Y4
ENGINE 2DD 101A 150A 104A
HARNESS F E B A A B E F 2G
FEMALE
CONNECTOR LOWER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
TRANS.
DIODE PACK DIODE PACK GRND = See Page 9.93 or 9.94.
MH43602
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.87

Electrical System
(SN 13198 Through 19079)
9.92,
2 9.93 or 14 BLK Splice 2A to Cab Ground Stud
9.94
9.92,
2A1 9.93 or 16 BLK Left Outrigger Lock Relay (Pin 85) to Right Outrigger Lock Relay (Pin 85)
9.94
9.92,
2A2 9.93 or 16 BLK Right Outrigger Lock Relay (Pin 85) to Boom Extend Interlock Relay (Pin 85)
9.94
9.92,
2A3 9.93 or 16 BLK Splice 2A to Left Outrigger Lock Relay (Pin 85)
9.94
9.92 or
2B1 16 BLK ‡ Outrigger Lockout Relay (Pin 85) to Boom Extend Lockout Relay (Pin 85)
9.93
9.92,
2B2 9.93 or 16 BLK Boom Extend Lockout Relay (Pin 85) to Park Brake Interlock Relay (Pin 85)
9.94
9.92 or
16 BLK ‡ Splice 2A to Outrigger Lockout Relay (Pin 85)
2B3 9.93
9.94 16 BLK ~ Splice 2A to Boom Extend Lockout Relay (Pin 85)
9.92,
2C1 9.93 or 16 BLK Stabil-TRAK Interlock Relay (Pin 85) to Stabil-TRAK Lock Up Relay (Pin 85)
9.94
9.92,
2C2 9.93 or 16 BLK Splice 2A to Stabil-TRAK Interlock Relay (Pin 85)
9.94
9.92,
2D 9.93 or 16 BLK Splice 2B to Outrigger Valve Solenoid (Left Down) (Pin 2)
9.94
9.92,
2E 9.93 or 16 BLK Splice 2B to Outrigger Valve Solenoid (Left Up) (Pin 2)
9.94
9.92,
2F 9.93 or 16 BLK Splice 2B to Outrigger Valve Solenoid (Right Down) (Pin 2)
9.94
9.92,
2G 9.93 or 16 BLK Splice 2B to Outrigger Valve Solenoid (Right Up) (Pin 2)
9.94
9.92,
2H 9.93 or 16 BLK Splice 2B to Boom Extend Solenoid Connector (Pin B)
9.94
9.92,
2J 9.93 or 14 BLK Splice 2B to Cab Ground Stud
9.94
9.92,
2K1 9.93 or 16 BLK Splice 2B to Secondary Function Manifold Park Brake Solenoid (PB B) (Pin B)
9.94
9.92,
2K2 9.93 or 16 BLK Splice 2B to Secondary Function Manifold Park Brake Solenoid (PB A) (Pin B)
9.94
9.92,
2L1 9.93 or 16 BLK Splice 2A to Right Outrigger Switch (Pin 7)
9.94
‡ SN 13198 through 17984
~ SN 17985 through 19079
9.88 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

9.92,
2L2 9.93 or 16 BLK Splice 2A to Left Outrigger Switch (Pin 7)
9.94
9.92,
3 9.93 or 14 RED Male Connector at Open Fuse (Cab Harness, Wire 3B) to Splice 3
9.94
9.92,
3A 9.93 or 14 RED Splice 3 to Outrigger Switches/Boom Sensor Fuse
9.94
9.92,
3B 9.93 or 14 RED Splice 3 to Outrigger Cylinders Fuse
9.94
9.92,
3C 9.93 or 14 RED Splice 3 to Female Connector (Option)
9.94
9.92,
7 9.93 or 16 TAN Stabil-TRAK Lock Up Relay (Pin 30) to Male Connector at Stabilizer Fuse
9.94
9.92,
23 9.93 or 16 ORG/GRN Boom Extend Interlock Relay (Pin 86) to Engine Harness Male Connector (Pin B)
9.94
9.92,
Stabil-TRAK Lock Up Relay (Pin 87A)
35 9.93 or 16 BRN/GRN
to Male Connector at Stabilizer Fuse (Cab Harness, Wire 35)
9.94
9.92,
Stabil-TRAK Lock Up Relay (Pin 87)
45A 9.93 or 16 DK BLU/ORG
to Male Connector at Park Brake Switch (Cab Harness, Wire 152A1)
9.94
9.92,
Female Connector at Park Brake Switch (Cab Harness, Wire 152B1)
45B 9.93 or 16 DK BLU/ORG
9.94
9.92,
49 9.93 or 16 RED/BLU Outrigger Switches/Boom Sensor Fuse to Engine Harness Male Connector (Pin A)
9.94
9.92 or
50A 16 RED/WHT ‡ Boom Extend Lockout Relay (Pin 87A) to Outrigger Lockout Relay (Pin 30)
9.93
9.92 or
16 RED/WHT ‡ Outrigger Lockout Relay (Pin 30) to Stabil-TRAK Interlock Relay (Pin 86)
50B 9.93
9.94 16 RED/WHT ~ Boom Extend Lockout Relay (Pin 87A) to Stabil-TRAK Interlock Relay (Pin 86)
9.92,
Right Outrigger Cylinder Pressure Switch Connector (Pin A)
50C 9.93 or 16 RED/WHT
to Boom Extend Lockout Relay (Pin 87A)
9.94
9.92,
51A 9.93 or 16 BLU/WHITE Park Brake Interlock Relay (Pin 87A) to Splice 51
9.94
9.92,
51B 9.93 or 16 BLU/WHITE Splice 51 to Female Connector at Park Brake Switch (Cab Harness, Wire 107B)
9.94
9.92,
51C 9.93 or 16 BLU/WHITE Splice 51 to Secondary Function Manifold Park Brake Solenoid (PB B) (Pin A)
9.94
9.92,
51D 9.93 or 16 BLU/WHITE Splice 51 to Secondary Function Manifold Park Brake Solenoid (PB A) (Pin A)
9.94
9.92,
Park Brake Interlock Relay (Pin 30)
52 9.93 or 16 DK BLU/RED
to Female Connector at Park Brake Switch (Cab Harness, Wire 41C)
9.94
‡ SN 13198 through 17984
~ SN 17985 through 19079
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.89

Electrical System

9.92,
55 9.93 or 16 ORG/RED Boom Extend Lockout Relay (Pin 87) to Splice 56
9.94
9.92,
56 9.93 or 16 GRY/BLU Splice 56 to Left Outrigger Cylinder Pressure Switch Connector (Pin A)
9.94
9.92,
56A 9.93 or 16 GRY/BLU Splice 56 to Outrigger Cylinder Fuse
9.94
9.92,
Right Outrigger Cylinder Pressure Switch Connector (Pin B)
57 9.93 or 16 GRY/ORG
to Left Outrigger Cylinder Pressure Switch Connector (Pin B)
9.94
9.92,
58 9.93 or 16 GRN Boom Extend Lockout Relay (Pin 30) to Boom Extend Solenoid Connector (Pin A)
9.94
9.92 or
59A 16 BRN ‡ Outrigger Lockout Relay (Pin 87A) to Right Outrigger Lock Relay (Pin 86)
9.93
9.92 or
59B 16 BRN ‡ Right Outrigger Lock Relay (Pin 86) to Left Outrigger Lock Relay (Pin 86)
9.93
9.92,
60A 9.93 or 16 YEL/GRN Outrigger Switches/Boom Sensor Fuse to Splice 60
9.94
9.92,
60B 9.93 or 16 YEL/GRN Splice 60 to Left Outrigger Switch (Pin 2)
9.94
9.92,
60C 9.93 or 16 YEL/GRN Splice 60 to Left Outrigger Switch (Pin 8)
9.94
9.92,
60D 9.93 or 16 YEL/GRN Splice 60 to Right Outrigger Switch (Pin 8)
9.94
9.92,
60E 9.93 or 16 YEL/GRN Splice 60 to Right Outrigger Switch (Pin 2)
9.94
9.92,
61 9.93 or 16 RED/GRY Right Outrigger Lock Relay (Pin 87A) to Outrigger Valve Solenoid (Right Up) (Pin 1)
9.94
9.92,
62 9.93 or 16 PUR/WHT Right Outrigger Switch Connector (Pin 3) to Outrigger Valve Solenoid (Right Down) (Pin 1)
9.94
9.92,
63 9.93 or 16 BRN/YEL Left Outrigger Lock Relay (Pin 87A) to Outrigger Valve Solenoid (Left Up) (Pin 1)
9.94
9.92,
64 9.93 or 16 GRY/PUR Left Outrigger Switch Connector (Pin 3) to Outrigger Valve Solenoid (Left Down) (Pin 1)
9.94
9.92 or
16 DK BLU ‡ Boom Extend Lockout Relay (Pin 86) to Outrigger Lockout Relay (Pin 86)
65A 9.93
9.94 16 DK BLU ~ Boom Extend Lockout Relay (Pin 86) to Boom Extend Interlock Relay (Pin 87)
9.92 or
65B 16 DK BLU ‡ Outrigger Lockout Relay (Pin 86) to Boom Extend Interlock Relay (Pin 87)
9.93
9.92,
66 9.93 or 16 ORG/GRY Splice 56 to Boom Extend Interlock Relay (Pin 30)
9.94
9.92,
67 9.93 or 16 BRN/BLK Left Outrigger Switch (Pin 1) to Left Outrigger Lock Relay (Pin 30)
9.94
‡ SN 13198 through 17984
~ SN 17985 through 19079
9.90 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

9.92,
68 9.93 or 16 RED/BLK Right Outrigger Switch (Pin 1) to Right Outrigger Lock Relay (Pin 30)
9.94
9.92,
70A 9.93 or 16 ORG/BLK
to Male Connector at Dash Panel (Cab Harness, Wire 152A2)
9.94
9.92,
70B 9.93 or 16 ORG/BLK Park Brake Interlock Relay (Pin 86) to Stabil-TRAK Interlock Relay (Pin 87)
9.94
9.92,
70C 9.93 or 16 ORG/BLK Stabil-TRAK Lock Up Relay (Pin 86) to Stabil-TRAK Interlock Relay (Pin 87)
9.94
9.92,
71 9.93 or 16 ORG/WHT Stabil-TRAK Interlock Relay (Pin 30) to Boom Extend Interlock Relay (Pin 87A)
9.94
71A 9.94 16 ORG/WHT ~ Boom Extend Interlock Relay (Pin 87A) to Right Outrigger Lock Relay (Pin 86)
71B 9.94 16 ORG/WHT ~ Right Outrigger Lock Relay (Pin 86) to Left Outrigger Lock Relay (Pin 86)
‡ SN 13198 through 17984
~ SN 17985 through 19079
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.91

Electrical System
(SN 13198 Through 16782, Without Lighting Package)
INSTRUMENT PANEL
TURN SIGNALS
HYD. OIL TEMP.
TRANS. TEMP.
WATER TEMP.
HOURMETER
FUEL GAUGE
STABIL-TRAK
ALTERNAT0R
PARK BRAKE
BACK LIGHT
(OPTIONAL)
(OPTIONAL)
(OPTIONAL)
ENGINE OIL
HIGH BEAM
GROUND
POWER
CAB ENGINE
HARNESS HARNESS
J1 J5 J14 J15 J7 J2 J10 J3 J12 J11 J8 J9 J6 J4 FEMALE MALE
CONNECTOR CONNECTOR
152 152A
A3 A3
LEFT 2G
OUTRIGGER B3 B3 62 61
SWITCH 2B
2F 2G
7 8
2L2 1 60C A1 A1
H UP 1 67
- + - +
2 - + - +
60B
70A DOWN 3
64 RIGHT RIGHT
DOWN UP
70A OUTRIGGER
NOT USED
52 VALVE
2L2 60 60
SOLENOIDS
30 PARK 2A 7 8 B1 B1 LEFT LEFT
86 AB AB
70B BRAKE 2L1 1 60D DOWN UP
INTERLOCK 2E 2F
85 UP 1 68
3A 87A 87 RELAY 2
41A 41B - + - +
60E C5 C5
41
7.5 2B2 60
OPEN DOWN 3 - + - +
51A 60A 62
41
RIGHT B2 B2
2D 2E
OUTRIGGER 2B
10.0
OPTION
E SWITCH A5 A5
2E
64 63
WIPER/ 7 35 35 35
WASHER B4 B4
51A
51 C4 C4
7
10.0 51B 59B 67
STABILIZER
86
30 LEFT
OUTRIGGER B5 B5
2K2
59B LOCK
10.0 85
87A 87 RELAY C1 C1 51D
STEER SELECT 59A
SWITCH 68 2A AB
2A3 63 C2 C2 41
30 RIGHT 41A AB
86 2A1 A2 A2
15.0 OUTRIGGER PB B
HORN/HEATER LOCK C3 C3 + -
85 + -
87A 87 RELAY PB A
10.0 61 61
61 62 62 AB SECONDARY
INSTR. PANEL
2A1 63 63 AB
FUNCTION
7.5 64 LOGIC 64 MANIFOLD
LIGHT
2A2 51 HARNESS 51C SOLENOIDS
SWITCH RELAY
51D 51D
51C 51C
3A 49 49 2K1
23 23 23 2K2
66
3A 2J LOGIC 2J
7.5 50B 71 30 HARNESS 2B 2B 2B
TRANSMISSION
86 BOOM EXT. 50C 50C
INTERLOCK 2H
30 85 RELAY 56 56
20.0 86 STABIL. 87A 87 58 58
LIGHTS 1 INTERLOCK 56 57 50C 57
85 RELAY 2A2 65B
87A 87 A B A B
71 A1 A1
3A 2C2 70C A2 A2 LEFT RIGHT

OUTRIGGER OUTRIGGER
2C1 70B CYLINDER CYLINDER
PRESSURE PRESSURE
2C2 2 2 2J 2E 2F SWITCH SWITCH
D 7.5 2B3
2A
20
A3 A3
20
20 20
OUTRIGGER
65B 50A
SWITCHES/ 65A 50B 2R
3 BOOM CAB
SENSOR 49 70C 7 GROUND B4 B4
3 30
3A 60A
86 OUTRIGGER STUD
30 LOCKOUT A4 A4
86 STABIL.
7.5 LOCK UP 85 RELAY B5 B5 23
87A 87
OUTRIGGER
85 RELAY 49
CYLINDERS 87A 87 58 2H
2B3 59A
3C 3B 56A AB
2C1 45A B A
2B1 AB
OPTION 35 F
+ -
66 65A 58 B A
BOOM
56 49 EXTEND
30 23 SOLENOID
BOOM EXT
For additional 56A
56
86
LOCKOUT
2R
55 RELAY A5 A5
information on 2B2
85
87A 87
B2 B2
C B A
50C
the 10054 Logic 50A G
55
Harness, refer 2B1
B1 B1
C B A
to Section 10.9, WHT BLK GRN

C4 C4
“Stabil-TRAK™
C3 C3
Boom Interlock 1
7
C2 C2
BOOM
EXTEND
Electrical Circuit 8
6 PARK
INTERLOCK
HARNESS
Operation and E
BRAKE
SWITCH
Troubleshooting 5
2 C5 C5 WHT BLK GRN
D 4
(10054, 13198- 45A C1 C1 C B A
17984).” E 3 152
152 45B A 152
B3 B3
C B A
NOT USED 41
2 BLK
CAB ENGINE
B
D 41
41 52 HARNESS HARNESS
1 BLU
BRN
MALE FEMALE
107 NOT USED
CONNECTOR CONNECTOR
51B C 107 - +
86
30 PARK
BRAKE BOOM
= See Pages 9.84 or 9.85 85
DIS. EXTEND
MH4990
87A 87 RELAY SENSOR
9.92 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
INSTRUMENT PANEL
TURN SIGNALS
HYD. OIL TEMP.
TRANS. TEMP.
WATER TEMP.
HOURMETER
FUEL GAUGE
STABIL-TRAK
ALTERNAT0R
PARK BRAKE
BACK LIGHT
(OPTIONAL)
(OPTIONAL)
(OPTIONAL)
ENGINE OIL
HIGH BEAM
GROUND
POWER
CAB ENGINE
HARNESS HARNESS
CONNECTOR CONNECTOR
152A3 A3 A3
LEFT 2G
152A2 OUTRIGGER 62 61
OPTION 152A
SWITCH
B3 B3
2B
152A1 2F 2G
3B 56A 7 8
7.5 A1 A1
3C OUTRIGGER 2L2 1 60C
CYLINDERS - + - +
3A 60A UP 1 67
3
3
OUTRIGGER
SWITCHES/
7.5
49 H 60B
2 - + - +
BOOM SENSOR DOWN 3

64 RIGHT RIGHT
DOWN UP
70A
D NOT USED
OUTRIGGER
VALVE
70A 2L2 60 60
SOLENOIDS
52 2A 7 8 B1 B1 AB AB LEFT LEFT
2L1 1 60D DOWN UP
3B 70B 30 PARK 2E 2F
86 UP 1 68
3A BRAKE 2
INTERLOCK 41A 41B - + - +
85 60E C5 C5
41
7.5 87A 87 RELAY 60
OPEN DOWN 3 - + - +
60A 62
2B2 41
RIGHT B2 B2
51A 2D 2E
OUTRIGGER 2B
10.0
OPTION
E SWITCH A5 A5
2E
64 63
WIPER/ 7 35 35 35
WASHER B4 B4
51A
51 C4 C4
7
10.0 51B 59B 67
STABILIZER
86
30 LEFT
OUTRIGGER B5 B5
2K2
59B LOCK
10.0 85
STEER SELECT 59A
SWITCH 68 2A AB
2A3 63 C2 C2 41
30 RIGHT 41A AB
86 2A1 A2 A2
15.0 OUTRIGGER PB B
85 + -
87A 87 RELAY PB A
10.0 61 61
INSTR. PANEL
2A1 63 63 AB
FUNCTION
LIGHT
SWITCH RELAY
51D 51D
51C 51C
49 49 2K1
23 23 23 2K2
66
3A 2J LOGIC 2J
7.5 50B 71 30 HARNESS 2B 2B 2B
TRANSMISSION
INTERLOCK 2H
30 85 RELAY 56 56
20.0 86 STABIL. 87A 87 58 58
85 RELAY 2A2 65B
87A 87 A B A B
71 A1 A1
2C2 70C A2 A2 LEFT RIGHT

For additional 2C1 70B
OUTRIGGER
CYLINDER
OUTRIGGER
CYLINDER
PRESSURE PRESSURE
information on 2C2
2A
2 2 2J 2E 2F SWITCH SWITCH
20
the 10054 Logic 2B3 65B 50A
20
A3 A3 20 20
65A 50B 2R
Harness, refer 70C 7
CAB
GROUND B4 B4
30
86 OUTRIGGER
to Section 10.9, 86
30
STABIL. LOCKOUT
STUD A4 A4
85 RELAY 23
“Stabil-TRAK™ 85
LOCK UP
RELAY
87A 87 B5 B5
49
58 2H
87A 87
59A
Boom Interlock 2C1 45A
2B3
B A AB
Electrical Circuit 2B1 AB

35 F
Operation and + -
66 65A 58 B A
Troubleshooting 56 49
BOOM
EXTEND
23 SOLENOID
(10054, 13198- 56A
56
86
30
BOOM EXT 2R
LOCKOUT
17984).” 55 85
87A 87
RELAY A5 A5 C B A
2B2 B2 B2
50C
50A G
2B1 55
C B A
B1 B1
WHT BLK GRN

C4 C4
C3 C3
7 BOOM
1 C2 C2 EXTEND
8 INTERLOCK
6 PARK HARNESS
BRAKE
E SWITCH
2 C5 C5 WHT BLK GRN
5 4
D
45A C1 C1 C B A
E 3
152B2
152B
152B1 45B A 152A1
B3 B3
C B A
NOT USED 41A
2 BLK
CAB ENGINE
B
D 41
41B 41C 52 HARNESS HARNESS
1 BLU
BRN
MALE FEMALE
107A NOT USED
CONNECTOR CONNECTOR
51B C 107B
- +
86
30 PARK
BRAKE BOOM
= See Pages 9.86 or 9.87 85
DIS. EXTEND
MH4260
87A 87 RELAY SENSOR
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.93

Electrical System
INSTRUMENT PANEL
TURN SIGNALS
~
HYD. OIL TEMP.
TRANS. TEMP.
WATER TEMP.
HOURMETER
FUEL GAUGE
STABIL-TRAK
ALTERNAT0R
PARK BRAKE
BACK LIGHT
(OPTIONAL)
(OPTIONAL)
(OPTIONAL)
ENGINE OIL
HIGH BEAM
GROUND
POWER
CAB ENGINE
HARNESS HARNESS
CONNECTOR CONNECTOR
152A3 A3 A3
LEFT 2G
OPTION 152A
SWITCH
B3 B3
2B
152A1 2F 2G
3B 56A 7 8
7.5 A1 A1
CYLINDERS 2 1 2 1
3A 60A UP 1 67
3
3
OUTRIGGER
SWITCHES/
7.5
49 H 60B
2 2 1 2 1
BOOM SENSOR DOWN 3

64 RIGHT RIGHT
DOWN UP
70A
D NOT USED
OUTRIGGER
VALVE
70A 60 60
SOLENOIDS
52 2L2 B1 B1 AB AB LEFT LEFT
2A 7 8
70B DOWN UP
3B 30 PARK 2L1 1 60D 2E 2F
86
BRAKE
3A UP 1 68 41A 41B
INTERLOCK 2
C5 C5 2 1 2 1
85
7.5 87A 87 RELAY 60E 41
OPEN 60 2 1 2 1
2B2 DOWN 3
60A 62 41
B2 B2
51A 2D 2E
RIGHT 2B
10.0
OPTION
E OUTRIGGER
SWITCH
A5 A5
2E
64 63
WIPER/ 7 35 35 35
WASHER B4 B4
51A
51 C4 C4
7
10.0 71B 67
STABILIZER 51B
86
30 LEFT
OUTRIGGER B5 B5
2K2
LOCK
10.0 68 85
STEER SELECT 71A
SWITCH 71B 2A AB
2A3 63 C2 C2 41
30 RIGHT 41A AB
86 2A1 A2 A2
15.0 OUTRIGGER PB B
85 + -
87A 87 RELAY PB A
10.0 61 61
INSTR. PANEL
2A1 63 63 AB
FUNCTION
LIGHT
SWITCH RELAY
51D 51D
51C 51C
49 49 2K1
23 23 23 2K2
66
3A 2J LOGIC 2J
7.5 50B 71 30 HARNESS 2B 2B 2B
TRANSMISSION
INTERLOCK 2H
30 85 RELAY 56 56
20.0 86 STABIL. 87A 87 58 58
85 RELAY 2A2 65A
87A 87 A B A B
71A 71 A1 A1
2C2 70C A2 A2 LEFT RIGHT

OUTRIGGER
CYLINDER
OUTRIGGER
CYLINDER
PRESSURE PRESSURE
information on 2J 2E 2F SWITCH SWITCH
20
the 10054 Logic 2C2
2A
2 2 20
A3 A3 20 20
2B3 2R
Harness, refer CAB
GROUND B4 B4
to Section 10.9, STUD A4 A4
23
“Stabil-TRAK™ 70C 7
B5 B5
49
58 2H
Boom Interlock 86
30
STABIL. B A AB
LOCK UP
Electrical Circuit RELAY AB
F
85
87A 87
Operation and 2C1 45A + -

66 65A 58 B A
Troubleshooting 35 56 49
BOOM
EXTEND
23 SOLENOID
(10054, 13198- 56A
56
86
30
BOOM EXT 2R
LOCKOUT
17984),” or 55 85
87A 87
RELAY A5 A5 C B A
2B2
Section 10.10, 50B
50C B2 B2
G
“Stabil-TRAK™ 2B3 55
C B A
B1 B1
Boom Interlock WHT BLK GRN
Electrical Circuit C4 C4
Operation and 7
C3 C3
BOOM
1 EXTEND
Troubleshooting 8
C2 C2
INTERLOCK
6 PARK HARNESS
(10054, 17985- BRAKE
E SWITCH
19987 and 2 C5 C5 WHT BLK GRN
0160002332 & 5
D 4
45A C1 C1 C B A
After).” E 3
152B2
152B
152B1 45B A 152A1
B3 B3
C B A
NOT USED 41A
2 BLK
CAB ENGINE
B
D 41
41B 41C 52 HARNESS HARNESS
1 BLU
BRN
MALE FEMALE
107A NOT USED CONNECTOR CONNECTOR
51B C 107B
- +
86
30 PARK
BRAKE BOOM
= See Pages 9.86 or 9.87 85
DIS. EXTEND
87A 87 RELAY SENSOR MH4370
9.94 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
(SN 19080 - 19987 And 0160002332 & After)
2A 9.103 16 BLK Splice 20 (Ground) to Fuel Level Sender
2B 9.103 16 BLK Splice 20A (Ground) to Steer Select Valve Solenoid (4-Wheel) (Pin B)
2D 9.103 16 BLK Splice 20 (Ground) to Diode VESPAK VP2 (Pin F)
2DD
2E 9.103 18 BLK Not Used
2F 9.103 18 BLK Not Used
2G 9.103 16 BLK Splice 20 (Ground) to Transmission Ground
2R 9.103 16 BLK Splice 20B (Ground) to Boom Extend Harness Male Connector (Pin C)
3B 9.102 10 PUR Open Fuse to Female Connector
9.102 18 YEL
6
9.103 &
9.104
9.102 16 GRN/WHT
8
9.103 Cab/Chassis Male Connector (Pin C2)
16 LT GRN/WHT
9.102 16 GRN/BLK
9
9.103 Cab/Chassis Male Connector (Pin C3)
16 LT GRN/BLK
9.102 16 TAN
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.95

Electrical System

12B 9.102 12 DK BLU Splice 12A to Option Connector
9.102 18 LT BLU
9.102 18 BRN
9.102 18 GRY
9.102 18 GRN
20
9.103 12 BLK Cab/Chassis Female Connector (Pin A3) to Splice 20 (Ground) (Engine Harness)
20A
9.102 16 GRN
to Roadlights Female Connector (Option) (Main Beam) (Cab Harness)
23
Logic Harness Female Connector (Pin B)
9.103 16 ORG/GRN
to Boom Extend Harness Male Connector (Pin B) (Engine Harness)
9.102 14 ORG/GRN
27C
27D
9.102 16 PUR/WHT
9.102 16 ORG/RED
9.96 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

9.102 16 RED/BLK
34
9.103 16 RED/BLK
34A 16 RED/WHT
35
9.102 16 ORG
38
9.103 &
9.104
40
41 9.103 16 BLU/WHT Not Used
9.102 16 DK BLU/WHT Not Used (Cab Harness)
41A
9.103 18 BLU/WHT Not Used (Engine Harness)
41B
9.103 18 BLU/WHT Not Used (Engine Harness)
9.102 16 ORG/WHT
49 9.103 16 RED/BLU Logic Harness Female Connector (Pin A) to Boom Extend Harness Male Connector (Pin A)
101
102
102A
102B
103
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.97

Electrical System

104
105
106 9.103 &
9.104
107A 9.102 18 BLU Not Used
150
9.102 16 YEL/GRN
152A2 9.102 16 BLK/WHT Splice 152A to Inline Diode to Female Connector
152B 9.102 16 BLK/WHT Park Brake Switch Connector (Pin 3) to Male Connector
156 9.102 16 RED/WHT
9.102 16 BLK Horn Button to Cab/Chassis Female Connector (Pin A5) (Cab Harness)
158
9.98 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

BP 9.104 16 RED/GRN
BPB 9.104 16 RED/WHT
BPC 9.104 16 RED/WHT
BPD 9.104 16 RED/WHT
BPM 9.104 14 RED/GRN
BPS 9.104 14 RED/GRN
DD 9.104 18 BLK
DI 9.104 18 BLK
DS 9.104 18 BLK
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.99

Electrical System

J87H 9.104 18 RED
J87L 9.104 18 BLK
ML 9.104 18 BLK
9.104 18 BLK
OFF1
9.104 18 ORG
9.104 18 BLK
ON1
9.104 18 VIO
PH1 9.104 18 BLU
RTS 9.104 18 BLK
SL 9.104 18 BLK
SL1 9.104 18 GRN
9.104 18 BLK
SWR
9.104 18 YEL
THG 9.104 18 BLK
THG1 9.104 18 BLK
THP 9.104 18 RED
THP1 9.104 18 RED
THS 9.104 18 WHT
THS1 9.104 18 WHT
WL 9.104 18 BLK
9.100 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

WL1 9.104 18 BRN
WSL 9.104 18 BLK
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.101

Electrical System

(SN 19080 - 19987 And 0160002332 & After)
INSTRUMENT PANEL
TURN SIGNALS
HYD. OIL TEMP.
TRANS. TEMP.
WATER TEMP.
HOURMETER
FUEL GAUGE
STABIL-TRAK
ALTERNAT0R
PARK BRAKE
BACK LIGHT
(OPTIONAL)
(OPTIONAL)
(OPTIONAL)
ENGINE OIL
HIGH BEAM
ROADLIGHTS
GROUND
OPTION CAB
POWER
CONNECTOR HARNESS
FEMALE
HIGH BEAM
J1 J5 J14 J15 J7 J2 J10 J3 J12 J11 J8 J9 J6 J4
CONNECTOR
23 47
22 154 155 152A3 156 38 40B 16 17 A3
21C 152A2
ROAD/ 28
2GG 152A 151 18 6 15 B3
WORKLIGHT
A1
40
12B 12AA H 40B
40
12B 3C 40A
12A
12A 26A 34 STEER
21C 27A
A B C D E SELECT
30 SWITCH
SWITCH 20A 7 8 11B
85 RELAY 2JJ 1 18
87A 87 B1
1
S 11B D 8
2KK 2
D 23 19 P
R
58
11A 16
C5
IGNITION O
E 3
S
SWITCH 9
P
R
24A
B2
15
3B O
30
3A 12 29
S
158 158
P
HORN A5
R
7.5 BUTTON
OPEN
50 OPTION 86
30 LIGHT 50
O 35
SWITCH B4
51 OPTION RELAY
85
A B C CAB
87A 87
GROUND 10
C4
10.0 WIPER/ STUD
32 2DD 12A 2KK 38
OPTION WASHER 1 B5
WIPER/ 2DD
WASHER 20 26 2MM 6
7
7 E 35
20A 20A
20A 20A
C1
A4
10.0
STABILIZER 39 8
C2
41A
11A A2
10.0 114B 48 10 39 9
STEER SELECT
46 C3
SWITCH 30 30
86 STABIL. 86 BOOM
LOCK SWITCH
15.0
52 52 HEATER 2CC 40A 2AA

10.0
42A 48 28
INSTR. PANEL 47
22
7.5
LIGHT SWITCH 12
20 20 20
RELAY
3C
29
40.0 153
LIGHTS 2 27F 27C 153A 15
A1
40.0 107B
MAIN
27 27 27D
27B 100 17
26B 86
30 PARK A2
26 BRAKE
26 26A DIS. CAB
85
87A 87 RELAY GROUND 2LL 20 20
3A 153A STUD 20 A3
7.5
TRANSMISSION 27B 2HH 2EE 113B 2FF
20A
27A 113 113A
20.0 113 151
LIGHTS 1 B4
12C 27C
A4
7
1 2HH 27D
B5
42B 8
111
6
HAZARDS 24A
PARK 111
OPTION SWITCH 113A
CONNECTOR 1 2 111
5 4 112A 30
D 45A2 111A 86 BACK-UP
ALARM
42B
E 3
152B A 152A1
86
30
NEUTRAL 85
87A 87
RELAY
NOT USED 41A START
42A RELAY
2 85 2BB 31
B
D 87A 87
41B
1
2FF
107A NOT USED 31
A5
C 107B
2BB
106 106
B2
20A
34
BRAKE 9 9 B1
B+ 153
PEDAL
SWITCH 8 8
GEAR 150
45A2 104
C4
7 7
45B 46 GEAR 103 103
45 1 2 C3
45 6 6 102
GEAR 105 C2
5 5
GEAR 101
F 112A 105
1 4 4 C5
2 NEUTRAL 112 112 114A
112 102B
3 N
3 3 101
4 REVERSE 102A 102A 102 C1
R 102
SHIFTER 2 2 150
ZF TRANSMISSION FORWARD 104 B3
1 1
B+ 113
CAB
114B HARNESS
MALE
45 114A CONNECTOR
114
= See Page 9.107
MH46701
9.102 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
10054 (19080 & After)
47 47B STARTER 12V BUSS BAR

47
+
ENGINE 47A
28 28B 106
GND (-)
HARNESS 28 47B
28B
MALE 28A BOOM
CONNECTOR 40 2K 2P 2N SENSOR
AB AB AB 27D
+ -
AB AB AB AB2 27C
47
A3 AB1 STARTER
B3
28 3 12B 4B 38 See
40
STABIL-TRAK
CYLINDER SOLENOIDS
BRN
BLU 6 D+ B+
GND (-)
AG1 Page 9.104
A1
4A 12A
BLK AG2
W
A B C
ALTERNATOR
AB AB
AB AB A B C
47A 2L 35 2T
28A
2M 10
18
B1
16
C5
24A
B2 B B
A A 8 2C
158
A5
HORN AB
35 AB
B4
4-WHEEL STEER
10 + - SELECT
C4 + - VALVE
CRAB
SOLENOIDS
38 AB
B5
AB NOT USED 18
6
C1
9 2B AB AB
20A TRANS. TEMP
A4
41B 2F SWITCH
8
C2 41A 2E
41 41 41
A2
9 P9
C3
IGNITION
SWITCH
FUSE
2B 2E 2F 2C 16
7.5 F
34A See Page 9.104
OIL PRESSURE E
34
20A 20B SWITCH
20A 20A
D
C
B
A
15 15
A1
2M 2N 2K
17 2A
A2 2L 2P WATER TEMP 2T
FUEL LEVEL SWITCH
SENDER 2A 20
20 20D 20B 20C
A3 20 20D 20B
2DD 2R
20E
2D 2G 2H 2J 2X
151 151
B4
27C
A4
27D HYDR. OIL
B5 TEMP SWITCH F
B A
49
23
2R 2X
C B A -
BACK-UP
ALARM
+
G 31
31
A5
106
B2
34
B1
2J 7 7
104 104B Y1 Y3 Y2
C4 104 1 1
E E E
103 103B Y1 Y3 Y2
C3 103 3 3
102 102B 2 2
C2 102
UPPER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
105 105B 4
C5 105 4
101 101B
C1 101 5 5 Y6 Y5 Y4
150 150B E E E
B3 150 6 6
102A 103A 105A 2D 2H 7 7 Y6 Y5 Y4
ENGINE 2DD 101A 150A 104A
HARNESS F C B A A B C F 2G
FEMALE
CONNECTOR LOWER
TRANSMISSION COILS
(VIEWED FROM
TRANS. 20E = See Page 9.107 FRONT OF VEHICLE)

20C
VP1 VP2 GRND
DIODE PACK DIODE PACK ENGINE GROUND BUSS BAR
MH46702
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.103

Electrical System

+
106 BPB1
See 38
GND (-)
+
BPC1
Page 9.103 6 BATTERY BPD1
1
BPM1
OPEN AB2 BPS1
-
6
51 AB1 BLOCK
OPTION
CNS4
ENGINE G J87L
GND (-)
+
E AG2
WASHER
D CNL2 W BATTERY
5 BNE
C CNH2 2
CNL3 ALTERNATOR
BNF
10.0 CNL4 B BP
A BN
B
C
CNL
CNS
CNL
2
CNL1
P7
DIAGNOSTIC
P8
RESISTOR
FEMALE
BNP
BNW
-
10.0 P3 CNH PLUG
CNH2 CONNECTOR
SWITCH
1 4
125
15.0 Fuse
ENGINE
A CNH1 CONTROL
MODULE FRAME
10.0 B CNL1 GROUND
INSTR. PANEL FUSES
C CNS1
BP
7.5 P4 10 F
LIGHT SWITCH BP1
RELAY RESISTOR E
FEMALE D
BPS
10
CONNECTOR BPS1
C
See Page 9.102 10 B
BPM
BNW W
A
BPM1
BPS S
BNP P
P5 BPM M
CAB DLP ENGINE
GROUND BNH H
CONTROL
6
FUSES BNE E
DLP1
CG1 BPD BPD D
7.5 F
DLP2
1B- 2B- E
BPD1 BPC C
PREHEAT P15 7.5 D
1
INDICATOR ENGINE C
BPC1 34A A
LIGHT
1 2 FUNCTION BPB
INDICATOR 7.5 B P1
1A+ 2A+ BPB1
LIGHT A ENGINE
1B- 2B-
CONTROL
PH1 MODULE
WL1
23 PIN FEMALE
SL1
See Page 9.103 34A
CONNECTOR
PH1 P P PH1A
O O RTS
N N DD
M M DI
L L DS J87L 50
1
2
3
G G WSL DS 37
P16
IDLE F F ML DD 36
SWITCH
SL1 D D SL GH2 31
THS1 C C THS THS 30
A A THG1 OFF1 25
ECM ECM
P14
WSL 11
ML 4
WL 3
SL 1
ENGINE GRID
HEATER RELAY 2 P2
GH4 GH4 ENGINE
F
1 2
CONTROL
MODULE
E 50 PIN FEMALE
PH1A GH2B CONNECTOR
3
B
GH3
A 4
ENGINE COMPARTMENT
P11 GHG2
DIODE PACK
GH1
125
GH1B Amp
Fuse
VEHICLE CAB
GH1A GH1A GH2B

A
GH2A GH2A GH2
B 9
GHG2
C
GHG GHG GHG3
F 7
GH3
1 2
ENGINE GRID
HEATER 3 AG2
ENGINE 2 4
BLOCK 1
AG1
GHG1

MH4740
9.104 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
(SN 19080 - 19987 And 0160002332 & After)
2 14 BLK Splice 2A to Cab Ground Stud
2A1 16 BLK Left Outrigger Lock Relay (Pin 85) to Right Outrigger Lock Relay (Pin 85)
2A2 16 BLK Right Outrigger Lock Relay (Pin 85) to Boom Extend Interlock Relay (Pin 85)
2A3 16 BLK Splice 2A to Left Outrigger Lock Relay (Pin 85)
2B2 16 BLK Boom Extend Lockout Relay (Pin 85) to Park Brake Interlock Relay (Pin 85)
2B3 16 BLK Splice 2A to Boom Extend Lockout Relay (Pin 85)
2C1 16 BLK Stabil-TRAK Interlock Relay (Pin 85) to Stabil-TRAK Lock Up Relay (Pin 85)
2C2 16 BLK Splice 2A to Stabil-TRAK Interlock Relay (Pin 85)
2D 16 BLK Splice 2B to Outrigger Valve Solenoid (Left Down) (Pin 2)
2E 16 BLK Splice 2B to Outrigger Valve Solenoid (Left Up) (Pin 2)
2F 16 BLK Splice 2B to Outrigger Valve Solenoid (Right Down) (Pin 2)
2G 16 BLK Splice 2B to Outrigger Valve Solenoid (Right Up) (Pin 2)
2H 16 BLK Splice 2B to Boom Extend Solenoid Connector (Pin B)
2J 14 BLK Splice 2B to Cab Ground Stud
2K1 16 BLK Splice 2B to Secondary Function Manifold Park Brake Solenoid (PB A) (Pin B)
2K2 16 BLK Splice 2B to Secondary Function Manifold Park Brake Solenoid (PB B) (Pin B)
2L1 16 BLK Splice 2A to Right Outrigger Switch (Pin 7)
2L2 16 BLK Splice 2A to Left Outrigger Switch (Pin 7)
3 14 RED Male Connector at Open Fuse (Cab Harness, Wire 3B) to Splice 3
3A 14 RED Splice 3 to Outrigger Switches/Boom Sensor Fuse
3B 14 RED Splice 3 to Outrigger Cylinders Fuse
3C 14 RED Splice 3 to Female Connector (Option)
7 16 TAN
23 16 ORG/GRN Boom Extend Interlock Relay (Pin 86) to Engine Harness Male Connector (Pin B)
Stabil-TRAK Lock Up Relay (Pin 87A)
35 9.107 16 BRN/GRN
45A 16 DK BLU/ORG
Female Connector at Park Brake Switch (Cab Harness, Wire 152B1)
45B 16 DK BLU/ORG
49 16 RED/BLU Outrigger Switches/Boom Sensor Fuse to Engine Harness Male Connector (Pin A)
50B 16 RED/WHT Boom Extend Lockout Relay (Pin 87A) to Stabil-TRAK Interlock Relay (Pin 86)
Right Outrigger Cylinder Pressure Switch Connector (Pin A)
50C 16 RED/WHT
to Boom Extend Lockout Relay (Pin 87A)
51A 16 BLU/WHITE Park Brake Interlock Relay (Pin 87A) to Splice 51
51B 16 BLU/WHITE Splice 51 to Female Connector at Park Brake Switch (Cab Harness, Wire 107B)
51C 16 BLU/WHITE Splice 51 to Secondary Function Manifold Park Brake Solenoid (PB B) (Pin A)
51D 16 BLU/WHITE Splice 51 to Secondary Function Manifold Park Brake Solenoid (PB A) (Pin A)
52 16 DK BLU/RED
to Female Connector at Park Brake Switch (Cab Harness, Wire 41C)
55 16 ORG/RED Boom Extend Lockout Relay (Pin 87) to Splice 56
56 16 GRY/BLU Splice 56 to Left Outrigger Cylinder Pressure Switch Connector (Pin A)
56A 16 GRY/BLU Splice 56 to Outrigger Cylinder Fuse
Right Outrigger Cylinder Pressure Switch Connector (Pin B)
57 16 GRY/ORG
to Left Outrigger Cylinder Pressure Switch Connector (Pin B)
58 16 GRN Boom Extend Lockout Relay (Pin 30) to Boom Extend Solenoid Connector (Pin A)
60A 16 YEL/GRN Outrigger Switches/Boom Sensor Fuse to Splice 60
60B 16 YEL/GRN Splice 60 to Left Outrigger Switch (Pin 2)
60C 16 YEL/GRN Splice 60 to Left Outrigger Switch (Pin 8)
60D 16 YEL/GRN Splice 60 to Right Outrigger Switch (Pin 8)
60E 16 YEL/GRN Splice 60 to Right Outrigger Switch (Pin 2)
61 16 RED/GRY Right Outrigger Lock Relay (Pin 87A) to Outrigger Valve Solenoid (Right Up) (Pin 1)
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.105

Electrical System

63 16 BRN/YEL Left Outrigger Lock Relay (Pin 87A) to Outrigger Valve Solenoid (Left Up) (Pin 1)
65A 16 DK BLU Boom Extend Lockout Relay (Pin 86) to Boom Extend Interlock Relay (Pin 87)
66 16 ORG/GRY Splice 56 to Boom Extend Interlock Relay (Pin 30)
67 16 BRN/BLK Left Outrigger Switch (Pin 1) to Left Outrigger Lock Relay (Pin 30)
68 16 RED/BLK Right Outrigger Switch (Pin 1) to Right Outrigger Lock Relay (Pin 30)
9.107
70A 16 ORG/BLK
to Male Connector at Dash Panel (Cab Harness, Wire 152A2)
70B 16 ORG/BLK Park Brake Interlock Relay (Pin 86) to Stabil-TRAK Interlock Relay (Pin 87)
70C 16 ORG/BLK Stabil-TRAK Lock Up Relay (Pin 86) to Stabil-TRAK Interlock Relay (Pin 87)
71 16 ORG/WHT Stabil-TRAK Interlock Relay (Pin 30) to Boom Extend Interlock Relay (Pin 87A)
71A 16 ORG/WHT Boom Extend Interlock Relay (Pin 87A) to Right Outrigger Lock Relay (Pin 86)
71B 16 ORG/WHT Right Outrigger Lock Relay (Pin 86) to Left Outrigger Lock Relay (Pin 86)
9.106 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
(SN 19080 - 19987 And 0160002332 & After)
INSTRUMENT PANEL
TURN SIGNALS
HYD. OIL TEMP.
TRANS. TEMP.
WATER TEMP.
HOURMETER
FUEL GAUGE
STABIL-TRAK
ALTERNAT0R
PARK BRAKE
BACK LIGHT
(OPTIONAL)
(OPTIONAL)
(OPTIONAL)
ENGINE OIL
HIGH BEAM
GROUND
POWER
CAB ENGINE
J1 J5 J14 J15 J7 J2 J10 J3 J12 J11 J8 J9 J6 J4 HARNESS HARNESS
FEMALE MALE
CONNECTOR CONNECTOR
152A3 2G
LEFT A3 A3
OPTION 152A
SWITCH 2B
B3 B3 2F 2G
3B 56A 152A1 7 8
7.5
CYLINDERS A1 A1 2 1 2 1
3A 60A UP 1 67
3
3
OUTRIGGER
SWITCHES/
7.5
49 H 60B
2 2 1 2 1
BOOM SENSOR DOWN 3

64 RIGHT RIGHT
DOWN UP
70A
D OUTRIGGER
VALVE
70A 60 60
SOLENOIDS
52 2L2 B1 B1 LEFT LEFT
2A 7 8
70B DOWN UP
3B 30 PARK 2L1 1 60D
86
BRAKE
3A UP 1 68
INTERLOCK 2
C5 C5 2 1 2 1
85
7.5 87A 87 RELAY 60E
OPEN 60 NOT USED 2 1 2 1
2B2 DOWN 3
60A 62 B2 B2
51A 2D 2E
RIGHT AB AB
2B
10.0
OPTION
E OUTRIGGER
SWITCH
A5 A5
41A 41B 2E
64 63
WIPER/ 7 35 35 35 41
WASHER B4 B4
CAB
51A
51 GROUND C4 C4
41 2E 2F
7 STUD
10.0 51B 71B 67
STABILIZER B5 B5
86
30 LEFT
OUTRIGGER 2MM C1 C1
68
LOCK 20A 20A 2K2
10.0 71A 71B 85 20A 20A
87A 87 RELAY A4 A4
STEER SELECT 51D
SWITCH 2A 41
86
30 RIGHT 2A3 63 C2 C2
AB
OUTRIGGER 2A1
15.0 LOCK 41A AB
85 A2 A2
HORN/HEATER 87A 87 RELAY
PB B
C3 C3 + -
10.0 61 + -
PB A
INSTR. PANEL 61 61
2A1 62 62 AB SECONDARY
7.5 63 63 FUNCTION
LIGHT
2A2 LOGIC
AB
MANIFOLD
64 64
SWITCH RELAY 51 HARNESS SOLENOIDS
51D 51D 20B 51C
51C 51C
49 49 2K1
23 23 23 2K2
3A 66
7.5 LOGIC
TRANSMISSION 50B 71 30
2J 2J
86 BOOM EXT. HARNESS 2B 2B 2B
50C 50C
30 INTERLOCK 2H
20.0 86 STABIL. 56 56
LIGHTS 1 INTERLOCK 85 RELAY
87A 87 58 58
85 RELAY 56 57 50C 57
87A 87 2A2 65A
A B A B
71A 71
2C2 70C
LEFT
OUTRIGGER
RIGHT
OUTRIGGER
information on 2J
CYLINDER
PRESSURE
CYLINDER
PRESSURE
SWITCH SWITCH
the 10054 Logic 2C2
2A
2 2
2B3
Harness, refer CAB
20B
20C
GROUND
to Section STUD 2R
20B
58 2H
10.10, “Stabil- 70C 7
23
49
AB
TRAK™ Boom 86
30
STABIL. B A
AB
LOCK UP
Interlock RELAY
F
85 + -
87A 87
BOOM
Electrical Circuit 2C1 45A EXTEND
66 65A 58 B A SOLENOID
Operation and 35 56 49
23
Troubleshooting 56A
56
86
30
BOOM EXT 2R
LOCKOUT
(10054, 17985- 55 85
87A 87
RELAY C B A
2B2
19987 and 50B
50C
G
0160002332 & 2B3 55
C B A
WHT BLK GRN
BOOM
7
1 EXTEND
8 INTERLOCK
HARNESS
6 PARK
BRAKE
E SWITCH WHT BLK GRN
2
5 4 C B A
D
45A
A
C B A
152B 45B 152A1
E 3
BLK
NOT USED 41A
2
B
BLU
D
41B 52 BRN
1
107A NOT USED
C
- +
51B 107B
BOOM
86
30 PARK EXTEND
BRAKE SENSOR 20C
= See Pages 9.102 or 9.103 85
DIS.
87A 87 RELAY ENGINE GROUND BUSS BAR
MH4750
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.107

Electrical System
9.7.30 Wiper/Washer & Heater Harness Electrical Schematic Legend
Wire No. Page Gauge Color Description

WIPER/WASHER HARNESS WIRES (OPTION)
1 14 BLK Splice 2 to Front Wiper Motor (Ground)
1A 14 BLK Splice 2 to Front Wiper Switch (Pin 7)
1B 14 BLK Splice 2 to Skylight Wiper Switch (Pin 7)
1C 14 BLK Splice 2 to Front Washer Switch (Pin 7)
1D 14 BLK Splice 2 to Cab Ground
1E 14 BLK Splice 2 to Skylight Wiper Motor (Ground)
1F 14 BLK Splice 2 to Front Washer Motor (Ground)
2 14 BLU Front Wiper Switch (Pin 1) to Front Wiper Motor (HIGH)
3 14 WHT Front Wiper Switch (Pin 3) to Front Wiper Motor (LOW)
4 14 GRN Front Wiper Switch (Pin 6) to Front Wiper Motor (PARK)
5 14 YEL Skylight Wiper Switch (Pin 1) to Skylight Wiper Motor (RUN)
9.109
6 14 RED/WHT Splice 30 to Front Wiper Switch (Pin 9)
6A 14 RED/WHT Front Wiper Switch (Pin 9) to Front Wiper Switch (Pin 5)
6B 14 RED/WHT Splice 30 to Skylight Wiper Switch (Pin 9)
6C 14 RED/WHT Skylight Wiper Switch (Pin 9) to Skylight Wiper Switch (Pin 5)
6D 14 RED/WHT Splice 30 to Front Washer Switch (Pin 8)
6E 14 RED/WHT Front Washer Switch (Pin 8) to Front Washer Switch (Pin 3)
6F 14 RED/WHT Splice 30 to Cab Harness Connector (Wire 32)
9 14 GRN Skylight Wiper Switch (Pin 6) to Skylight Wiper Motor (PARK)
10 14 GRN Front Washer Switch (Pin 2) to Front Washer Motor (POWER)
PUR 14 PUR Front Wiper Switch Connector Jumper from Pin 2 to Pin 4
PUR 14 PUR Skylight Wiper Switch Connector Jumper from Pin 2 to Pin 4
HEATER HARNESS WIRES (OPTION)
1 14 YEL Heater Switch (Pin 1) to Heater Blower Motor (Pin 1)
2 14 RED/WHT Heater Switch (Pin 2) to Cab Harness Connector (Wire 52)
3 14 ORG Heater Switch (Pin 3) to Heater Blower Motor (Pin 3)
4 14 RED Heater Switch (Pin 4) to Heater Blower Motor (Pin 4)
5 14 BLK Heater Blower Motor (Pin 2) to Cab Ground Stud
9.108 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
9.7.31 Wiper/Washer & Heater Harness Electrical Schematic
6B PUR
6C 9 5
5
9 6 4 3 1
C
9 6 4 3 1 Run
Park
9 A M
SKYLIGHT
WIPER
2 1 GND MOTOR
1E
7 5 2 SKYLIGHT
WIPER
SWITCH
7 5 2
1B 6C PUR
1E
1B
2
6B
10.0
OPTION
32 6F
30
WIPER/
WASHER
6D
6E
8 3
8 3
6 PUR
6A 4 3 2
3 2
9 6 4 3 1 1
L
15.0
52 2 9 6 4 3 1 L H FRONT
HORN/HEATER WASHER
P H 7 2 SWITCH
4 P M FRONT
WIPER 7 2
MOTOR
2 1 GND
1C 10
1
3C FRONT
POWER
FRONT
7 5 2 WIPER WASHER
TO SWITCH M PUMP
IGNITION MOTOR
SWITCH 7 5 2
GND
RUN
1A 6A PUR
1F
1 1C
1A 1F
2 2 2
1D
CAB
GROUND
STUD
1 HEATER
1
POWER BLOWER
MOTOR
BLOWER
4
4 MOTOR M
RESISTOR
PACK GND
3
3
1 4 3 2
1 4 3
5
L M
O
H
CAB
C GROUND
B BLOWER STUD
SWITCH
2
MH5160
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.109

Electrical System
9.7.32 Roadlight Harness Electrical Schematic Legend

1 12 RED Splice 1 to Cab Harness Fuse Block Connector (Wire 12AA)
1A 14 RED Splice 1 to Worklight Switch (Pin 5)
1B 14 RED Splice 1 to Hazard Switch (Pin 8)
1C 14 RED Splice 1 to Lighting Control Lever 3-Way Connector (Pin C)
1D 14 RED Splice 1 to Brake Pedal Switch (Pin 4)
1E 14 RED Splice 1 to Worklight Switch (Pin 2)
1F 14 RED Splice 1 to Worklight Switch (Pin 8)
1J 14 RED Jumper from Hazard Switch (Pin 8) to Hazard Switch (Pin 1)
2A 12 BLK Splice 2 to Cab Ground Stud
2B 16 BLK Splice 2 to Hazard Switch (Pin 10)
2C 16 BLK Splice 2 to Boom Worklight Harness Connector (Pin B)
2D 16 BLK Splice 2 to Left Rear Worklight (Pin N)
2E 16 BLK Splice 2 to Left Taillight (Pin 1)
2F 16 BLK Splice 2 to Right Taillight (Pin 1)
2G 16 BLK Splice 2 to Right Rear Worklight (Pin N)
2H 16 BLK Splice 2 to Right Front Roadlight (Pin 6)
2J 16 BLK Splice 2 to Left Front Roadlight (Pin 6)
2K 16 BLK Splice 2 to Worklight Switch (Pin 7)
3A 16 LT BLU Worklight Switch (Pin 3) to Boom Worklight Harness Connector (Pin A)
4A 14 YEL Splice 4 to Worklight Switch (Pin 6)
4B 14 YEL Splice 4 to Left Rear Worklight (Pin P)
4C 14 YEL Splice 4 to Right Rear Worklight (Pin P)
20 16 WHT Splice 20 to Lighting Control Lever 3-Way Connector (Pin A)
20A 16 WHT Splice 20 to Left Front Roadlight (Pin 2)
20B 16 WHT Splice 20 to Right Front Roadlight (Pin 2)
20C 16 WHT Splice 20 to Left Taillight (Pin 3)
20D 16 WHT Splice 20 to Right Taillight (Pin 3)
20F 9.111 16 WHT Splice 20 to Cab Harness Instrument Panel Connector (Wire 156)
21 16 RED Splice 21 to Lighting Control Lever 3-Way Connector (Pin B)
21A 16 RED Splice 21 to Left Front Roadlight (Pin 1)
21B 16 RED Splice 21 to Right Front Roadlight (Pin 1)
21C 16 RED Splice 21 to Cab Harness Fuse Block Connector (Wire 21C)
22 16 ORG Splice 22 to Lighting Control Lever 6-Way Connector (Pin E)
22A 16 ORG Splice 22 to Left Front Roadlight (Pin 3)
22B 16 ORG Splice 22 to Left Taillight (Pin 2)
22C 16 ORG Splice 22 to Hazard Switch (Pin 18)
23 16 GRN Splice 23 to Lighting Control Lever 6-Way Connector (Pin D)
23A 16 GRN Splice 23 to Right Front Roadlight (Pin 3)
23B 16 GRN Splice 23 to Right Taillight (Pin 2)
23C 16 GRN Splice 23 to Hazard Switch (Pin 17)
24 16 DK BLU Splice 24 to Lighting Control Lever 6-Way Connector (Pin A)
24A 16 DK BLU Splice 24 to Left Front Roadlight (Pin 4)
24B 16 DK BLU Splice 24 to Right Front Roadlight (Pin 4)
24C 16 DK BLU Splice 24 to Cab Harness Instrument Panel Connector (Wire 154)
25 16 PNK Splice 24 to Lighting Control Lever 6-Way Connector (Pin B)
26 16 GRY Splice 26 to Brake Pedal Switch (Pin 5)
26A 16 GRY Splice 26 to Left Taillight (Pin 4)
26B 16 GRY Splice 26 to Right Taillight (Pin 4)
27 16 PUR/WHT Flasher (Pin P) to Cab Harness Instrument Panel Connector (Wire 155)
28 16 PUR Splice 28 to Flasher (Pin L)
28A 16 PUR Splice 28 to Lighting Control Lever 6-Way Connector (Pin F)
28B 16 PUR Splice 28 to Hazard Switch (Pin 5)
31 16 YEL Cab Harness Fuse Block Connector (Wire 23) to Lighting Control Lever 6-Way Connector (Pin C)
32 14 GRN Cab Harness Fuse Block Connector (Wire 12C) to Hazard Switch (Pin 3)
33 16 PUR Flasher (Pin X) to Hazard Switch (Pin 2)
BOOMLIGHT HARNESS WIRES
2B 14 BLK Boom Worklight Harness Connector (Pin B) to Boom Light (Pin N)
9.111
3D 14 LT BLU Boom Worklight Harness Connector (Pin A) to Boom Light (Pin P)
9.110 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
9.7.33 Roadlight Harness Electrical Schematic
DIPPED DIPPED
BOOM
LEFT BEAM BEAM RIGHT WORKLIGHT
FRONT FRONT
ROADLIGHT 21A 21B ROADLIGHT
1 21 1
P N
3D 2B
4 24A 24B 4
BOOM
SIDE LT IND MAIN MAIN IND SIDE LT WORKLIGHT
BEAM BEAM
HARNESS
LIGHTING
2 3 6 6 3 2 P06A CONTROL
LEVER
C (15)
1C OFF
20A 22A 2J 2H 23A 20B
L11 POSITION
A (58) LOW BEAM
See Pages 9.38, 9.40, 20A
20 20
20
L10 3D 2B
9.50, 9.62, 9.64, 9.74, 21 21
B (56)
21 A B
9.84, 9.86, or 9.102 21C
P04B
C (+15/56) A B
INSTRUMENT 31
HIGH
PANEL BEAM
CONNECTOR L14 3A 2C
24B B (56a)
BACK 25 25
LIGHT 156 20F A LH
20 24A 24 24
(J2) 24
TURN 24C
SIGNALS 155 27 2H OFF
R D
(J15) 23
2J ON
HIGH 2
F 49a
BEAM 154 24C 28A
(J14) ON L E
22
OFF
22A
21C 21C 22
22 22
21C 27A 22C 22B
23 31
23A 23
30
86 HEADLIGHT
SWITCH 23C 23B
23 23
85 RELAY
87A 87
2KK 23
1C
1F 3A
1
1F 4A
2B
2
12 29
1J 32 23C 22C 2B
30 WORKLIGHT 8 3 6
86 LIGHT SWITCH
SWITCH 12B 1 3 17 18 10 BOOM BOOM
OFF OFF ALL ALL
85 RELAY ON OFF OFF
87A 87 ON
HAZARD 1 1 2
12B SWITCH
2DD 2 5 8
7.5 12A 12AA 1 7 2 5
LIGHT SWITCH 12 12A
RELAY 1J
3C 2K 1A
2KK
33 28B 1B 1E
TO 2DD
20
IGNITION 29 1 1A
1 1 1
SWITCH
RUN 1D
40.0
LIGHTS 2
28A 2K
28
27F 33 28 2C
27 2 2 2
27C 2A 2G
TO STARTER
TO MAIN FUSE 27 27 27D
100 P X L
TO
27B FLASHER CAB
GROUND
20.0 12C 32 20D STUD
LIGHTS 1 20
2D
27A 2 2
4B 4A
4
TO 20C 2E 4C 2F 20D
PARK
BRAKE 3 1 1 3
SWITCH
TO & LEFT RIGHT
STEER STABIL. TAILLIGHT TAILLIGHT
SELECT LOCK
SWITCH RELAY BRK IND IND BRK
RELAY
46 45B
4 2 2 4
1 2 3 BRAKE 26A 22B 23B 26B

PEDAL LEFT
SWITCH REAR
(Switch shown WORKLIGHT RIGHT
with Pedal REAR
4 5 6 Released) 2D 4B WORKLIGHT
N P
1D 26 26A 4C 2G
P N
26 26B
26
MH6080
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.111

Electrical System
9.7.34 Worklight Harness Electrical Schematic Legend

1 12 RED Splice 1 to Cab Harness Fuse Block Connector (Wire 12AA)
1A 14 RED Splice 1 to Worklight Switch (Pin 8)
1B 14 RED Splice 1 to Worklight Switch (Pin 2)
1C 14 RED Splice 1 to Worklight Switch (Pin 5)
2A 12 BLK Splice 2 to Cab Ground
2B1 16 BLK Splice 2 to Left Front Worklight (Pin N)
2B2 16 BLK Splice 2 to Right Front Worklight (Pin N)
2B3 16 BLK Splice 2 to Left Rear Worklight (Pin N)
2B4 16 BLK Splice 2 to Worklight Harness Connector (Pin B)
2B5 9.113 16 BLK Splice 2 to Right Rear Worklight (Pin N)
2C 14 BLK Splice 2 to Worklight Switch (Pin 7)
3A 14 LT BLU Worklight Switch (Pin 3) to Cab Harness Instrument Panel Connector (Wire 156)
3A1 14 LT BLU Splice 3 to Worklight Switch (Pin 3)
3B 14 LT BLU Splice 3 to Left Front Worklight (Pin P)
3C 14 LT BLU Splice 3 to Right Front Worklight (Pin P)
3D 14 LT BLU Splice 3 to Worklight Harness Connector (Pin A)
4A 14 YEL Splice 4 to Worklight Switch (Pin 6)
4B 14 YEL Splice 4 to Left Rear Worklight (Pin P)
4C 14 YEL Splice 4 to Right Rear Worklight (Pin P)
BOOMLIGHT HARNESS WIRES
2B 14 BLK Boom Worklight Harness Connector (Pin B) to Boom Light (Pin N)
9.113
3D 14 LT BLU Boom Worklight Harness Connector (Pin A) to Boom Light (Pin P)
9.112 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
9.7.35 Worklight Harness Electrical Schematic
BOOM
WORKLIGHT
3D 2B
P N
LEFT RIGHT Boom

FRONT
WORKLIGHT
FRONT
WORKLIGHT Worklight 3D 2B
Harness
A B
2B1 3B 3C 2B2
N P P N
A B
3D 2B4
3C 3D
3B
3 3
3A1
See Pages 9.38, 9.40,

9.50, 9.62, 9.64, 9.74, 2B2
2B1 2B4
9.84, 9.86, or 9.102 2
INSTRUMENT
PANEL
CONNECTOR
BACK
LIGHT 156 3A
(J2)
3A1
3A
1A 4A
WORKLIGHT 8 3 6
SWITCH
BOOM BOOM
ALL ALL
OFF OFF
12 29 1 2
30 LIGHT
86
SWITCH 12B 7 2 5
85 RELAY
87A 87
2C 1B 1C
12B 1A
2DD
7.5 12A 12AA 1 1 1C
LIGHT SWITCH 12 12A 1 1
RELAY
3C
2DD 2C
TO 20
IGNITION 29 2B3
SWITCH 2 2
RUN 40.0 2B5 2A
LIGHTS 2
27F
TO
27C CAB
TO STARTER
TO MAIN FUSE 27 27 27D GROUND
100 STUD
4A
4
4B 4C
LEFT RIGHT
REAR REAR
WORKLIGHT WORKLIGHT
2B3 4B 4C 2B5
N P P N
MH5180
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.113

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/ 5
WASHER 30 50
10.0
STABILIZER
GND
STARTER
10.0
STEER SELECT
5
SWITCH
B+
15.0
HORN/HEATER D+
GND
3C
(-)
See pages 9.39, 9.41, 9.63,
10.0
INSTR. PANEL
26A ALTERNATOR 9.65, 9.85 or 9.87.
7.5
LIGHT A B C D E
SWITCH RELAY
A B C D E
3C
STARTER 12V
S
P
BUSS BAR
19
R
+
O
58
106
IGNITION S GND (-)
SWITCH
+
P
R
O
15
AB2 BATTERY
30 S 1
P AB1
R
50
-
O
STARTER ENGINE
BLOCK
A B C B+
D+
GND (-)
26A 1 W
26
26
26 ALTERNATOR BATTERY
2 +
26B A1 A1
-
27C
A2 A2
40.0 27 27D
MAIN 100
3A 153A
7.5
TRANSMISSION
A3 A3
FRAME
GROUND
B4 B4
1 27C
8 7 A4 A4
111 27D
6 B5 B5
111
2 PARK
E BRAKE 113A
111
1 SWITCH
153A
5
D 153 111A
4 112A
30
E 3 86 PARK
BRAKE 30
DIS. 86 NEUTRAL
2 RELAY
D 85 START
1 87A 87 RELAY
113A 85
87A 87
113B A5 A5
113
106 106
113 B2 B2
B1 B1
C4 C4
C3 C3
C2 C2
F 9 9
B+ 153 112A
1
2 4 4
3 N NEUTRAL 112
112
4 1 1 C5 C5
R B+ 113
SHIFTER
ZF TRANSMISSION C1 C1
B3 B3
MALE AND FEMALE

BULKHEAD HARNESS
CONNECTORS
MH4950
9.114 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
Engine will not crank or

starter solenoid does
not engage.
Check that transmission gear

select lever is in the
Before troubleshooting any NEUTRAL (N) position.
electrical circuit, ALWAYS
If OK
following:
1. All connections relating to
circuit are clean and tight. Check that parking brake
switch is ENGAGED.
2. On 10042 or 10054, if the
vehicle is starting hard, If OK
make sure that both

outrigger switches are in Check 40 amp main fuse and
the neutral (center) 7.5 amp transmission fuse.
position.
If OK
Check battery for proper

charge and that connections
are clean and tight.
If OK
Check for battery voltage at

starter positive (+) battery
post (RED cable). Check Not
Clean, tighten and recheck.
negative (-) cables for proper OK
ground and that they are
clean and tight.
If OK
With ignition switch in START

position, check starter
solenoid terminal, wire Continued on Page 9.117
[106] (BLU/ORG) connection
for battery voltage.
If OK
Replace starter.
† SN 13198 through 16782 w/o Lighting Package. See pages 9.38, 9.39, 9.62, 9.63, 9.84 or 9.85.
§ SN 13198 through 16782 w/Lighting Package and SN 16783 through 18990. See pages 9.40, 9.41, 9.64, 9.65, 9.86 or 9.87.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.115

Electrical System
9.7.36 Engine Start Circuit and Troubleshooting (Continued)

+
BATTERY
-

3A
7.5
§
OPEN
BATTERY
GRND
10.0
OPTION
WIPER/ 5
WASHER 30 50
10.0
STABILIZER
GND
STARTER
10.0
STEER SELECT
5
SWITCH
B+
15.0
HORN/HEATER D+
GND
3C
(-)
See pages 9.39, 9.41, 9.63,
10.0
INSTR. PANEL
26A ALTERNATOR 9.65, 9.85 or 9.87.
7.5
LIGHT A B C D E
SWITCH RELAY
A B C D E
3C
STARTER 12V
S
P
BUSS BAR
19
R
+
O
58
106
IGNITION S GND (-)
SWITCH
+
P
R
O
15
AB2 BATTERY
30 S 1
P AB1
R
50
-
O
STARTER ENGINE
BLOCK
A B C B+
D+
GND (-)
26A 1 W
26
26
2 +
26B A1 A1
-
27C
A2 A2
40.0 27 27D
MAIN 100
3A 153A
7.5
TRANSMISSION
A3 A3
FRAME
GROUND
B4 B4
1 27C
8 7 A4 A4
111 27D
6 B5 B5
111
2 PARK
E BRAKE 113A
111
1 SWITCH
153A
5
D 153 111A
4 112A
30
E 3 86 PARK
BRAKE 30
DIS. 86 NEUTRAL
2 RELAY
D 85 START
1 87A 87 RELAY
113A 85
87A 87
113B A5 A5
113
106 106
113 B2 B2
B1 B1
C4 C4
C3 C3
C2 C2
F 9 9
B+ 153 112A
1
2 4 4
3 N NEUTRAL 112
112
4 1 1 C5 C5
R B+ 113
SHIFTER
B3 B3
MALE AND FEMALE

BULKHEAD HARNESS
CONNECTORS
MH4950
9.116 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
Continued from
Page 9.115.
With ignition switch
in start position, Not OK Before troubleshooting any
check starter
solenoid terminal,
wire [ST2] (BLU) begin by checking the
connection for following:
battery voltage. Check for power at
wire [106] (BLU/ORG), If Repair/replace 1. All connections relating to
Pin B2, at female bulkhead OK engine harness. circuit are clean and tight.
connector.
2. On 10042 or 10054, if the
Not OK vehicle is starting hard,
make sure that both
Check for power at outrigger switches are in
If Repair/replace the neutral (center)
wire [106] (BLU/ORG), OK cab harness.
Pin 87, at neutral start relay. position.
Not OK
Check for power at

Check for power at
If wire [112A] (GRY), If Replace neutral
wire [111A] (RED), Pin 30, at OK Pin 86, at neutral OK start relay.
neutral start relay.
start relay.
Not OK
Not
OK
Continued on Page 9.119
Check for power at

If Repair/replace
wire [111] (RED), Pin 6, at OK cab harness.
park brake switch.
Not OK
Check for power at

If Replace park
wire [1] (WHT), Pin 5, at park OK brake switch.
brake switch.
Not OK
Check for power at

If Replace ignition
wire [26] (RED), Pin A, at OK switch.
ignition switch.
Not OK
Check for power at

Not Replace 40 amp
wire [26B] (RED) at 40 amp OK main fuse.
main fuse.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.117

Electrical System
9.7.36 Engine Start Circuit and Troubleshooting (Continued)

+
BATTERY
-

3A
7.5
§
OPEN
BATTERY
GRND
10.0
OPTION
WIPER/ 5
WASHER 30 50
10.0
STABILIZER
GND
STARTER
10.0
STEER SELECT
5
SWITCH
B+
15.0
HORN/HEATER D+
GND
3C
(-)
See pages 9.39, 9.41, 9.63,
10.0
INSTR. PANEL
26A ALTERNATOR 9.65, 9.85 or 9.87.
7.5
LIGHT A B C D E
SWITCH RELAY
A B C D E
3C
STARTER 12V
S
P
BUSS BAR
19
R
+
O
58
106
IGNITION S GND (-)
SWITCH
+
P
R
O
15
AB2 BATTERY
30 S 1
P AB1
R
50
-
O
STARTER ENGINE
BLOCK
A B C B+
D+
GND (-)
26A 1 W
26
26
2 +
26B A1 A1
-
27C
A2 A2
40.0 27 27D
MAIN 100
3A 153A
7.5
TRANSMISSION
A3 A3
FRAME
GROUND
B4 B4
1 27C
8 7 A4 A4
111 27D
6 B5 B5
111
2 PARK
E BRAKE 113A
111
1 SWITCH
153A
5
D 153 111A
4 112A
30
E 3 86 PARK
BRAKE 30
DIS. 86 NEUTRAL
2 RELAY
D 85 START
1 87A 87 RELAY
113A 85
87A 87
113B A5 A5
113
106 106
113 B2 B2
B1 B1
C4 C4
C3 C3
C2 C2
F 9 9
B+ 153 112A
1
2 4 4
3 N NEUTRAL 112
112
4 1 1 C5 C5
R B+ 113
SHIFTER
B3 B3
MALE AND FEMALE

BULKHEAD HARNESS
CONNECTORS
MH4950
9.118 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
Continued from
Page 9.117. Check
for power at wire
Not OK
[112A] (GRY),
Pin 86, at neutral
Before troubleshooting any
start relay. electrical circuit, ALWAYS
following:
Check for power at wire 1. All connections relating to
If Repair/replace
[112] (GRY), Pin 4, at circuit are clean and tight.
OK cab harness.
transmission shifter.
2. On 10042 or 10054, if the
Not OK vehicle is starting hard,
make sure that both
outrigger switches are in
Check for power at wire Replace
[113] (RED), Pin 1, at If
transmission
the neutral (center)
OK position.
transmission shifter. shifter.
Not OK
Check for power at

If Repair/replace
wire [111] (RED), Pin 6, at OK cab harness.
park brake switch.
Not OK
Check for power at

If Replace park
wire [1] (WHT), Pin 5, at park OK brake switch.
brake switch.
Not OK
Check for power at

If Replace ignition
wire [26] (RED), Pin A, at OK switch.
ignition switch.
Not OK
Check for power at

Not Replace 40 amp
wire [26B] (RED) at 40 amp OK main fuse.
main fuse.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.119

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 50 DLP
OPEN
51 OPTION
10.0
OPTION
WIPER/
WASHER
DLP
DLP3 OPTION
6
10.0 DLP1
STABILIZER
DLP2
P19 1A+ 2A+ P P
PREHEAT P15
10.0 ENGINE O O
STEER SELECT INDICATOR
SWITCH LIGHT 1 2 FUNCTION N N
INDICATOR
1B- 2B-
LIGHT M M
15.0 L L 50
HORN/HEATER WL1 K K 49
SL1 J J 45
10.0 H H 41
INSTR. PANEL
G G 37
7.5 F F 36
LIGHT SWITCH
RELAY WL1 E E WL 35
SL1 D D SL 31
THS1 C C THS THS 30
B B THS1 THG1 A A THG 26
A A THG1 25
ECM MALE AND FEMALE
20
P14 BULKHEAD HARNESS
THROTTLE CONNECTORS THG 19
SENSOR 11
4
WL 3
SL 1
P2
ENGINE
CONTROL
MODULE
50 PIN FEMALE
CONNECTOR
MH5010
9.120 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
Engine speed drops to low

idle and there is no
response when the throttle
Before troubleshooting any pedal is depressed.
following:
At P2, engine control module
At ECM power harness
1. Fuses. female bulkhead connector, at
50 pin female harness
Not
connector, at Pin 29,
2. All connections relating to Pin B, wire [THP] (RED), OK
wire [THP] (RED), check
circuit are clean and tight. check for 5 VDC.
for 5 VDC.
If OK Not OK
If OK Repair/replace ECM issue.

engine harness. Contact Cummins.
Check for 5 VDC at throttle

sensor female harness Not Repair/replace ECM
connector, at Pin C, wire OK cab harness.
[THP1] (RED).
If OK
Check resistance across pins

at throttle sensor male
connector. Resistance across
Pins A and C should be
2,000 - 3,000 ohms.
Not Replace throttle
Resistance across Pins A and OK pedal assembly.
B should vary from
approximately 500±100
ohms, with throttle pedal at
rest, to approximately
2,200±100 ohms, with pedal
fully depressed.
If OK
Refer to Section 9.7.2, b.

“Flash-Out of Fault Codes,” to
retrieve fault codes.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.121

Electrical System
9.7.38 Charging Circuit and Troubleshooting
+
BATTERY
-
§
BATTERY
GRND
5
30 50
GND
STARTER
5
B+
D+
GND
(-)
See pages 9.39, 9.41, 9.63,
ALTERNATOR
FEMALE AND MALE
BULKHEAD HARNESS
9.65, 9.85 or 9.87.
CONNECTORS
A3 A3
INSTRUMENT PANEL B3 B3
CONNECTOR
HOURMETER
ALTERNAT0R
A1 A1
J3 J8
STARTER 12V
BUSS BAR
B1 B1 +
38 6 GND (-)
C5 C5
BATTERY
1
+
-
B2 B2
STARTER ENGINE
BLOCK
A5 A5
AB2
B4 B4 AB1
C4 C4 BATTERY
2 +
38 38 38
B5 B5
6
C1 C1
6 6 D+ B+
GND (-)
-
W
C2 C2
ALTERNATOR
A2 A2
C3 C3
FRAME
GROUND
MH5020
9.122 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
Dash panel alternator

indicator ON continuously.
Check alternator at Check for proper, low

Not
terminal “B+” for voltage OK
resistance, ground at
output of 13.8 -14.2 volts. alternator.
If OK
If OK
Replace alternator.
Before troubleshooting any With engine running, check

electrical circuit, ALWAYS for battery voltage at Not
Replace alternator.
OK
begin by checking the alternator terminal "D+".
following:
1. Fuses.
If OK
circuit are clean and tight.
3. Check that bulb is OK.
Not
male bulkhead connector, OK
Repair/replace
wire [6] (YEL), Pin C1. engine harness.
If OK

Not
instrument panel connector, OK
Repair/replace cab harness.
wire [6] (YEL), Pin 8.
If OK
Replace instrument panel.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.123

Electrical System
9.7.39 Front Steer Circuit and Troubleshooting
§
See pages 9.50,
FEMALE AND MALE FEMALE AND MALE
9.52, 9.74, 9.76,
BULKHEAD HARNESS
CONNECTORS
BULKHEAD HARNESS
CONNECTORS
9.102 and 9.104.
See pages 9.38, 9.39, A3 A3
9.40, 9.41, 9.62, 9.63, A3 A3
B3 B3
9.64, 9.65, 9.84, 9.85, B3 B3
9.86 or 9.87. A1 A1
A1 A1
INSTRUMENT PANEL
CONNECTOR
GROUND
B1 B1
B1 B1
STEER
J5 SELECT
C5 C5 VALVE
C5 C5 STEER SOLENOIDS
SELECT 8 2C
2GG VALVE B2 B2
SOLENOIDS A B
B2 B2
8 2C A5 A5 AB
A5 A5
+ -
B4 B4 DE
+ -
B4 B4
4-WHEEL
C4 C4 + -
DE + -
C4 C4 CRAB
STEER 20A 20A
4-WHEEL A4 A4
SELECT + - DE
SWITCH B5 B5 + -
2GG CRAB B5 B5
7 8 11B C1 C1 A B
20
2JJ 1 DE C1 C1
AB
11B 1 8 8
20 D 8 8 + - C2 C2 9 2B
2 C2 C2
10.0 + - A2 A2
11A 11A 9
STEER 9
SELECT E 3 A2 A2 2B C3 C3
SWITCH 2C
9 9
C3 C3 20A
20A 20A
20B
3C
INSTRUMENT PANEL
CONNECTOR
TO A1 A1
GROUND
IGNITION 20B
SWITCH A2 A2 2B
RUN J5 20C
20 20 20 2C
A3 A3 20
CAB
GROUND STUD 2G STEER
SELECT
B4 B4 SWITCH
2GG
A4 A4 7 8
2JJ 1 11B
B5 B5 20A
11B 1
D 8
2
11A
E 3
9
CAB
GROUND
STUD
A5 A5
B2 B2 2MM
20A
20A
B1 B1
10.0
C4 C4 STEER
11A
SELECT
SWITCH
C3 C3
C2 C2
SOLENOID COIL
STATE 2G
DE DE-ENERGIZED
C5 C5
E ENERGIZED
C1 C1 3C
TRANS.
GRND
B3 B3
TO
IGNITION 20C
MALE AND FEMALE SWITCH
BULKHEAD HARNESS RUN
CONNECTORS ENGINE GROUND
BUSS BAR
MH5050
9.124 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

following:
1. Fuses.
Front-wheel steer mode

does not function when the
steer select switch is in the
center position

“Front-Wheel Steering Circuit
Disconnect both connectors at
(Left Turn) and
the steer select valve solenoids, Not
Troubleshooting,” or Section
wires [8], [2C] and [9], [2B]. OK
8.8.16, “Front-Wheel Steering
Check for front-wheel steer
Circuit (Right Turn) and
Troubleshooting.”
If OK
Verify 0 volts at steer select Not

Replace steer select switch.
switch, Pins 1 and 3. OK
If OK
Solenoids are energized.

Identify short in either the cab
or engine harness on
wires [8] or [9] to battery
voltage. Repair/replace
shorted harness.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.125

Electrical System
9.7.40 Four-Wheel Steer Circuit and Troubleshooting
§
See pages 9.50,
9.52, 9.74, 9.76,
BULKHEAD HARNESS
CONNECTORS
BULKHEAD HARNESS
CONNECTORS
9.102 and 9.104.
See pages 9.38, 9.39, A3 A3
9.40, 9.41, 9.62, 9.63, A3 A3
B3 B3
9.64, 9.65, 9.84, 9.85, B3 B3
9.86 or 9.87. A1 A1
A1 A1
INSTRUMENT PANEL
CONNECTOR
GROUND
B1 B1
B1 B1
STEER
J5 SELECT
C5 C5 VALVE
SELECT 8 2C
2GG VALVE B2 B2
SOLENOIDS A B
B2 B2
8 2C A5 A5 AB
A5 A5
+ -
B4 B4 E
+ -
B4 B4
4-WHEEL
C4 C4 + -
E + -
C4 C4 CRAB
STEER 20A 20A
4-WHEEL A4 A4
SELECT + - DE
SWITCH B5 B5 + -
2GG CRAB B5 B5
7 8 11B C1 C1 A B
20
2JJ 1 DE C1 C1
AB
11B 1 8 8
20 D 8 8 + - C2 C2 9 2B
2 C2 C2
10.0 + - A2 A2
11A 11A 9
STEER 9
SWITCH 2C
9 9
C3 C3 20A
20A 20A
20B
3C INSTRUMENT PANEL
CONNECTOR
TO A1 A1
GROUND
IGNITION 20B
SWITCH A2 A2 2B
RUN J5 20C
20 20 20 2C
A3 A3 20
CAB
SELECT
B4 B4 SWITCH
2GG
A4 A4 7 8
2JJ 1 11B
B5 B5 20A
11B 1
D 8
2
11A
E 3
9
CAB
GROUND
STUD
A5 A5
B2 B2 2MM
20A
20A
B1 B1
10.0
C4 C4 STEER
11A
SELECT
SWITCH
C3 C3
C2 C2
SOLENOID COIL
STATE 2G
DE DE-ENERGIZED
C5 C5
E ENERGIZED
C1 C1 3C
TRANS.
GRND
B3 B3
TO
IGNITION 20C
BUSS BAR
MH5070
9.126 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
Four-wheel steer mode

does not function with the
steer select switch in the
Before troubleshooting any four-wheel steer mode
position.
following: Disconnect steer select valve Reconnect steer select valve
solenoid male connector solenoid male connector and
1. All connections relating to If
and check for battery OK
verify that solenoid is
circuit are clean and tight. voltage, across wires magnetized by holding a
[9] (LT GRN/BLK) and metal object next to
[2B] (BLK). the solenoid.
If OK Not OK
Refer to Section Replace solenoid.

8.8.17, “Four-
Wheel Steering
Not OK
Circuit (Left Turn)
and
Troubleshooting,”
or Section 8.8.18,
“Four-Wheel
Steering Circuit
(Right Turn) and
Troubleshooting.”

If Repair/replace engine
wire [9] (LT GRN/BLK) at OK harness.
bulkhead connector, Pin C3.
Not OK

If
wire [9] (GRN/BLK) at steer OK
select switch, Pin 3.
Not OK

If
wire [11B] (LT GRN/BLU) at OK
steer select switch, Pin 2.
Not OK

If
10 amp steer select switch OK
fuse, output side.
Not OK
Replace fuse.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.127

Electrical System
9.7.41 Crab Steer Circuit and Troubleshooting
§
See pages 9.50,
9.52, 9.74, 9.76,
BULKHEAD HARNESS
CONNECTORS
BULKHEAD HARNESS
CONNECTORS
9.102 and 9.104.
See pages 9.38, 9.39, A3 A3
9.40, 9.41, 9.62, 9.63, A3 A3
B3 B3
9.64, 9.65, 9.84, 9.85, B3 B3
9.86 or 9.87. A1 A1
A1 A1
INSTRUMENT PANEL
CONNECTOR
GROUND
B1 B1
B1 B1
STEER
J5 SELECT
C5 C5 VALVE
SELECT 8 2C
2GG VALVE B2 B2
SOLENOIDS A B
B2 B2
8 2C A5 A5 AB
A5 A5
+ -
B4 B4 DE
+ -
B4 B4
4-WHEEL
C4 C4 + -
DE + -
C4 C4 CRAB
STEER 20A 20A
4-WHEEL A4 A4
SELECT + - E
SWITCH B5 B5 + -
2GG CRAB B5 B5
7 8 11B C1 C1 AB
20
2JJ 1 E C1 C1
AB
11B 1 8 8
20 D 8 8 + - C2 C2 9 2B
2 C2 C2
10.0 + - A2 A2
11A 11A 9
STEER 9
SWITCH 2C
9 9
C3 C3 20A
20A 20A
20B
3C INSTRUMENT PANEL
CONNECTOR
TO A1 A1
GROUND
IGNITION 20B
SWITCH A2 A2 2B
RUN J5 20C
20 20 20 2C
A3 A3 20
CAB
SELECT
B4 B4 SWITCH
2GG
A4 A4 7 8
2JJ 1 11B
B5 B5 20A
11B 1
D 8
2
11A
E 3
9
CAB
GROUND
STUD
A5 A5
B2 B2 2MM
20A
20A
B1 B1
10.0
C4 C4 STEER
11A
SELECT
SWITCH
C3 C3
C2 C2
SOLENOID COIL
STATE 2G
DE DE-ENERGIZED
C5 C5
E ENERGIZED
C1 C1 3C
TRANS.
GRND
B3 B3
TO
IGNITION 20C
BUSS BAR
MH5090
9.128 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
Crab steer mode does not

function with the steer
select switch in the crab
Before troubleshooting any steer mode position.
Disconnect steer select valve Reconnect steer select valve
following: solenoid male connector solenoid male connector and
If
1. All connections relating to and check for battery OK
verify that solenoid is
circuit are clean and tight. voltage, across wires magnetized by holding a
[8] (LT GRN/WHT) and metal object next to
[2C] (BLK). the solenoid.
If OK Not OK
Refer to Section Replace solenoid.

8.8.19, “Crab
Steering Circuit
Not OK
(Left Turn) and
Troubleshooting,”
or Section 8.8.20,
“Crab Steering
Circuit (Right Turn)
and
Troubleshooting.”

If Repair/replace engine
wire [8] (LT GRN/WHT) at OK harness.
bulkhead connector, Pin C2.
Not OK

If
wire [8] (LT GRN/WHT) at OK
Not OK

If
wire[11B] (LT GRN/BLU) at OK
Not OK

If
10 amp steer select switch OK
fuse, output side.
Not OK
Replace fuse.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.129

Electrical System
9.7.42 10042 Outrigger Circuit and Troubleshooting

7.5
OUTRIGGERS
50 60E
60E
60
60C 60B
60A
60D RIGHT
OUTRIGGER
SWITCH
7 8
2B 1 60B
LEFT
OUTRIGGER UP 1 61
2
SWITCH
60A
7 8 61 61
2A 1 60D DOWN 3 63 61
62 62 OUTRIGGER 62 + + LEFT RIGHT + +
UP 1 63 63 63 2E 2G
2
60C 64 64 OUTRIGGER VALVE
SOLENOIDS
DOWN 3 2E 2E 2E
64 64 + + + +
62
LEFT RIGHT
2D 2D 2D - - DOWN DOWN - -
2A 2D 2F
2 2F 2F OUTRIGGER 2F
3C HARNESS
20 2G 2G 2G
TO
IGNITION
SWITCH
RUN
CAB
GROUND
STUD
MH5110
9.130 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
Note: No outrigger functions

• If no outrigger functions work or a single function
fails to work .
work, the problem is
most likely the main
power to the outrigger Check battery voltage at 7.5
circuit. Not
amp outrigger fuse, OK
Replace fuse.
• If a single outrigger output side.
function (up/down) does
If OK
not work, the problem is
most likely the switch or
that individual circuit. Check battery voltage at fuse
Not Repair/replace
block female connector, wire OK cab harness.
[50] (WHT/YEL).
If OK
Check battery voltage at right

Before troubleshooting any outrigger switch, Pin 2, wire
electrical circuit, ALWAYS [60A] (YEL), Pin 8, wire [60B]
Not Repair/replace
(YEL) and left outrigger
begin by checking the OK cab harness.
switch, Pin 2, wire [60C]
following: (YEL), Pin 8, wire
1. All connections relating to [60D] (YEL).
circuit are clean and tight. If OK
With the bottom of the

Does right outrigger right outrigger switch
Not Not Replace RIGHT
DOWN function pressed in, check for
OK OK outrigger switch.
work? battery voltage at Pin 3,
wire [62] (PUR/WHT).
Follow same procedure as If OK
If OK
right outrigger DOWN
function, testing voltage at Pin
Not Does right outrigger
1, wire [61] (RED/GRY) at Check for battery
OK UP function work?
switch and across connector voltage, across wires
wires [61] (RED/GRY) and [62] (PUR/WHT) and Not Repair/replace
[2G] (BLK) at valve solenoid. [2F] (BLK) at male OK outrigger harness.
If OK connector at the
outrigger valve solenoid.
Follow same procedure as
right outrigger DOWN If OK
function, testing voltage at Does left outrigger
Not
Pin 3, wire [64] (GRY/PUR) at OK
DOWN function
switch and across connector work? Reconnect outrigger
wires [64] (GRY/PUR) and valve solenoid male
[2D] (BLK) at valve solenoid. connector and verify that
Not
solenoid is magnetized OK
Replace solenoid.
If OK by holding a metal object
Follow same procedure as next to the solenoid with
right outrigger DOWN power applied.
function, testing voltage at
Not Does left outrigger If OK
Pin 1, wire [63] (BRN/YEL) at OK UP function work?
switch and across connector
wires [63] (BRN/YEL) and Refer to Section 8.8.28, “Outrigger
[2E] (BLK) at valve solenoid. Circuit Description (10042/10054).”
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.131

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).”
9.132 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.133

Electrical System
9.7.44 Front Windshield Wiper Circuit and Troubleshooting (Option)
10.0
OPTION
32 6F
30
WIPER/
WASHER
6 PUR
6A 4 3 2
3 2
9 6 4 3 1
L
9 6 4 3 1 L H
P H
4 P M FRONT
WIPER
MOTOR
2 1 GND
FRONT
7 5 2 WIPER
SWITCH
3C
7 5 2
TO 1A 6A PUR
IGNITION
SWITCH
RUN 1
1A
2
1D
CAB
GROUND
STUD
MH5120
9.134 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

With front wiper switch in LOW or HIGH
electrical circuit, ALWAYS position, the wiper does not operate.
following:
Not
Note: When troubleshooting Check 10-amp wiper fuse. OK
Replace fuse.
the wiper circuit, verify and fix
If OK
the LOW speed function before
the HIGH speed function.
Check for battery voltage at fuse block Not Repair/replace
1. All connections relating to female connector wire 32 (GRY/WHT). OK cab harness.
If OK
Check for battery voltage on wiper switch

Not Repair/replace
connector at Pins 9 and 5, OK wiper harness.
wires 6 (RED/WHT) and 6A (RED/WHT).
With front wiper switch in
LOW position, the wiper
If OK
does not operate.
With the front wiper switch in

the LOW position, check for Not Replace front
battery voltage at Pin 4 at OK wiper switch.
switch connector.
If OK With front wiper switch in

HIGH position, the wiper
does not operate.
Check for battery voltage at Not Repair/replace
Pin 2 at switch connector. OK wiper harness.
With the front wiper switch in
If OK the HIGH position, check for Not Replace front
battery voltage at Pin 1, wire OK wiper switch.
Replace front [2] (BLU), at switch connector.
Check for battery voltage at Not
Pin 3 at switch connector. OK wiper switch.
If OK
If OK
Pin H, wire [2] (BLU) at front OK wiper harness.
Check for battery voltage at Repair/replace
Not wiper motor connector.
Pin L, wire [3] (WHT) at front OK wiper harness.
wiper motor connector.
If OK
If OK
Check for proper ground at Not Clean, tighten
front wiper motor. OK and recheck.
front wiper motor. OK and recheck.
If OK
If OK
Replace front wiper motor.
Replace front wiper motor.
Then
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.135

Electrical System
9.7.45 Skylight Wiper Circuit and Troubleshooting (Option)
10.0
OPTION
32 6F
30
WIPER/
WASHER
6B PUR
6C 9 5
5
9 6 4 3 1
C
9 6 4 3 1 Run
Park
9 A M
SKYLIGHT
WIPER
2 1 GND MOTOR
1E
7 5 2 SKYLIGHT
WIPER
3C SWITCH
7 5 2
TO 1B 6C PUR
IGNITION
SWITCH
RUN 1E
1B
2
1D
CAB
GROUND
STUD
MH5130
9.136 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
With skylight wiper switch

in the RUN position, the
wiper does not operate.

Not
electrical circuit, ALWAYS Check 10-amp wiper fuse. OK
Replace fuse.
If OK
following:
circuit are clean and tight. fuse block female connector Not Repair/replace
OK cab harness.
wire [32] (GRY/WHT).
If OK
Check for battery voltage on

wiper switch connector at
Not Repair/replace
Pins 9 and 5, OK wiper harness.
wires [6B] (RED/WHT) and
[6C] (RED/WHT).
If OK
With the skylight wiper switch

Replace
in the RUN position, check for Not
skylight wiper
battery voltage at Pin 4 at OK
switch.
switch connector.
If OK

Pin 2 at switch connector. OK wiper harness.
If OK
Replace
Check for battery voltage at Not
skylight wiper
Pin 1 at switch connector. OK
switch.
If OK

Not Repair/replace
Pin C, wire [5] (YEL) at OK wiper harness.
skylight wiper motor
connector.
If OK

skylight wiper motor. OK and recheck.
If OK
Replace skylight wiper motor.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.137

Electrical System
9.7.46 Front Windshield & Skylight Washer Circuit and Troubleshooting (Option)
10.0
OPTION
32 6F
30
WIPER/
WASHER
6D
6E
8 3
8 3
1
FRONT
WASHER
3C 7 2 SWITCH
TO 7 2
IGNITION
SWITCH 1C 10
RUN
POWER
FRONT
WASHER
M PUMP
MOTOR
GND
1F
1C
2
1D
CAB
GROUND
STUD
MH5140
9.138 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
Washer does not spray

water on front windshield
and skylight.
following: Check reservoir for Not Fill reservoir with
Not OK
washer fluid. OK washer fluid.
circuit are clean and tight. If OK
Not
Check hose connections. OK
Fix hose connections.
If OK
Verify that both wipers are Not

Troubleshoot and fix.
operating properly. OK
If OK
Check for battery voltage on

washer switch connector at
Not Repair/replace
Pins 3 and 8, OK wiper harness.
wires [6D] (RED/WHT) and
[6E] (RED/WHT).
If OK
With the washer switch

pressed, check for battery Not
Replace front washer switch.
voltage at Pin 2 at switch OK
connector.
If OK

Not Repair/replace
wire [10] (GRN) at washer OK wiper harness.
pump motor connector.
If OK
Check for proper ground at Not

washer pump motor. OK
If OK
Replace washer pump motor.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.139

Electrical System
9.7.47 Heater Circuit and Troubleshooting (Option)
1 HEATER
1
POWER BLOWER
MOTOR
BLOWER
4
4 MOTOR M
RESISTOR
PACK GND
3
3
1 4 3 2
1 4 3
5
L M
O
H
CAB
C GROUND
B BLOWER STUD
SWITCH
2
2
15.0
HORN/HEATER 52 2
3C
TO
IGNITION
SWITCH
RUN
MH5150
9.140 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
Heater fan does not

operate.
Not
Check 15-amp heater fuse. OK
Replace fuse.
If OK

Not
fuse block female connector OK
wire [52] (ORG).
If OK

electrical circuit, ALWAYS Not Repair/replace
blower switch connector,
begin by checking the OK heater harness.
Pin 2, wire [2] (RED/WHT).
following:
1. All connections relating If OK
to circuit are clean and
tight.
blower switch connector; Pin
1, wire [1] (YEL) with switch
set to LOW speed; Pin 4, Not
Replace blower switch.
wire [4] (RED) with switch set OK
to MEDIUM speed; and Pin 3,
wire [3] (ORG) with switch set
to HIGH speed.
If OK

blower connector; Pin 1, wire
[1] (YEL) with switch set to
LOW speed; Pin 4, wire [4] Not Repair/replace
(RED) with switch set to OK heater harness.
MEDIUM speed; and Pin 3,
wire [3] (ORG) with switch set
to HIGH speed.
If OK
Check for proper ground at Not

blower motor. OK
If OK
Replace blower motor.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.141

Electrical System
9.7.48 Roadlights Main Beam Circuit and Troubleshooting (Option)
DIPPED DIPPED
BOOM
FRONT FRONT
1 21 1
P N
3D 2B
4 24A 24B 4
BOOM
BEAM BEAM
HARNESS
LIGHTING
2 3 6 6 3 2 P06A CONTROL
LEVER
C (15)
1C OFF
20A 22A 2J 2H 23A 20B
L11 POSITION
See Pages 9.38, 9.40, A (58) LOW BEAM
20A 20
20 20
L10 3D 2B
9.50, 9.62, 9.64, 9.74, B (56)
21 21
9.84, 9.86, or 9.102 21
P04B
A B
21C
C (+15/56) A B
INSTRUMENT 31
HIGH
PANEL BEAM
CONNECTOR L14 3A 2C
24B B (56a)
BACK 25 25
LIGHT 156 20F A LH
20 24A 24 24
(J2) 24
TURN 24C
R D
(J15) 23
2J ON
HIGH 2
F 49a
BEAM 154 24C 28A
(J14) ON L E
22
OFF
22A
21C 21C 22
22 22
21C 27A 22C 22B
23 31
23A 23
30
86 HEADLIGHT
SWITCH 23C 23B
23 23
85 RELAY
87A 87
2KK 23
1C
1F 3A
1
1F 4A
2B
2
12 29
1J 32 23C 22C 2B
30 WORKLIGHT 8 3 6
86 LIGHT SWITCH
OFF OFF ALL ALL
85 RELAY ON OFF OFF
87A 87 ON
HAZARD 1 1 2
12B SWITCH
2DD 2 5 8
7.5 12A 12AA 1 7 2 5
LIGHT SWITCH 12 12A
RELAY 1J
3C 2K 1A
2KK
33 28B 1B 1E
TO 2DD
20
IGNITION 29 1 1A
1 1 1
SWITCH
RUN 1D
40.0
LIGHTS 2
28A 2K
28
27F 33 28 2C
27 2 2 2
27C 2A 2G
TO STARTER
100 P X L
TO
27B FLASHER CAB
GROUND
20.0 12C 32 20D STUD
LIGHTS 1 20
2D
27A 2 2
4B 4A
4
TO 20C 2E 4C 2F 20D
PARK
BRAKE 3 1 1 3
SWITCH
TO & LEFT RIGHT
SELECT LOCK
RELAY
46 45B
4 2 2 4
1 2 3 BRAKE 26A 22B 23B 26B

PEDAL LEFT
SWITCH REAR
with Pedal REAR
N P
1D 26 26A 4C 2G
P N
26 26B
26
MH5620
9.142 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

following:
1. Fuses.
3. If dipped beam headlights
do not work, follow the
steps listed at, Section
With the ignition ON and
9.7.51, “Roadlights Side &
the lighting control lever Dipped Beam Lights
rotated to 2nd position Circuit and
(Side Lights & Headlights) Troubleshooting (Option),”
and pulled back for main before troubleshooting
beams ON, main beam
indicator and main beams
the main beam circuit.
remain OFF. 4. If one of the main beams
work, the circuit is fine,
the failed bulb needs to be
Check for battery voltage at replaced.
Not
Pin 30, wire [27A] (RED), on OK
headlight switch relay.
If OK
Check for battery

Disconnect two position
Check for battery voltage at voltage across headlight
Not Not connector on roadlight
Pin 87, wire [23] (GRN), on switch relay coil
OK OK harness and check for battery
headlight switch relay. Pins 85, wire [2KK] (BLK) &
voltage at wire [21C].
86, wire [21C] (RED).
If OK
If OK Not OK
If OK Replace headlight
switch relay Repair/replace cab Repair/replace
harness. roadlight harness.
Disconnect six position plug

at lighting control lever and
Not
check for voltage at roadlight OK
Replace cab harness.
harness pin C, wire
[31] (YEL).
If OK
Connect six position plug at

lighting control lever and pull Not
Replace lighting control lever.
back on lever to flash main OK
beams.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.143

Electrical System
9.7.49 Roadlights Hazard Lights Circuit and Troubleshooting (Option)
DIPPED DIPPED
BOOM
FRONT FRONT
1 21 1
P N
3D 2B
4 24A 24B 4
BOOM
BEAM BEAM
HARNESS
LIGHTING
2 3 6 6 3 2 P06A CONTROL
LEVER
C (15)
1C OFF
20A 22A 2J 2H 23A 20B
L11 POSITION
20A 20
20 20
L10 3D 2B
9.50, 9.62, 9.64, 9.74, B (56)
21 21
9.84, 9.86, or 9.102 21
P04B
A B
21C
C (+15/56) A B
INSTRUMENT 31
HIGH
PANEL BEAM
CONNECTOR L14 3A 2C
24B B (56a)
BACK 25 25
LIGHT 156 20F A LH
20 24A 24 24
(J2) 24
TURN 24C
R D
(J15) 23
2J ON
HIGH 2
F 49a
BEAM 154 24C 28A
(J14) ON L E
22
OFF
22A
21C 21C 22
22 22
21C 27A 22C 22B
23 31
23A 23
30
86 HEADLIGHT
SWITCH 23C 23B
23 23
85 RELAY
87A 87
2KK 23
1C
1F 3A
1
1F 4A
2B
2
12 29
1J 32 23C 22C 2B 8 3 6
30 WORKLIGHT
86 LIGHT SWITCH
OFF OFF ALL ALL
85 RELAY ON OFF OFF
87A 87 ON
HAZARD 1 1 2
12B SWITCH
2DD 2 5 8
7.5 12A 12AA 1 7 2 5
LIGHT SWITCH 12 12A
RELAY 1J
3C 2K 1A
2KK
33 28B 1B 1E
TO 2DD
20
IGNITION 29 1 1A
1 1 1
SWITCH
RUN 1D
40.0
LIGHTS 2
28A 2K
28
27F 33 28 2C
27 2 2 2
27C 2A 2G
TO STARTER
100 P X L
TO
27B FLASHER CAB
GROUND
20.0 12C 32 20D STUD
LIGHTS 1 20
2D
27A 2 2
4B 4A
4
TO 20C 2E 4C 2F 20D
PARK
BRAKE 3 1 1 3
SWITCH
TO & LEFT RIGHT
SELECT LOCK
RELAY
46 45B
4 2 2 4
1 2 3 BRAKE 26A 22B 23B 26B

PEDAL LEFT
SWITCH REAR
with Pedal REAR
N P
1D 26 26A 4C 2G
P N
26 26B
26
MH5170
9.144 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
With ignition switch OFF,

Before troubleshooting any hazard indicator and all
electrical circuit, ALWAYS hazard lights remain OFF
begin by checking the with the 4 way hazard
following: switch in the ON position.
1. Fuses.
2. All connections relating
Disconnect connector at fuse
tight. block, wire [12C] to wire [32]
Not
3. If one or more of the on roadlight harness. Check OK
hazard lights work, the for battery voltage at
wire [12C] (DK BLU).
circuit is fine, the failed
bulb(s) need to be
If OK
replaced.
Reconnect leads and check

for battery voltage at Pin 3, Not
Repair/replace roadlight
wire [32] (GRN) on hazard OK
harness.
switch.
If OK

Not
Pin 2, wire [33] (VIO) on OK
Replace hazard switch.
hazard switch.
If OK

Not
Pin 5, wire [28B] (VIO) on OK
Replace flasher.
hazard switch.
If OK

Pin 17 (right signals), wire
Not
[23C] (GRN), and Pin 18 (left OK
signals), wire [22C] (ORG) on
hazard switch.
If OK

turn signal light connections
Not Repair/replace roadlight
([2H] & [23A], [2F] & [23B], OK harness.
[2J] & [22A] and
[2E] & [22B]).
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.145

Electrical System
9.7.50 Roadlights Turn Signals Circuit and Troubleshooting (Option)
DIPPED DIPPED
BOOM
FRONT FRONT
1 21 1
P N
3D 2B
4 24A 24B 4
BOOM
BEAM BEAM
HARNESS
LIGHTING
2 3 6 6 3 2 P06A CONTROL
LEVER
C (15)
1C OFF
20A 22A 2J 2H 23A 20B
L11 POSITION
20A 20
20 20
L10 3D 2B
9.50, 9.62, 9.64, 9.74, B (56)
21 21
9.84, 9.86, or 9.102 21
P04B
A B
21C
C (+15/56) A B
INSTRUMENT 31
HIGH
PANEL BEAM
CONNECTOR L14 3A 2C
24B B (56a)
BACK 25 25
LIGHT 156 20F A LH
20 24A 24 24
(J2) 24
TURN 24C
R D
(J15) 23
2J ON
HIGH 2
F 49a
BEAM 154 24C 28A
(J14) ON L E
22
OFF
22A
21C 21C 22
22 22
21C 27A 22C 22B
23 31
23A 23
30
86 HEADLIGHT
SWITCH 23C 23B
23 23
85 RELAY
87A 87
2KK 23
1C
1F 3A
1
1F 4A
2B
2
12 29
1J 32 23C 22C 2B 8 3 6
30 WORKLIGHT
86 LIGHT SWITCH
OFF OFF ALL ALL
85 RELAY ON OFF OFF
87A 87 ON
HAZARD 1 1 2
12B SWITCH
2DD 2 5 8
7.5 12A 12AA 1 7 2 5
LIGHT SWITCH 12 12A
RELAY 1J
3C 2K 1A
2KK
33 28B 1B 1E
TO 2DD
20
IGNITION 29 1 1A
1 1 1
SWITCH
RUN 1D
40.0
LIGHTS 2
28A 2K
28
27F 33 28 2C
27 2 2 2
27C 2A 2G
TO STARTER
100 P X L
TO
27B FLASHER CAB
GROUND
20.0 12C 32 20D STUD
LIGHTS 1 20
2D
27A 2 2
4B 4A
4
TO 20C 2E 4C 2F 20D
PARK
BRAKE 3 1 1 3
SWITCH
TO & LEFT RIGHT
SELECT LOCK
RELAY
46 45B
4 2 2 4
1 2 3 BRAKE 26A 22B 23B 26B

PEDAL LEFT
SWITCH REAR
with Pedal REAR
N P
1D 26 26A 4C 2G
P N
26 26B
26
MH5630
9.146 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

the lighting control lever
pushed up for left turn
Before troubleshooting any signal or down for right
electrical circuit, ALWAYS turn signal, turn signal
indicator and turn signals
remain OFF.
following:
1. Fuses.
With hazard switch OFF,
2. All connections relating check for battery voltage at Not Repair/replace roadlight
to circuit are clean and Pin 8, wire [1B] (RED) on OK harness.
tight. hazard switch.
3. Before troubleshooting
If OK
the turn signal circuit,
verify that the hazard
light circuit is operating. Check for battery voltage at
If not, follow the steps Not Repair/replace roadlight
Pin 1, wire [1B] (RED) on OK harness.
listed at, Section 9.7.49, hazard switch.
“Roadlights Hazard
Lights Circuit and If OK
Troubleshooting
(Option),” before
troubleshooting the turn Check for battery voltage at
Not
Pin 2, wire [33] (VIO) on OK
signal circuit. hazard switch.
the turn signal circuit, If OK
verify that the worklight
circuit is operating. If
not, follow the steps Check for battery voltage at
Pin X, wire [33] (VIO)
listed at, Section 9.7.53, OK harness.
on flasher.
“Roadlights w/
Worklights Circuit and If OK
Troubleshooting
(Option),” before
troubleshooting the turn Check for battery voltage at
Not
signal circuit. Pin L, wire [28] (VIO) OK
Replace flasher.
on flasher.
5. If one of the turn signals
work, the circuit is fine, If OK
the failed bulb needs to
be replaced.
Disconnect six position plug
at lighting control lever and
check for voltage at roadlight OK harness.
harness Pin F, wire
[28A] (VIO).
If OK
Connect six position plug at

Not
lighting control lever and try OK
Replace lighting control lever.
turn signals.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.147

Electrical System
9.7.51 Roadlights Side & Dipped Beam Lights Circuit and Troubleshooting (Option)
DIPPED DIPPED
BOOM
FRONT FRONT
1 21 1
P N
3D 2B
4 24A 24B 4
BOOM
BEAM BEAM
HARNESS
LIGHTING
2 3 6 6 3 2 P06A CONTROL
LEVER
C (15)
1C OFF
20A 22A 2J 2H 23A 20B
L11 POSITION
20A 20
20 20
L10 3D 2B
9.50, 9.62, 9.64, 9.74, B (56)
21 21
9.84, 9.86, or 9.102 21
P04B
A B
21C
C (+15/56) A B
INSTRUMENT 31
HIGH
PANEL BEAM
CONNECTOR L14 3A 2C
24B B (56a)
BACK 25 25
LIGHT 156 20F A LH
20 24A 24 24
(J2) 24
TURN 24C
R D
(J15) 23
2J ON
HIGH 2
F 49a
BEAM 154 24C 28A
(J14) ON L E
22
OFF
22A
21C 21C 22
22 22
21C 27A 22C 22B
23 31
23A 23
30
86 HEADLIGHT
SWITCH 23C 23B
23 23
85 RELAY
87A 87
2KK 23
1C
1F 3A
1
1F 4A
2B
2
12 29
1J 32 23C 22C 2B 8 3 6
30 WORKLIGHT
86 LIGHT SWITCH
OFF OFF ALL ALL
85 RELAY ON OFF OFF
87A 87 ON
HAZARD 1 1 2
12B SWITCH
2DD 2 5 8
7.5 12A 12AA 1 7 2 5
LIGHT SWITCH 12 12A
RELAY 1J
3C 2K 1A
2KK
33 28B 1B 1E
TO 2DD
20
IGNITION 29 1 1A
1 1 1
SWITCH
RUN 1D
40.0
LIGHTS 2
28A 2K
28
27F 33 28 2C
27 2 2 2
27C 2A 2G
TO STARTER
100 P X L
TO
27B FLASHER CAB
GROUND
20.0 12C 32 20D STUD
LIGHTS 1 20
2D
27A 2 2
4B 4A
4
TO 20C 2E 4C 2F 20D
PARK
BRAKE 3 1 1 3
SWITCH
TO & LEFT RIGHT
SELECT LOCK
RELAY
46 45B
4 2 2 4
1 2 3 BRAKE 26A 22B 23B 26B

PEDAL LEFT
SWITCH REAR
with Pedal REAR
N P
1D 26 26A 4C 2G
P N
26 26B
26
MH5640
9.148 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
Before troubleshooting any With the ignition ON and

electrical circuit, ALWAYS the lighting control lever
begin by checking the rotated to 1st position
following: (Side Lights Only), side
lights remain OFF.
1. Fuses.
If one position light is not ON,
tight. Disconnect three position
verify voltage at that position
3. Before troubleshooting light, wires plug at lighting control lever
Not
either the side lights [2J] & [20A] (Left Front), OK
and check for voltage at
[2H] & [20B] (Right Front), roadlight harness Pin C,
circuit or the dipped wire [1C] (RED).
[2F] & [20D] (Right Rear) or
beam lights circuit, verify [2E] & [20C] (Left Rear).
that the worklight circuit
is operating. If not, follow
If OK
the steps listed at, If OK Not OK
Section 9.7.53,
“Roadlights w/
Replace bulb. Replace lighting Repair/replace
Worklights Circuit and
control lever. roadlight harness.
Troubleshooting
(Option),” before
troubleshooting either
the side lights circuit or
the dipped beam lights
circuit.

the lighting control lever
rotated to 2nd position
(Side Lights & Headlights)
and pulled back for dipped
beam lights ON, dipped
beam lights remain OFF.
If one dipped beam light is not Disconnect three position

ON, verify voltage at that plug at lighting control lever
Not
dipped beam light, wires OK
and check for voltage at
[2J] & [21A] (Left Front), roadlight harness Pin C,
[2H] & [21B] (Right Front). wire [1C] (RED).
If OK
If OK Not OK
Replace bulb. Replace lighting Repair/replace

control lever. roadlight harness.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.149

Electrical System
9.7.52 Roadlights Brake Lights Circuit and Troubleshooting (Option)
DIPPED DIPPED
BOOM
FRONT FRONT
1 21 1
P N
3D 2B
4 24A 24B 4
BOOM
BEAM BEAM
HARNESS
LIGHTING
2 3 6 6 3 2 P06A CONTROL
LEVER
C (15)
1C OFF
20A 22A 2J 2H 23A 20B
L11 POSITION
20A 20
20 20
L10 3D 2B
9.50, 9.62, 9.64, 9.74, B (56)
21 21
9.84, 9.86, or 9.102 21
P04B
A B
21C
C (+15/56) A B
INSTRUMENT 31
HIGH
PANEL BEAM
CONNECTOR L14 3A 2C
24B B (56a)
BACK 25 25
LIGHT 156 20F A LH
20 24A 24 24
(J2) 24
TURN 24C
R D
(J15) 23
2J ON
HIGH 2
F 49a
BEAM 154 24C 28A
(J14) ON L E
22
OFF
22A
21C 21C 22
22 22
21C 27A 22C 22B
23 31
23A 23
30
86 HEADLIGHT
SWITCH 23C 23B
23 23
85 RELAY
87A 87
2KK 23
1C
1F 3A
1
1F 4A
2B
2
12 29
1J 32 23C 22C 2B 8 3 6
30 WORKLIGHT
86 LIGHT SWITCH
OFF OFF ALL ALL
85 RELAY ON OFF OFF
87A 87 ON
HAZARD 1 1 2
12B SWITCH
2DD 2 5 8
7.5 12A 12AA 1 7 2 5
LIGHT SWITCH 12 12A
RELAY 1J
3C 2K 1A
2KK
33 28B 1B 1E
TO 2DD
20
IGNITION 29 1 1A
1 1 1
SWITCH
RUN 1D
40.0
LIGHTS 2
28A 2K
28
27F 33 28 2C
27 2 2 2
27C 2A 2G
TO STARTER
100 P X L
TO
27B FLASHER CAB
GROUND
20.0 12C 32 20D STUD
LIGHTS 1 20
2D
27A 2 2
4B 4A
4
TO 20C 2E 4C 2F 20D
PARK
BRAKE 3 1 1 3
SWITCH
TO & LEFT RIGHT
SELECT LOCK
RELAY
46 45B
4 2 2 4
1 2 3 BRAKE 26A 22B 23B 26B

PEDAL LEFT
SWITCH REAR
with Pedal REAR
N P
1D 26 26A 4C 2G
P N
26 26B
26
MH5650
9.150 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

following:
1. Fuses.
tight.
the brake lights circuit,
verify that the worklight
circuit is operating. If
not, follow the steps
listed at, Section 9.7.53,
“Roadlights w/
With the ignition ON and Worklights Circuit and
the brake pedal depressed, Troubleshooting
brake lights remain OFF. (Option),” before
troubleshooting the
brake lights circuit.
If one brake light is not

ON with the brake pedal
depressed, verify voltage Check for voltage at brake
Not
at that brake light OK
pedal switch Pin 4,
connector, wires wire [1D] (RED).
[2E] & [26A] (Left Rear) or
[2F] & [26B] (Right Rear).
If OK
If OK Not OK
Replace bulb.
Check for voltage at Repair/replace
brake pedal switch roadlight harness.
Pin 5, wire [26]
If OK Not OK
Repair/replace Replace brake

roadlight harness. switch.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.151

Electrical System
9.7.53 Roadlights w/Worklights Circuit and Troubleshooting (Option)
DIPPED DIPPED
BOOM
FRONT FRONT
1 21 1
P N
3D 2B
4 24A 24B 4
BOOM
BEAM BEAM
HARNESS
LIGHTING
2 3 6 6 3 2 P06A CONTROL
LEVER
C (15)
1C OFF
20A 22A 2J 2H 23A 20B
L11 POSITION
A (58) LOW BEAM
See Pages 9.38, 9.40, 20A
20 20
20
L10 3D 2B
9.50, 9.62, 9.64, 9.74, 21 21
B (56)
21 A B
9.84, 9.86, or 9.102 21C
P04B
C (+15/56) A B
INSTRUMENT 31
HIGH
PANEL BEAM
CONNECTOR L14 3A 2C
24B B (56a)
BACK 25 25
LIGHT 156 20F A LH
20 24A 24 24
(J2) 24
TURN 24C
R D
(J15) 23
2J ON
HIGH 2
F 49a
BEAM 154 24C 28A
(J14) ON L E
22
OFF
22A
21C 21C 22
22 22
21C 27A 22C 22B
23 31
23A 23
30
86 HEADLIGHT
SWITCH 23C 23B
23 23
85 RELAY
87A 87
2KK 23
1C
1F 3A
1
1F 4A
2B
2
12 29
1J 32 23C 22C 2B
30 WORKLIGHT 8 3 6
86 LIGHT SWITCH
OFF OFF ALL ALL
85 RELAY ON OFF OFF
87A 87 ON
HAZARD 1 1 2
12B SWITCH
2DD 2 5 8
7.5 12A 12AA 1 7 2 5
LIGHT SWITCH 12 12A
RELAY 1J
3C 2K 1A
2KK
33 28B 1B 1E
TO 2DD
20
IGNITION 29 1 1A
1 1 1
SWITCH
RUN 1D
40.0
LIGHTS 2
28A 2K
28
27F 33 28 2C
27 2 2 2
27C 2A 2G
TO STARTER
100 P X L
TO
27B FLASHER CAB
GROUND
20.0 12C 32 20D STUD
LIGHTS 1 20
2D
27A 2 2
4B 4A
4
TO 20C 2E 4C 2F 20D
PARK
BRAKE 3 1 1 3
SWITCH
TO & LEFT RIGHT
SELECT LOCK
RELAY
46 45B
4 2 2 4
1 2 3 BRAKE 26A 22B 23B 26B

PEDAL LEFT
SWITCH REAR
with Pedal REAR
N P
1D 26 26A 4C 2G
P N
26 26B
26
MH5610
9.152 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

Worklights remain OFF
with the ignition ON
following:
position and the bottom of 1. Fuses.
the worklight switch
pushed in. 2. All connections relating to
Check for battery voltage at Check for battery voltage at

Not Not
light switch relay Pin 30, OK
wire [12AA] (DK BLU). wire [29] (RED).
If OK
Check for battery voltage

across light switch relay coil Not
Pins 85, wire [2DD] (BLK) & OK
If OK
86, wire [12A] (DK BLU).
If OK
Replace light switch relay.

worklight switch Pin 8, OK harness.
wire [1F] (RED).
If OK

at worklight switch Not Repair/replace roadlight
Pins 2, wire [1E] (RED) and OK harness.
5, wire 1A (RED).
For boom worklight, check

If OK
Not battery voltage at worklight Not
Replace worklight switch.
OK switch Pin 3, OK
wire [3A] (LT BLU).
Make sure that the switch is
If OK
pushed all the way in on the
bottom. Measure voltage at
both wire leads at each light. Repair/replace roadlight
[2D] & [4B] (Left Rear), harness.
[2G] & [4C] (Right Rear) and
[2B] & [3D] (Boom).
For rear worklights, check

If OK Not Not
OK
battery voltage at worklight OK
switch Pin 6, wire [4A] (YEL).
Replace bulb. If OK
harness.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.153

Electrical System
9.7.54 Worklight (Without Roadlights) Circuit and Troubleshooting (Option)
BOOM
WORKLIGHT
3D 2B
P N
LEFT RIGHT Boom

FRONT
WORKLIGHT
FRONT
WORKLIGHT Worklight 3D 2B
Harness
A B
2B1 3B 3C 2B2
N P P N
A B
3D 2B4
3C 3D
3B
3 3
3A1
See Pages 9.38, 9.40,

9.50, 9.62, 9.64, 9.74, 2B2
2B1 2B4
9.84, 9.86, or 9.102 2
INSTRUMENT
PANEL
CONNECTOR
BACK
LIGHT 156 3A
(J2)
3A1
3A
1A 4A
WORKLIGHT 8 3 6
SWITCH
BOOM BOOM
ALL ALL
OFF OFF
12 29 1 2
30 LIGHT
86
SWITCH 12B 7 2 5
85 RELAY
87A 87
2C 1B 1C
12B 1A
2DD
7.5 12A 12AA 1 1 1C
LIGHT SWITCH 12 12A 1 1
RELAY
3C
2DD 2C
TO 20
IGNITION 29 2B3
SWITCH 2 2
RUN 40.0 2B5 2A
LIGHTS 2
27F
TO
27C CAB
TO STARTER
TO MAIN FUSE 27 27 27D GROUND
100 STUD
4A
4
4B 4C
LEFT RIGHT
REAR REAR
WORKLIGHT WORKLIGHT
2B3 4B 4C 2B5
N P P N
MH5180
9.154 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

Worklights remain OFF
with the ignition ON
following:
position and the bottom of 1. Fuses.
the worklight switch
pushed in. 2. All connections relating to
Check for battery voltage at Check for battery voltage at

Not Not
light switch relay Pin 30, OK
wire [12AA] (DK BLU). wire [29] (RED).
If OK

across light switch relay coil Not
Pins 85, wire [2DD] (BLK) & OK
If OK
86, wire [12] (DK BLU).
If OK
Replace light switch relay.

worklight switch Pin 8, OK harness.
wire [1F] (RED).
If OK

at worklight switch Not Repair/replace roadlight
Pins 2, wire [1E] (RED) and OK harness.
5, wire 1A (RED).
If OK
For front worklights, check
Not battery voltage at worklight Not
OK switch Pin 3, OK
Make sure that the switch is wire [3A] (LT BLU).
pushed all the way in on the
bottom. Measure voltage at If OK
both wire leads at each light.
[2B3] & [4B] (Left Rear),
[2B5] & [4C] (Right Rear), Repair/replace roadlight
[2B4] & [3D] (Boom), harness.
[2B1] & [3B] (Left Front) and
[2B2] & [3C] (Right Front).
For rear worklights, check
Not Not
OK
battery voltage at worklight OK
If OK switch Pin 6, wire [4A] (YEL).
If OK
Replace bulb.
harness.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.155

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. 10/03

Electrical System
9.8.1 Transmission, Forward First Gear Circuit, (SN 8042, 13198 - 18990, 10042 13198 - 19030)
3A

1
8 7
6
2 PARK
E BRAKE
SWITCH
3C 5
D
26A 4
A B C D E E 3
A B C D E TO
2
41 PARK
D
107 107 BRAKE
1
DIS.
S
RELAY
19 P
R TO
O
58
26A IGNITION
IGNITION S SWITCH
SWITCH P 26
R
15
O
30 S
P
R 7.5 40.0
7.5 O
50
LIGHT SWITCH
RELAY
MAIN
See pages
LIGHT SWITCH
RELAY
3C A B C
3
TO 9.38 or 9.62.
IGNITION
153A SWITCH
1 2HH
1 8 7
111
26A 6
26 111
PARK 107B
E 2 153
BRAKE 113A
26 1 SWITCH 30 111
26 86 PARK
5
BRAKE 112A 111A
D
26B 4 DIS. 30 A1 A1
27C RELAY 86
TO STARTER E 3
85 NEUTRAL
87A 87 A2 A2
40.0 27 27D 113A START
MAIN
100 RELAY
2 85
D 41 113B
41B 107A 107B 2EE 113 87A 87
1
113 2FF
3A 153A
7.5 2HH 20 20 20
TRANSMISSION 9 9 20 20 A3 A3
B+ 153
FORWARD 8
GEAR
8
150 CAB
1st Gear 7 7
GROUND
STUD
MALE AND FEMALE
BULKHEAD HARNESS
GEAR 103 CONNECTORS
6 6
1 F GEAR
2
5 5
3
N GEAR 101
112A
4 4
R NEUTRAL 112 112
SHIFTER 112
ZF TRANSMISSION 3 3
REVERSE
2 2
FORWARD 104
1 1
B+ 113
20
2DD 20
A5 A5
B2 B2
2G 2H
2D 2J
B1 B1 2J 7 7
104
104 104B Y1 Y3 Y2
C4 C4 104 1 1
E E DE
103 103 103B Y1 Y3 Y2
C3 C3 103 3 3
C2 C2 2 2
UPPER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
C5 C5 4 4 Upper Lower
Valve Valve
101 101 101B Body Body
C1 C1 101 5 5 Y6 Y5 Y4
150 150 150B E E DE
B3 B3 150 6 6 Driving Speed
103A 104A 2H Direction Y1 Y2 Y3 Y4 Y5 Y6
7 7
MALE AND FEMALE 2DD 101A 150A 2D
BULKHEAD HARNESS Forward 1
CONNECTORS F E B A A B E F
Forward 2
Forward 3
Y6 Y5 Y4 Forward 4
2G
Reverse 1
LOWER Reverse 2
TRANSMISSION COILS
TRANS.
(VIEWED FROM
FRONT OF VEHICLE)
Reverse 3
GRND
MH5270
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.157

Electrical System
9.8.2 Transmission, Forward First Gear Circuit, (SN 10054, 13198 - 19079)
3A

8 7
6
2 PARK
E BRAKE
SWITCH
3C 5
D
26A 4
A B C D E E 3
A B C D E TO
2 PARK
B
D 41
41 52 BRAKE
1
INTERLOCK
S 107 NOT USED RELAY
19 P
R TO
58
26A IGNITION
IGNITION
O
S
52 SWITCH
SWITCH P 26
R
15 86
30 PARK
O BRAKE
30 S INTERLOCK
P 85
87A 87 RELAY 40.0
R 7.5
50 MAIN
7.5 O LIGHT SWITCH
51A RELAY
LIGHT SWITCH
RELAY
3C A B C 8
1
7
2HH 3
TO See page 9.84.
111 IGNITION
6 SWITCH
PARK 51A
2
1 E BRAKE
SWITCH 51
26A 26 1
5 51B 153A 111
D 107B
4
153
26 113A
30 111
26 E 3 86 PARK
BRAKE 112A 111A
26B DIS. 30 A1 A1
27C 2
RELAY
B
D 41 86
TO STARTER 41B 41C 52 85 NEUTRAL
1 87A 87 A2 A2
40.0 27 27D 113A START
MAIN
100 RELAY
107A NOT USED
85
113B 87A 87
C 2EE 113
51B 107B 113 2FF
3A 153A
7.5 2HH 20 20 20
B+ 153
FORWARD 8
GEAR
8
150 CAB
1st Gear 7 7
GROUND
STUD
MALE AND FEMALE
BULKHEAD HARNESS
GEAR 103 CONNECTORS
6 6
1 F GEAR
2
5 5
3
N GEAR 101
112A
4 4
R NEUTRAL 112 112
SHIFTER 112
ZF TRANSMISSION 3 3
REVERSE
2 2
FORWARD 104
1 1
B+ 113
20
2DD 20
A5 A5
B2 B2
2G 2H
2D 2J
B1 B1 2J 7 7
104
104 104B Y1 Y3 Y2
C4 C4 104 1 1
E E DE
103 103 103B Y1 Y3 Y2
C3 C3 103 3 3
C2 C2 2 2
UPPER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
Valve Valve
C1 C1 101 5 5 Y6 Y5 Y4
150 150 150B E E DE
7 7
Forward 2
Forward 3
Y6 Y5 Y4 Forward 4
2G
Reverse 1
LOWER Reverse 2
TRANSMISSION COILS
= See Page 9.92, 9.93, 9.94 TRANS.

(VIEWED FROM
FRONT OF VEHICLE)
Reverse 3
GRND
MH5420
9.158 Model 8042, 10042, 10054 Legacy Rev. 10/03

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
19 P
R
58
O
IGNITION S
SWITCH P
R
15
O
30 S
P
R
50
7.5 O
LIGHT SWITCH
RELAY
3C A B C 153A
1 2HH
8 7
111
6
1
PARK 107B
26A 26 E 2 153
BRAKE
1 SWITCH 30
PARK
5 86
26 D BRAKE
26 4 DIS.
85
RELAY
26B 27C
E 3 87A 87 FEMALE AND MALE
TO STARTER BULKHEAD HARNESS
40.0 27 27D 2
100 D 113B CONNECTORS
MAIN 107A 107B 2EE
1
3A 153A 2HH 20A 20A 20B 20C

7.5 20A 20A A4 A4 20A 20B
TRANSMISSION 9 9
B+ 153 2MM
FORWARD 8
GEAR
8
150
1st Gear 7 7
CAB
GEAR 103 GROUND
STUD
6 6 113B 111
1 F GEAR
2
5 5
113A 113A
113 111
3
N GEAR 101
113
4 4 111A
R NEUTRAL 112 112 112A
SHIFTER 112
ZF TRANSMISSION 3 3 30
REVERSE 86 NEUTRAL
2 2 START
FORWARD 104 RELAY
85
1 1 87A 87
B+ 113
2FF
20 20 20D
20 A3 A3 20 20D
2LL 20E
MALE AND FEMALE
CAB BULKHEAD HARNESS
GROUND CONNECTORS
STUD
20
2DD 20
A5 A5
B2 B2
2G 2H
2D 2J
B1 B1 2J 7 7
104
104 104B Y1 Y3 Y2
C4 C4 104 1 1
E E DE
103 103 103B Y1 Y3 Y2
C3 C3 103 3 3
20E 20C
C2 C2 2 2
UPPER
TRANSMISSION COILS ENGINE GROUND BUSS BAR
(VIEWED FROM
FRONT OF VEHICLE)
Valve Valve
C1 C1 101 5 5 Y6 Y5 Y4
150 150 150B E E DE
7 7
Forward 2
Forward 3
Y6 Y5 Y4 Forward 4
2G
Reverse 1
LOWER Reverse 2
TRANSMISSION COILS
TRANS.
(VIEWED FROM
FRONT OF VEHICLE)
Reverse 3
GRND
MH5280
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.159

Electrical System

(SN 10054, 19080 - 19987 And 0160002332 & After)
3A
3C
26A
A B C D E
A B C D E
S
19 P
R
58
O
IGNITION S 52
SWITCH P
R
15 86
30 PARK
O BRAKE
30 S
INTERLOCK
P 85
R 87A 87 RELAY
50
O
51A
A B C
7.5 1 2HH
LIGHT SWITCH 8 7
RELAY 111
6
3C 1
PARK 51A
2
26 E BRAKE
SWITCH 51
1 153A
5
D
51B 107B
26A 4
153
30
E 3 86 PARK
26 BRAKE
26 DIS.
2
RELAY
26B 27C
D
1
41B B 52 85
87A 87
FEMALE AND MALE
TO STARTER 107A NOT USED BULKHEAD HARNESS
40.0 27 27D 113B CONNECTORS
100
MAIN
51B C 107B
2EE
3A 153A 2HH 20A 20A 20B 20C

7.5 20A 20A A4 A4 20A 20B
TRANSMISSION 9 9
B+ 153 2MM
FORWARD 8
GEAR
8
150
1st Gear 7 7
CAB
GEAR 103 GROUND
STUD
6 6 113B 111
1 F GEAR
2
5 5
113A 113A
113 111
3
N GEAR 101
113
4 4 111A
SHIFTER 112
REVERSE 86 NEUTRAL
2 2 START
FORWARD 104 RELAY
85
1 1 87A 87
B+ 113
2FF
20 20 20D
20 A3 A3 20 20D
2LL 20E
MALE AND FEMALE
BULKHEAD HARNESS
CAB CONNECTORS
GROUND
STUD
20
2DD 20
A5 A5
B2 B2
2G 2H
2D 2J
B1 B1 2J 7 7
104
104 104B Y1 Y3 Y2
C4 C4 104 1 1
E E DE
103 103 103B Y1 Y3 Y2
C3 C3 103 3 3
20E 20C
C2 C2 2 2
UPPER
(VIEWED FROM
FRONT OF VEHICLE)
Valve Valve
C1 C1 101 5 5 Y6 Y5 Y4
150 150 150B E E DE
7 7
Forward 2
Forward 3
Y6 Y5 Y4 Forward 4
2G
Reverse 1
LOWER Reverse 2
TRANSMISSION COILS
= See Page 9.107 TRANS.

(VIEWED FROM
FRONT OF VEHICLE)
Reverse 3
GRND
MH5430
9.160 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

(SN 8042, 13198 - 18990, 10042 13198 - 19030)
3A

1
8 7
6
2 PARK
E BRAKE
SWITCH
3C 5
D
26A 4
A B C D E E 3
A B C D E TO
2
41 PARK
D
107 107 BRAKE
1
DIS.
S
RELAY
19 P
R TO
O
58
26A IGNITION
IGNITION S SWITCH
SWITCH P 26
R
15
O
30 S
P
R 7.5 40.0
7.5 O
50
LIGHT SWITCH
RELAY
MAIN
See pages
LIGHT SWITCH
RELAY
3C A B C
3
TO 9.38 or 9.62.
IGNITION
153A SWITCH
1 2HH
1 8 7
111
26A 6
26 111
PARK 107B
E 2 153
BRAKE 113A
26 1 SWITCH 30 111
26 86 PARK
5
BRAKE 112A 111A
D
26B 4 DIS. 30 A1 A1
27C RELAY 86
TO STARTER E 3
85 NEUTRAL
87A 87 A2 A2
40.0 27 27D 113A START
MAIN
100 RELAY
2 85
D 41 113B
41B 107A 107B 2EE 113 87A 87
1
113 2FF
3A 153A
7.5 2HH 20 20 20
B+ 153
FORWARD 8
GEAR
8 CAB
2nd Gear 7 7
GROUND
STUD
MALE AND FEMALE
BULKHEAD HARNESS
GEAR 103 CONNECTORS
1 6 6
2 F GEAR 105
3
4 5 5
N GEAR 101
112A
4 4
R NEUTRAL 112 112
SHIFTER 112
ZF TRANSMISSION 3 3
REVERSE
2 2
FORWARD 104
1 1
B+ 113
20
2DD 20
A5 A5
B2 B2
2G 2H
2D 2J
B1 B1 2J 7 7
104
104 104B Y1 Y3 Y2
C4 C4 104 1 1
E E DE
103 103 103B Y1 Y3 Y2
C3 C3 103 3 3
C2 C2 2 2
UPPER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
105
C5 C5
105
105
105B 4 4 Upper Lower
Valve Valve
C1 C1 101 5 5 Y6 Y5 Y4
DE E E
B3 B3 6 6 Driving Speed
7 7
Forward 2
Forward 3
Y6 Y5 Y4 Forward 4
2G
Reverse 1
LOWER Reverse 2
TRANSMISSION COILS
TRANS.
(VIEWED FROM
FRONT OF VEHICLE)
Reverse 3
GRND
MH5290
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.161

Electrical System
9.8.6 Transmission, Forward Second Gear Circuit, (SN 10054, 13198 - 19079)
3A

1
8 7
6
2 PARK
E BRAKE
SWITCH
3C 5
D
26A 4
A B C D E E 3
A B C D E TO
2 PARK
B
D 41
41 52 BRAKE
1
INTERLOCK
19 P
R TO
58
26A IGNITION
IGNITION
O
S
52 SWITCH
SWITCH P 26
R
15 86
30 PARK
O BRAKE
30 S INTERLOCK
P 85
87A 87 RELAY 40.0
R 7.5
50 MAIN
7.5 O LIGHT SWITCH
51A RELAY
LIGHT SWITCH
RELAY
3C A B C 8
1
7
2HH 3
TO See page 9.84.
111 IGNITION
6 SWITCH
PARK 51A
2
1 E BRAKE
SWITCH 51
26A 26 1
5 51B 153A 111
D 107B
4
153
26 113A
30 111
26 E 3 86 PARK
BRAKE 112A 111A
26B DIS. 30 A1 A1
27C 2
RELAY
B
D 41 86
1 87A 87 A2 A2
40.0 27 27D 113A START
MAIN
100 RELAY
107A NOT USED
85
113B 87A 87
C 2EE 113
51B 107B 113 2FF
3A 153A
7.5 2HH 20 20 20
B+ 153
FORWARD 8
GEAR
8 CAB
2nd Gear 7 7
GROUND
STUD
MALE AND FEMALE
BULKHEAD HARNESS
GEAR 103 CONNECTORS
1 6 6
2 F GEAR 105
3
4 5 5
N GEAR 101
112A
4 4
R NEUTRAL 112 112
SHIFTER 112
ZF TRANSMISSION 3 3
REVERSE
2 2
FORWARD 104
1 1
B+ 113
20
2DD 20
A5 A5
B2 B2
2G 2H
2D 2J
B1 B1 2J 7 7
104
104 104B Y1 Y3 Y2
C4 C4 104 1 1
E E DE
103 103 103B Y1 Y3 Y2
C3 C3 103 3 3
C2 C2 2 2
UPPER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
105
C5 C5
105
105
Valve Valve
C1 C1 101 5 5 Y6 Y5 Y4
DE E E
7 7
Forward 2
Forward 3
Y6 Y5 Y4 Forward 4
2G
Reverse 1
LOWER Reverse 2
TRANSMISSION COILS
= See Page 9.92, 9.93, 9.94 TRANS.

(VIEWED FROM
FRONT OF VEHICLE)
Reverse 3
GRND
MH5440
9.162 Model 8042, 10042, 10054 Legacy Rev. 10/03

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
19 P
R
58
O
IGNITION S
SWITCH P
R
15
O
30 S
P
R
50
7.5 O
LIGHT SWITCH
RELAY
3C A B C 153A
1 2HH
8 7
111
6
1
PARK 107B
26A 26 E 2 153
BRAKE
1 SWITCH 30
PARK
5 86
26 D BRAKE
26 4 DIS.
85
RELAY
26B 27C
E 3 87A 87 FEMALE AND MALE
TO STARTER BULKHEAD HARNESS
40.0 27 27D 2
100 D 113B CONNECTORS
MAIN 107A 107B 2EE
1
3A 153A 2HH 20A 20A 20B 20C

7.5 20A 20A A4 A4 20A 20B
TRANSMISSION 9 9
B+ 153 2MM
FORWARD 8
GEAR
8
2nd Gear 7 7
CAB
GEAR 103 GROUND
STUD
1 6 6 113B 111
2 F GEAR 105
3
5 5
113A 113A
4 113 111
N GEAR 101
113
4 4 111A
SHIFTER 112
REVERSE 86 NEUTRAL
2 2 START
FORWARD 104 RELAY
85
1 1 87A 87
B+ 113
2FF
20 20 20D
20 A3 A3 20 20D
2LL 20E
MALE AND FEMALE
BULKHEAD HARNESS
CAB CONNECTORS
GROUND
20 STUD
A5 A5 2DD 20
B2 B2
2G 2H
2D 2J
B1 B1 2J 7 7
104
104 104B Y1 Y3 Y2
C4 C4 104 1 1
E E DE
103 103 103B Y1 Y3 Y2
C3 C3 103 3 3
20E 20C
C2 C2 2 2
UPPER
(VIEWED FROM
FRONT OF VEHICLE)
105 105 105B 4
C5 C5 105 4
101 101 101B

Upper Lower
C1 C1 101 5 5 Y6 Y5 Y4 Valve Valve
B3 B3 6 6
DE E E Body Body
103A 104A 2H Driving Speed
7 7
Direction Y1 Y2 Y3 Y4 Y5 Y6
BULKHEAD HARNESS
Forward 1
Forward 2
Y6 Y5 Y4 Forward 3
DIODE PACK DIODE PACK Forward 4
2G
LOWER
Reverse 1
TRANSMISSION COILS
(VIEWED FROM Reverse 2
TRANS. FRONT OF VEHICLE)
GRND
Reverse 3
MH5300
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.163

Electrical System

(SN 10054, 19080 - 19987 And 0160002332 & After)
3A
3C
26A
A B C D E
A B C D E
S
19 P
R
58
O
IGNITION S 52
SWITCH P
R
15 86
30 PARK
O BRAKE
30 S
INTERLOCK
P 85
R 87A 87 RELAY
50
O
51A
A B C
7.5 1 2HH
LIGHT SWITCH 8 7
RELAY 111
6
3C 1
PARK 51A
2
26 E BRAKE
SWITCH 51
1 153A
5
D
51B 107B
26A 4
153
30
E 3 86 PARK
26 BRAKE
26 DIS.
2
RELAY
26B 27C
D
1
41B B 52 85
87A 87
FEMALE AND MALE
TO STARTER 107A NOT USED BULKHEAD HARNESS
40.0 27 27D 113B
100 CONNECTORS
MAIN
51B C 107B
2EE
3A 153A 2HH 20A 20A 20B 20C

7.5 20A 20A A4 A4 20A 20B
TRANSMISSION 9 9
B+ 153 2MM
FORWARD 8
GEAR
8
2nd Gear 7 7
CAB
GEAR 103 GROUND
STUD
1 6 6 113B 111
2 F GEAR 105
3
5 5
113A 113A
4 113 111
N GEAR 101
113 111A
4 4
SHIFTER 112
REVERSE 86 NEUTRAL
2 2 START
FORWARD 104 RELAY
85
1 1 87A 87
B+ 113
2FF
20 20 20D
20 A3 A3 20 20D
2LL 20E
MALE AND FEMALE
BULKHEAD HARNESS
CAB CONNECTORS
GROUND
STUD
20
A5 A5 2DD 20
B2 B2
2G 2H
2D 2J
B1 B1 2J 7 7
104
104 104B Y1 Y3 Y2
C4 C4 104 1 1
E E DE
103 103 103B Y1 Y3 Y2
C3 C3 103 3 3
20E 20C
C2 C2 2 2
UPPER
(VIEWED FROM
FRONT OF VEHICLE)
105 105 105B 4
C5 C5 105 4
101 101 101B

Upper Lower
C1 C1 101 5 5 Y6 Y5 Y4 Valve Valve
B3 B3 6 6
DE E E Body Body
103A 104A 2H Driving Speed
7 7
BULKHEAD HARNESS
Forward 1
Forward 2
Y6 Y5 Y4 Forward 3
2G
LOWER
Reverse 1
TRANSMISSION COILS
GRND
= See Page 9.107 Reverse 3
MH5450
9.164 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
9.8.9 Transmission, Forward Third Gear Circuit, (SN 8042, 13198 - 18990, 10042 13198 - 19030)
3A

1
8 7
6
2 PARK
E BRAKE
SWITCH
3C 5
D
26A 4
A B C D E E 3
A B C D E TO
2
41 PARK
D
107 107 BRAKE
1
DIS.
S
RELAY
19 P
R TO
O
58
26A IGNITION
IGNITION S SWITCH
SWITCH P 26
R
15
O
30 S
P
R 7.5 40.0
7.5 O
50
LIGHT SWITCH
RELAY
MAIN
See pages
LIGHT SWITCH
RELAY
3C A B C
3
TO 9.38 or 9.62.
IGNITION
153A SWITCH
1 2HH
1 8 7
111
26A 6
26 111
PARK 107B
E 2 153
BRAKE 113A
26 1 SWITCH 30 111
26 86 PARK
5
BRAKE 112A 111A
D
26B 4 DIS. 30 A1 A1
27C RELAY 86
TO STARTER E 3
85 NEUTRAL
87A 87 A2 A2
40.0 27 27D 113A START
MAIN
100 RELAY
2 85
D 41 113B
41B 107A 107B 2EE 113 87A 87
1
113 2FF
3A 153A
7.5 2HH 20 20 20
B+ 153
FORWARD 8
GEAR
8
150 CAB
3rd Gear 7 7
GROUND
STUD
MALE AND FEMALE
BULKHEAD HARNESS
GEAR 103 CONNECTORS
2 6 6
3 F GEAR 105
4
5 5
N GEAR
112A
4 4
R NEUTRAL 112 112
SHIFTER 112
ZF TRANSMISSION 3 3
REVERSE
2 2
FORWARD 104
1 1
B+ 113
20
2DD 20
A5 A5
B2 B2
2G 2H
2D 2J
B1 B1 2J 7 7
104
104 104B Y1 Y3 Y2
C4 C4 104 1 1
E E DE
103 103 103B Y1 Y3 Y2
C3 C3 103 3 3
C2 C2 2 2
UPPER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
105
C5 C5
105
105
Valve Valve
C1 C1 5 5 Y6 Y5 Y4 Body Body
150 150 150B E DE E
103A 105A 2D 2H Direction Y1 Y2 Y3 Y4 Y5 Y6
7 7
MALE AND FEMALE
BULKHEAD HARNESS 2DD 150A 104A
CONNECTORS
Forward 1
F E B A A B E F
Forward 2
Forward 3
Y6 Y5 Y4 Forward 4
2G
Reverse 1
LOWER Reverse 2
TRANSMISSION COILS
TRANS.
(VIEWED FROM
FRONT OF VEHICLE)
Reverse 3
GRND
MH5310
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.165

Electrical System
9.8.10 Transmission, Forward Third Gear Circuit, (SN 10054, 13198 - 19079)
3A

8 7
6
2 PARK
E BRAKE
3C
SWITCH
26A 5
D
4
A B C D E
A B C D E E 3
TO
2 PARK
B
D 41
41 52 BRAKE
1
S INTERLOCK
19 P
107 NOT USED RELAY
R
58
O TO
IGNITION S
IGNITION
SWITCH P
52 26A
R SWITCH
15
26
30
O
S 86
30 PARK
P BRAKE
R INTERLOCK
50 85
O 87A 87 RELAY 40.0
7.5
MAIN
7.5 LIGHT SWITCH
51A RELAY
LIGHT SWITCH A B C
RELAY
3C 8
1
7
2HH 3
TO See page 9.84.
111 IGNITION
6 SWITCH
1 51A
2 PARK
E BRAKE
26
SWITCH 51
26A 1
5 51B 153A 111
D 107B 153
4
26 113A
30 111
26 E 3 86 PARK
BRAKE 112A 111A
26B DIS. 30 A1 A1
27C 2
RELAY
B
D 41 86
1 87A 87 A2 A2
40.0 27 27D 113A START
MAIN
100 RELAY
107A NOT USED
85
113B 87A 87
C 2EE 113
51B 107B 113 2FF
3A 153A
7.5 2HH 20 20 20
B+ 153
FORWARD 8
GEAR
8
150 CAB
3rd Gear 7 7
GROUND
STUD
MALE AND FEMALE
BULKHEAD HARNESS
GEAR 103 CONNECTORS
2 6 6
3 F GEAR 105
4
5 5
N GEAR
112A
4 4
R NEUTRAL 112 112
SHIFTER 112
ZF TRANSMISSION 3 3
REVERSE
2 2
FORWARD 104
1 1
B+ 113
20
2DD 20
A5 A5
B2 B2
2G 2H
2D 2J
B1 B1 2J 7 7
104
104 104B Y1 Y3 Y2
C4 C4 104 1 1
E E DE
103 103 103B Y1 Y3 Y2
C3 C3 103 3 3
C2 C2 2 2
UPPER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
105
C5 C5
105
105
Valve Valve
150 150 150B E DE E
103A 105A 2D 2H Direction Y1 Y2 Y3 Y4 Y5 Y6
7 7
MALE AND FEMALE
CONNECTORS
Forward 1
F E B A A B E F
Forward 2
Forward 3
Y6 Y5 Y4 Forward 4
2G
Reverse 1
LOWER Reverse 2
TRANSMISSION COILS
= See Page 9.92, 9.93, 9.94 TRANS.

(VIEWED FROM
FRONT OF VEHICLE)
Reverse 3
GRND
MH5460
9.166 Model 8042, 10042, 10054 Legacy Rev. 10/03

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
19 P
R
58
O
IGNITION S
SWITCH P
R
15
O
30 S
P
R
50
7.5 O
LIGHT SWITCH
RELAY
3C A B C 153A
1 2HH
8 7
111
6
1
PARK 107B
26A 26 E 2 153
BRAKE
1 SWITCH 30
PARK
5 86
26 D BRAKE
26 4 DIS.
85
RELAY
26B 27C
E 3 87A 87
TO STARTER
40.0 27 27D 2
100 D 113B
MAIN 107A 107B 2EE
1
3A 153A 2HH 20A 20A 20B 20C

7.5 20A 20A A4 A4 20A 20B
TRANSMISSION 9 9
B+ 153 2MM
FEMALE AND MALE
FORWARD 8
GEAR
8
150 BULKHEAD HARNESS
3rd Gear 7 7
CAB CONNECTORS
GEAR 103 GROUND
STUD
2 6 6 113B 111
3 F GEAR 105
4
5 5
113A 113A
113 111
N GEAR
113
4 4 111A
SHIFTER 112
REVERSE 86 NEUTRAL
2 2 START
FORWARD 104 RELAY
85
1 1 87A 87
B+ 113
2FF
20 20 20D
20 A3 A3 20 20D
2LL 20E
MALE AND FEMALE
BULKHEAD HARNESS
CAB CONNECTORS
GROUND
20 STUD
A5 A5 2DD 20
B2 B2
2G 2H
2D 2J
B1 B1 2J 7 7
104
104 104B Y1 Y3 Y2
C4 C4 104 1 1
E E DE
103 103 103B Y1 Y3 Y2
C3 C3 103 3 3
20E 20C
C2 C2 2 2
UPPER
(VIEWED FROM
FRONT OF VEHICLE)
105 105 105B 4
C5 C5 105 4
Upper Lower
C1 C1 5 5 Y6 Y5 Y4 Valve Valve
150
B3 B3
150
150
150B 6 6
E DE E Body Body
103A 105A 2D 2H Driving Speed
MALE AND FEMALE 2DD 150A 104A
7 7
BULKHEAD HARNESS
Forward 1
Forward 2
Y6 Y5 Y4 Forward 3
2G
LOWER
Reverse 1
TRANSMISSION COILS
GRND
Reverse 3
MH5320
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.167

Electrical System

(SN 10054, 19080 - 19987 And 0160002332 & After)
3A
3C
26A
A B C D E
A B C D E
S
19 P
R
58
O
IGNITION S 52
SWITCH P
R
15 86
30 PARK
O BRAKE
30 S
INTERLOCK
P 85
R 87A 87 RELAY
50
O
51A
A B C
7.5 1 2HH
LIGHT SWITCH 8 7
RELAY 111
6
3C 1
PARK 51A
2
26 E BRAKE
SWITCH 51
1 153A
5
D
51B 107B
26A 4
153
30
E 3 86 PARK
26 BRAKE
26 DIS.
2
RELAY
26B 27C
D
1
41B B 52 85
87A 87
TO STARTER 107A NOT USED
40.0 27 27D 113B
100
MAIN
51B C 107B
2EE
3A 153A 2HH 20A 20A 20B 20C

7.5 20A 20A A4 A4 20A 20B
TRANSMISSION 9 9
B+ 153 2MM
FEMALE AND MALE
FORWARD 8
GEAR
8
3rd Gear 7 7
CAB CONNECTORS
GEAR 103 GROUND
STUD
2 6 6 113B 111
3 F GEAR 105
4
5 5
113A 113A
113 111
N GEAR
113
4 4 111A
SHIFTER 112
REVERSE 86 NEUTRAL
2 2 START
FORWARD 104 RELAY
85
1 1 87A 87
B+ 113
2FF
20 20 20D
20 A3 A3 20 20D
2LL 20E
MALE AND FEMALE
BULKHEAD HARNESS
CAB CONNECTORS
GROUND
20 STUD
A5 A5 2DD 20
B2 B2
2G 2H
2D 2J
B1 B1 2J 7 7
104
104 104B Y1 Y3 Y2
C4 C4 104 1 1
E E DE
103 103 103B Y1 Y3 Y2
C3 C3 103 3 3
20E 20C
C2 C2 2 2
UPPER
(VIEWED FROM
FRONT OF VEHICLE)
105 105 105B 4
C5 C5 105 4
Upper Lower
150
B3 B3
150
150
150B 6 6
E DE E Body Body
103A 105A 2D 2H Driving Speed
7 7
BULKHEAD HARNESS
Forward 1
Forward 2
Y6 Y5 Y4 Forward 3
2G
LOWER
Reverse 1
TRANSMISSION COILS
GRND
MH5470
9.168 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
9.8.13 Transmission, Forward Fourth Gear Circuit, (SN 8042, 13198 - 18990, 10042 13198 - 19030)
3A

1
8 7
6
2 PARK
E BRAKE
SWITCH
3C 5
D
26A 4
A B C D E E 3
A B C D E TO
2
41 PARK
D
107 107 BRAKE
1
DIS.
S
RELAY
19 P
R TO
O
58
26A IGNITION
IGNITION S SWITCH
SWITCH P 26
R
15
O
30 S
P
R 7.5 40.0
7.5 O
50
LIGHT SWITCH
RELAY
MAIN
See pages
LIGHT SWITCH
RELAY
3C A B C
3
TO 9.38 or 9.62.
IGNITION
153A SWITCH
1 2HH
1 8 7
111
26A 6
26 111
PARK 107B
E 2 153
BRAKE 113A
26 1 SWITCH 30 111
26 86 PARK
5
BRAKE 112A 111A
D
26B 4 DIS. 30 A1 A1
27C RELAY 86
TO STARTER E 3
85 NEUTRAL
87A 87 A2 A2
40.0 27 27D 113A START
MAIN
100 RELAY
2 85
D 41 113B
41B 107A 107B 2EE 113 87A 87
1
113 2FF
3A 153A
7.5 2HH 20 20 20
B+ 153
FORWARD 8
GEAR
8
150 CAB
4th Gear 7 7
GROUND
STUD
MALE AND FEMALE
BULKHEAD HARNESS
GEAR
CONNECTORS
3 6 6
4 F GEAR 105
5 5
N GEAR
112A
4 4
R NEUTRAL 112 112
SHIFTER 112
ZF TRANSMISSION 3 3
REVERSE
2 2
FORWARD 104
1 1
B+ 113
20
2DD 20
A5 A5
B2 B2
2G 2H
2D 2J
B1 B1 2J 7 7
104
104 104B Y1 Y3 Y2
C4 C4 104 1 1
E DE DE
Y1 Y3 Y2
C3 C3 3 3
C2 C2 2 2
UPPER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
105
C5 C5
105
105
Valve Valve
150 150 150B E DE E
105A 2D 2H Direction Y1 Y2 Y3 Y4 Y5 Y6
7 7
MALE AND FEMALE
CONNECTORS
Forward 1
F E B A A B E F
Forward 2
Forward 3
Y6 Y5 Y4 Forward 4
2G
Reverse 1
LOWER Reverse 2
TRANSMISSION COILS
TRANS.
(VIEWED FROM
FRONT OF VEHICLE)
Reverse 3
GRND
MH5330
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.169

Electrical System
9.8.14 Transmission, Forward Fourth Gear Circuit, (SN 10054, 13198 - 19079)
3A

1
8 7
6
3C
2 PARK
26A E BRAKE
SWITCH
A B C D E 5
D
A B C D E 4
E 3
TO
S 2 PARK
B
P D 41
19
R
41 52 BRAKE
1
58 INTERLOCK
IGNITION
O
SWITCH P
R TO
O
15
26A IGNITION
30 S 52 SWITCH
P
26
R
50 86
30 PARK
O BRAKE
INTERLOCK
85
87A 87 RELAY 40.0
A B C 7.5
MAIN
7.5 LIGHT SWITCH
51A RELAY
LIGHT SWITCH
RELAY
3C 1 8
1
7
2HH 3
TO See page 9.84.
111 IGNITION
26
6 SWITCH
PARK 51A
E 2
BRAKE
SWITCH 51
26A 1
5 51B 153A 111
D 107B 153
4
26 113A
30 111
26 E 3 86 PARK
BRAKE 112A 111A
26B DIS. 30 A1 A1
27C 2
RELAY
B
D 41 86
1 87A 87 A2 A2
40.0 27 27D 113A START
MAIN
100 RELAY
107A NOT USED
85
113B 87A 87
C 2EE 113
51B 107B 113 2FF
3A 153A
7.5 2HH 20 20 20
B+ 153
FORWARD 8
GEAR
8
150 CAB
4th Gear 7 7
GROUND
STUD
MALE AND FEMALE
BULKHEAD HARNESS
GEAR
CONNECTORS
3 6 6
4 F GEAR 105
5 5
N GEAR
112A
4 4
R NEUTRAL 112 112
SHIFTER 112
ZF TRANSMISSION 3 3
REVERSE
2 2
FORWARD 104
1 1
B+ 113
20
2DD 20
A5 A5
B2 B2
2G 2H
2D 2J
B1 B1 2J 7 7
104
104 104B Y1 Y3 Y2
C4 C4 104 1 1
E DE DE
Y1 Y3 Y2
C3 C3 3 3
C2 C2 2 2
UPPER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
105
C5 C5
105
105
Valve Valve
150 150 150B E DE E
105A 2D 2H Direction Y1 Y2 Y3 Y4 Y5 Y6
7 7
MALE AND FEMALE
CONNECTORS
Forward 1
F E B A A B E F
Forward 2
Forward 3
Y6 Y5 Y4 Forward 4
2G
Reverse 1
LOWER Reverse 2
TRANSMISSION COILS
= See Page 9.92, 9.93, 9.94 TRANS.

(VIEWED FROM
FRONT OF VEHICLE)
Reverse 3
GRND
MH5480
9.170 Model 8042, 10042, 10054 Legacy Rev. 10/03

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
19 P
R
58
O
IGNITION S
SWITCH P
R
15
O
30 S
P
R
50
7.5 O
LIGHT SWITCH
RELAY
3C A B C 153A
1 2HH
8 7
111
6
1
PARK 107B
26A 26 E 2 153
BRAKE
1 SWITCH 30
PARK
5 86
26 D BRAKE
26 4 DIS.
85
RELAY
26B 27C
E 3 87A 87
TO STARTER
40.0 27 27D 2
100 D 113B
MAIN 107A 107B 2EE
1
3A 153A 2HH 20A 20A 20B 20C

7.5 20A 20A A4 A4 20A 20B
TRANSMISSION 9 9
B+ 153 2MM
FEMALE AND MALE
FORWARD 8
GEAR
8
4th Gear 7 7
CAB CONNECTORS
GEAR GROUND
STUD
3 6 6 113B 111
4 F GEAR 105
5 5
113A 113A
113 111
N GEAR
113
4 4 111A
SHIFTER 112
REVERSE 86 NEUTRAL
2 2 START
FORWARD 104 RELAY
85
1 1 87A 87
B+ 113
2FF
20 20 20D
20 A3 A3 20 20D
2LL 20E
MALE AND FEMALE
BULKHEAD HARNESS
CAB CONNECTORS
GROUND
20 STUD
A5 A5 2DD 20
B2 B2
2G 2H
2D 2J
B1 B1 2J 7 7
104
104 104B Y1 Y3 Y2
C4 C4 104 1 1
E DE DE
Y1 Y3 Y2
C3 C3 3 3
20E 20C
C2 C2 2 2
UPPER
(VIEWED FROM
FRONT OF VEHICLE)
105 105 105B 4
C5 C5 105 4
Upper Lower
150
B3 B3
150
150
150B 6 6
E DE E Body Body
105A 2D 2H Driving Speed
7 7
BULKHEAD HARNESS
Forward 1
Forward 2
Y6 Y5 Y4 Forward 3
2G
LOWER
Reverse 1
TRANSMISSION COILS
GRND
Reverse 3
MH5340
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.171

Electrical System

(SN 10054, 19080 - 19987 And 0160002332 & After)
3A
3C
26A
A B C D E
A B C D E
S
19 P
R
58
O
IGNITION S 52
SWITCH P
R
15 86
30 PARK
O BRAKE
30 S
INTERLOCK
P 85
R 87A 87 RELAY
50
O
51A
A B C
7.5 1 2HH
LIGHT SWITCH 8 7
RELAY 111
6
3C 1
PARK 51A
2
26 E BRAKE
SWITCH 51
1 153A
5
D
51B 107B
26A 4
153
30
E 3 86 PARK
26 BRAKE
26 DIS.
2
RELAY
26B 27C
D
1
41B B 52 85
87A 87
40.0 27 27D 113B
100
MAIN
51B C 107B
2EE
3A 153A 2HH 20A 20A 20B

7.5 20A 20A A4 A4 20A 20B
TRANSMISSION 9 9
B+ 153 2MM
20C
FEMALE AND MALE
FORWARD 8
GEAR
8
4th Gear 7 7
CAB CONNECTORS
GEAR GROUND
STUD
3 6 6 113B 111
4 F GEAR 105
5 5
113A 113A
113 111
N GEAR
113
4 4 111A
SHIFTER 112
ZF TRANSMISSION 3 3
REVERSE 30
86 NEUTRAL
2 2
FORWARD 104 START
RELAY
1 1 85
B+ 113 87A 87
2FF
20 20 20D
20 A3 A3 20 20D
2LL 20E
MALE AND FEMALE
BULKHEAD HARNESS
CAB CONNECTORS
GROUND
A5 A5 STUD
20
B2 B2
2DD 20
2G 2H
2D 2J
B1 B1
7 7
104
104 104B Y1 Y3 Y2
C4 C4 104 1 1
E DE DE
Y1 Y3 Y2
C3 C3 3 3
20E 20C
C2 C2 2 2
UPPER
(VIEWED FROM
FRONT OF VEHICLE)
105 105 105B 4
C5 C5 105 4
Upper Lower
150
B3 B3
150
150
150B 6 6
E DE E Body Body
105A 2D 2H Driving Speed
7 7
BULKHEAD HARNESS
Forward 1
Forward 2
Y6 Y5 Y4 Forward 3
2G
LOWER
Reverse 1
TRANSMISSION COILS
GRND
MH5490
9.172 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
9.8.17 Transmission, Reverse First Gear Circuit, (SN 8042, 13198 - 18990, 10042 13198 - 19030)
3A

1
8 7
6
2 PARK
E BRAKE
SWITCH
3C 5
D
26A 4
A B C D E E 3
A B C D E TO
2
41 PARK
D
107 107 BRAKE
1
DIS.
S
RELAY
19 P
R TO
O
58
26A IGNITION
10.0 IGNITION S SWITCH
HORN/HEATER 24 SWITCH P 26
R
15
O
30 S
P
R 7.5 40.0
7.5 O
50
LIGHT SWITCH
RELAY
MAIN
See pages
LIGHT SWITCH
RELAY
3C A B C
3
TO 9.38 or 9.62.
IGNITION
153A SWITCH
1 2HH
1 8 7
111
26A 6
26 111
PARK 107B
E 2 153
BRAKE 113A
26 1 SWITCH 30 111
26 86 PARK
5
BRAKE 112A 111A
D
26B 4 DIS. 30 A1 A1
27C RELAY 86
TO STARTER E 3
85 NEUTRAL
87A 87 A2 A2
40.0 27 27D 113A START
MAIN
100 RELAY
2 85
D 41 113B
41B 107A 107B 2EE 113 87A 87
1
113 2FF
3A 153A
7.5 2HH 20 20 20
TRANSMISSION 20 20 A3 A3
2BB
9 9
B+ 153 CAB
8 8 GROUND MALE AND FEMALE
GEAR 150 STUD BULKHEAD HARNESS
1 Gearst
7
GEAR
7
103
CONNECTORS
F 6 6
GEAR
5 5
N GEAR 101
1 112A
4 4
2 R NEUTRAL 112 112
3
112
3 3 24
REVERSE 102A 102A 102B 102B
SHIFTER 102
ZF TRANSMISSION 2 2
FORWARD 102 30
REVERSE 1 1
86 BACK-UP
B+ 113 ALARM
RELAY
85
87A 87
2BB 31
20
2DD 20
20
31 2X
2G 2H
31 31 +
A5 A5
2D 2J
B2 B2 -
2X
B1 B1 2J 7 7
Y1 Y3 Y2
C4 C4 1 1
DE E E
103 103 103B Y1 Y3 Y2
C3 C3 103 3 3
102 102 102B 2 2

C2 C2 102
UPPER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
Valve Valve
C1 C1 101 5 5 Y6 Y5 Y4
150 150 150B E E DE
7 7
Forward 2
Forward 3
Y6 Y5 Y4 Forward 4
2G
Reverse 1
LOWER Reverse 2
TRANSMISSION COILS
TRANS.
(VIEWED FROM
FRONT OF VEHICLE)
Reverse 3
GRND
MH5350
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.173

Electrical System
9.8.18 Transmission, Reverse First Gear Circuit, (SN 10054, 13198 - 19079)
3A

1
8 7
6
3C
2 PARK
26A E BRAKE
SWITCH
A B C D E 5
D
A B C D E 4
E 3
TO
S 2 PARK
B
P D 41
19
R
41 52 BRAKE
1
58 INTERLOCK
IGNITION
O
SWITCH P
R TO
O
15
26A IGNITION
30 S 52 SWITCH
10.0
HORN/HEATER 24 P
26
R
50 86
30 PARK
O BRAKE
INTERLOCK
85
87A 87 RELAY 40.0
A B C 7.5
MAIN
7.5 LIGHT SWITCH
51A RELAY
LIGHT SWITCH
RELAY
3C 1 8
1
7
2HH 3
TO See page 9.84.
111 IGNITION
26
6 SWITCH
PARK 51A
E 2
BRAKE
SWITCH 51
26A 1 153A
5 51B 111
D 107B 153
4
26 113A
30 111
26 E 3 86 PARK
BRAKE 112A 111A
26B DIS. 30 A1 A1
27C 2
RELAY
B
D 41 86
1 87A 87 A2 A2
40.0 27 27D 113A START
MAIN
100 RELAY
107A NOT USED
85
113B 87A 87
C 2EE 113
51B 107B 113 2FF
3A 153A
7.5 2HH 20 20 20
20 20 A3 A3
2BB
9 9
B+ 153 CAB MALE AND FEMALE
8 8 GROUND BULKHEAD HARNESS
GEAR 150 STUD
1 Gear
st
7
GEAR
7
103
CONNECTORS
F 6 6
GEAR
5 5
N GEAR 101
1 112A
4 4
2 R NEUTRAL 112 112
3
112
3 3 24
SHIFTER 102
ZF TRANSMISSION 2 2
FORWARD 102 30
REVERSE 1 1
86 BACK-UP
B+ 113 ALARM
RELAY
85
87A 87
2BB 31
20
2DD 20
20
31 2X
2G 2H
31 31 +
A5 A5
2D 2J
B2 B2 -
2X
B1 B1 2J 7 7
Y1 Y3 Y2
C4 C4 1 1
DE E E
103 103 103B Y1 Y3 Y2
C3 C3 103 3 3
102 102 102B 2 2

C2 C2 102
UPPER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE) Upper Lower
C5 C5 4 4 Valve Valve
101 101 101B
Body Body
C1 C1 101 5 5 Y6 Y5 Y4
E E DE Driving Speed
150
B3 B3
150
150
150B 6 6 Direction Y1 Y2 Y3 Y4 Y5 Y6
102A 103A 2H 7 7
MALE AND FEMALE
BULKHEAD HARNESS
2DD 101A 150A 2D Forward 1
CONNECTORS F E B A A B E F Forward 2
Forward 3
Forward 4
Y6 Y5 Y4
Reverse 1
2G Reverse 2
LOWER
= See Page 9.92, 9.93, 9.94

TRANSMISSION COILS Reverse 3
TRANS. (VIEWED FROM
GRND FRONT OF VEHICLE)
MH5500
9.174 Model 8042, 10042, 10054 Legacy Rev. 10/03

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
102B 24
30
S 86 BACK-UP
19 P
R ALARM
O
58
RELAY
85
10.0 S
87A 87
HORN/HEATER 24 P
R
O
15
2BB 31
30 S IGNITION
P SWITCH
R
50
7.5 O
LIGHT SWITCH
RELAY
3C A B C 153A
1 2HH
8 7
111
6
1
PARK 107B
26A 26 E 2 153
BRAKE
1 SWITCH 30
PARK
5 86
26 D BRAKE
26 4 DIS.
85
RELAY
26B 27C
E 3 87A 87
TO STARTER
40.0 27 27D 2
100 D 113B
MAIN 107A 107B 2EE
1 2BB
3A 153A 2HH 20A 20A 20B 20C
7.5 20A 20A A4 A4 20A 20B
TRANSMISSION 9 9 2X
B+ 153 2MM
FEMALE AND MALE -
8 8 BACK-UP
GEAR 150 BULKHEAD HARNESS
CAB CONNECTORS ALARM
1st Gear 7
GEAR
7
103
GROUND
STUD
+
6 6 111 31
F GEAR 113B
5 5
113A 113A
113 111
N GEAR 101
1 113 102B
4 4 111A
2 R NEUTRAL 112 112 112A
3 112
3 3 30
SHIFTER REVERSE 102A 102A 86 NEUTRAL
102
ZF TRANSMISSION START
2 2 102
REVERSE FORWARD RELAY
85
1 1 87A 87
B+ 113
2FF
20 20 20 20D
20 A3 A3 20 20D
2LL 20E
MALE AND FEMALE
BULKHEAD HARNESS
CAB CONNECTORS
GROUND STUD
31
31
A5 A5
20
2DD 20
B2 B2
2G 2H
2D 2J
B1 B1
7 7
Y1 Y3 Y2
C4 C4 1 1
DE E E 20E 20C
103 103 103B Y1 Y3 Y2
C3 C3 103 3 3
102 102 102B ENGINE GROUND BUSS BAR

C2 C2 102 2 2
UPPER
TRANSMISSION COILS
(VIEWED FROM
101 101 101B
Body Body
C1 C1 101 5 5 Y6 Y5 Y4
150
B3 B3
150
150
102A 103A 2H 7 7
MALE AND FEMALE
BULKHEAD HARNESS
Forward 3
Forward 4
Y6 Y5 Y4
Reverse 1
2G Reverse 2
LOWER
TRANS. (VIEWED FROM
MH5360
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.175

Electrical System

(SN 10054, 19080 - 19987 And 0160002332 & After)
3A
3C
26A
A B C D E
A B C D E
S
19 P 102B 24
R
58
O
52 30
S 86
P BACK-UP
R 30 PARK ALARM
15 86
O BRAKE RELAY
30 S
INTERLOCK 85
10.0
24 P
IGNITION 85 87A 87
HORN/HEATER R SWITCH 87A 87 RELAY
50
O 2BB 31
51A
A B C
7.5 1 2HH
LIGHT SWITCH 8 7
RELAY 111
6
3C 1
PARK 51A
2
26 E BRAKE
SWITCH 51
1 153A
5
D
51B 107B
26A 4
153
30
E 3 86 PARK
26 BRAKE
26 DIS.
2
RELAY
26B 27C
D
1
41B B 52 85
87A 87
40.0 27 27D 113B
100
MAIN
51B C 107B
2EE 2BB
3A 153A 2HH 20A 20A 20B
7.5 20A 20A A4 A4 20A 20B
TRANSMISSION
9 9 20C
B+ 153 2MM 2X
FEMALE AND MALE
8 8 BULKHEAD HARNESS -
GEAR 150
CONNECTORS
1st Gear 7
GEAR
7
103 CAB
BACK-UP
+
GROUND
6 6 111 STUD ALARM 31
F GEAR 113B
5 5
113A 113A
113 111
N GEAR 101
1 113 102B
4 4 111A
2 R NEUTRAL 112 112 112A
3 112
3 3 30
102
2 2 102
85
1 1 87A 87
B+ 113
2FF
20 20 20 20D
20 A3 A3 20 20D
2LL 20E
MALE AND FEMALE
BULKHEAD HARNESS
CAB CONNECTORS
GROUND STUD
31
31
A5 A5
20
2DD 20
B2 B2
2G 2H
2D 2J
B1 B1
7 7
Y1 Y3 Y2
C4 C4 1 1
DE E E 20E 20C
103 103 103B Y1 Y3 Y2
C3 C3 103 3 3
102 102 102B ENGINE GROUND BUSS BAR

C2 C2 102 2 2
UPPER
TRANSMISSION COILS
(VIEWED FROM
101 101 101B
Body Body
C1 C1 101 5 5 Y6 Y5 Y4
150
B3 B3
150
150
102A 103A 2H 7 7
MALE AND FEMALE
BULKHEAD HARNESS
Forward 3
Forward 4
Y6 Y5 Y4
Reverse 1
2G Reverse 2
LOWER
= See Page 9.107 TRANS. (VIEWED FROM
MH5510
9.176 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System

(SN 8042, 13198 - 18990, 10042 13198 - 19030)
3A

1
8 7
6
2 PARK
E BRAKE
SWITCH
3C 5
D
26A 4
A B C D E E 3
A B C D E TO
2
41 PARK
D
107 107 BRAKE
1
DIS.
S
RELAY
19 P
R TO
O
58
26A IGNITION
HORN/HEATER 24 SWITCH P 26
R
15
O
30 S
P
R 7.5 40.0
7.5 O
50
LIGHT SWITCH
RELAY
MAIN
See pages
LIGHT SWITCH
RELAY
3C A B C
3
TO 9.38 or 9.62.
IGNITION
153A SWITCH
1 2HH
1 8 7
111
26A 6
26 111
PARK 107B
E 2 153
BRAKE 113A
26 1 SWITCH 30 111
26 86 PARK
5
BRAKE 112A 111A
D
26B 4 DIS. 30 A1 A1
27C RELAY 86
TO STARTER E 3
85 NEUTRAL
87A 87 A2 A2
40.0 27 27D 113A START
MAIN
100 RELAY
2 85
D 41 113B
41B 107A 107B 2EE 113 87A 87
1
113 2FF
3A 153A
7.5 2HH 20 20 20
9 9
B+ 153 CAB
GEAR
2nd Gear 7 7
STUD BULKHEAD HARNESS
CONNECTORS
GEAR 103
F 6 6
GEAR 105
5 5
1 N GEAR 101
2 112A
4 4
3 R NEUTRAL 112 112
4
112
3 3 24
SHIFTER 102
ZF TRANSMISSION 2
FORWARD
2
102 30
REVERSE 86 BACK-UP
1 1
B+ 113 ALARM
RELAY
85
87A 87
2BB 31
20
2DD 20
20
31 2X
2G 2H
31 31 +
A5 A5
2D 2J
B2 B2 -
2X
B1 B1 2J 7 7
Y1 Y3 Y2
C4 C4 1 1
DE E E
103 103 103B Y1 Y3 Y2
C3 C3 103 3 3
102 102 102B 2 2

C2 C2 102
UPPER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
105
C5 C5
105
105
Valve Valve
C1 C1 101 5 5 Y6 Y5 Y4
DE E E
102A 103A 105A 2H Direction Y1 Y2 Y3 Y4 Y5 Y6
7 7
MALE AND FEMALE 2DD 101A 2D
Forward 2
Forward 3
Y6 Y5 Y4 Forward 4
2G
Reverse 1
LOWER Reverse 2
TRANSMISSION COILS
TRANS.
(VIEWED FROM
FRONT OF VEHICLE)
Reverse 3
GRND
MH5370
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.177

Electrical System
9.8.22 Transmission, Reverse Second Gear Circuit, (SN 10054, 13198 - 19079)
3A

1
8 7
6
3C
2 PARK
26A E BRAKE
SWITCH
A B C D E 5
D
A B C D E 4
E 3
TO
S 2 PARK
B
P D 41
19
R
41 52 BRAKE
1
58 INTERLOCK
IGNITION
O
SWITCH P
R TO
O
15
26A IGNITION
30 S 52 SWITCH
10.0
HORN/HEATER 24 P
26
R
50 86
30 PARK
O BRAKE
INTERLOCK
85
87A 87 RELAY 40.0
A B C 7.5
MAIN
7.5 LIGHT SWITCH
51A RELAY
LIGHT SWITCH
RELAY
3C 1 8
1
7
2HH 3
TO See page 9.84.
111 IGNITION
26
6 SWITCH
PARK 51A
E 2
BRAKE
SWITCH 51
26A 1
5 51B 153A 111
D 107B 153
4
26 113A
30 111
26 E 3 86 PARK
BRAKE 112A 111A
26B DIS. 30 A1 A1
27C 2
RELAY
B
D 41 86
1 87A 87 A2 A2
40.0 27 27D 113A START
MAIN
100 RELAY
107A NOT USED
85
113B 87A 87
C 2EE 113
51B 107B 113 2FF
3A 153A
7.5 2HH 20 20 20
9 9 2BB
B+ 153 CAB
GEAR
2nd Gear 7 7
STUD BULKHEAD HARNESS
CONNECTORS
GEAR 103
F 6 6
GEAR 105
5 5
1 N GEAR 101
2 112A
4 4
3 R NEUTRAL 112 112
4
112
3 3 24
SHIFTER 102
ZF TRANSMISSION 2
FORWARD
2
102 30
REVERSE 86 BACK-UP
1 1
B+ 113 ALARM
RELAY
85
87A 87
2BB 31
20
2DD 20
20
31 2X
2G 2H
31 31 +
A5 A5
2D 2J
B2 B2 -
2X
B1 B1 2J 7 7
Y1 Y3 Y2
C4 C4 1 1
DE E E
103 103 103B Y1 Y3 Y2
C3 C3 103 3 3
102 102 102B 2 2

C2 C2 102
UPPER
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
105
C5 C5
105
105
Valve Valve
C1 C1 101 5 5 Y6 Y5 Y4
DE E E
102A 103A 105A 2H Direction Y1 Y2 Y3 Y4 Y5 Y6
7 7
Forward 2
Forward 3
Y6 Y5 Y4 Forward 4
2G
Reverse 1
LOWER Reverse 2
TRANSMISSION COILS
= See Page 9.92, 9.93, 9.94 TRANS.

(VIEWED FROM
FRONT OF VEHICLE)
Reverse 3
GRND
MH5520
9.178 Model 8042, 10042, 10054 Legacy Rev. 10/03

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
102B 24
30
S 86 BACK-UP
19 P
R ALARM
O
58
RELAY
85
10.0 S
87A 87
HORN/HEATER 24 P
R
O
15
2BB 31
30 S
IGNITION
P
R SWITCH
50
7.5 O
LIGHT SWITCH
RELAY
3C A B C 153A
1 2HH
8 7
111
6
1
PARK 107B
26A 26 E 2 153
BRAKE
1 SWITCH 30
PARK
5 86
26 D BRAKE
26 4 DIS.
85
RELAY
26B 27C
E 3 87A 87
TO STARTER
40.0 27 27D 2
100 D 113B
MAIN 107A 107B 2EE
1 2BB
3A 153A 2HH 20A 20A 20B 20C
7.5 20A 20A A4 A4 20A 20B
TRANSMISSION 9 9
B+ 153 2MM 2X
8 8 FEMALE AND MALE
GEAR BULKHEAD HARNESS -
BACK-UP
2 Gear
nd
7
GEAR
7
103
CAB
GROUND
CONNECTORS ALARM
+
STUD
6 6 113B 111
F GEAR 105 31
5 5
113A 113A
113 111
1 N GEAR 101
2 113 102B
4 4 111A
3 R NEUTRAL 112 112 112A
4 112
3 3 30
102
2 2 102
85
1 1 87A 87
B+ 113
2FF
20 20 20 20D
20 A3 A3 20 20D
2LL 20E
MALE AND FEMALE
GROUND STUD CONNECTORS
31
31
A5 A5
20
B2 B2 2DD 20
2G 2H
2D 2J
B1 B1
7 7
Y1 Y3 Y2
C4 C4 1 1
DE E E
103 103 103B Y1 Y3 Y2
C3 C3 103 3 3
20E 20C
102 102 102B 2 2
C2 C2 102
UPPER ENGINE GROUND BUSS BAR
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
105 105 105B Upper Lower
4 4
C5 C5 105
Valve Valve
101
C1 C1
101
101
101B
5 5 Y6 Y5 Y4
Body Body
DE E E Driving Speed
B3 B3 6 6
102A 103A 105A 2H 7 7
Forward 2
Forward 3
Y6 Y5 Y4 Forward 4
DIODE PACK DIODE PACK Reverse 1
2G
LOWER Reverse 2
TRANSMISSION COILS
TRANS.
FRONT OF VEHICLE)
GRND
MH5380
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.179

Electrical System

(SN 10054, 19080 - 19987 And 0160002332 & After)
3A
3C
26A
A B C D E
A B C D E
S
19 P 102B 24
R
58
O
52 30
S 86
P BACK-UP
R 30 PARK ALARM
15 86
O BRAKE RELAY
30 S
IGNITION INTERLOCK 85
10.0 87A 87
HORN/HEATER 24 P
SWITCH 85
87A 87 RELAY
R
50
O 2BB 31
51A
A B C
7.5 1 2HH
LIGHT SWITCH 8 7
RELAY 111
6
3C 1
PARK 51A
2
26 E BRAKE
SWITCH 51
1 153A
5
D
51B 107B
26A 4
153
30
E 3 86 PARK
26 BRAKE
26 DIS.
2
RELAY
26B 27C
D
1
41B B 52 85
87A 87
40.0 27 27D 113B
100
MAIN
51B C 107B
2EE 2BB
3A 153A 2HH 20A 20A 20B
7.5 20A 20A A4 A4 20A 20B
TRANSMISSION 9 9
B+ 153 20C
2MM
8 8 FEMALE AND MALE
GEAR BULKHEAD HARNESS 2X
2nd Gear 7
GEAR
7
103 CAB
CONNECTORS
-
GROUND
6 6 113B 111 STUD +
F GEAR 105
BACK-UP
5 5
113A 113A ALARM 31
113 111
1 N GEAR 101
2 113 102B
4 4 111A
3 R NEUTRAL 112 112 112A
4 112
3 3 30
102
2 2 102
85
1 1 87A 87
B+ 113
2FF
20 20 20 20D
20 A3 A3 20 20D
2LL 20E
MALE AND FEMALE
GROUND STUD CONNECTORS
31
31
A5 A5
20
B2 B2 2DD 20
2G 2H
2D 2J
B1 B1
7 7
Y1 Y3 Y2
C4 C4 1 1
DE E E
103 103 103B Y1 Y3 Y2
C3 C3 103 3 3
20E 20C
102 102 102B 2 2
C2 C2 102
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
4 4
C5 C5 105
Valve Valve
101
C1 C1
101
101
101B
5 5 Y6 Y5 Y4
Body Body
DE E E Driving Speed
B3 B3 6 6
102A 103A 105A 2H 7 7
Forward 2
Forward 3
Y6 Y5 Y4 Forward 4
2G
LOWER Reverse 2
TRANSMISSION COILS
= See Page 9.107 TRANS.
FRONT OF VEHICLE)
GRND
MH5530
9.180 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
9.8.25 Transmission, Reverse Third Gear Circuit, (SN 8042, 13198 - 18990, 10042 13198 - 19030)
3A

1
8 7
6
2 PARK
E BRAKE
3C SWITCH
5
26A D
4
A B C D E E 3
A B C D E TO
2
41 PARK
D
107 107 BRAKE
1
DIS.
S RELAY
19 P
R TO
58
O 26A IGNITION
24 SWITCH P
HORN/HEATER
R 26
15
O
30 S
P
R
7.5 40.0
7.5 O
50
LIGHT SWITCH
RELAY
MAIN See pages
LIGHT SWITCH
RELAY
3C A B C
3
TO
9.38 or 9.62.
IGNITION
153A SWITCH
1 2HH
1 8 7
111
26A 6
26 111
PARK 107B
E 2 153
BRAKE 113A
26 1 SWITCH 30 111
26 86 PARK
5
BRAKE 112A 111A
D
26B 4 DIS. 30 A1 A1
27C RELAY 86
TO STARTER E 3
85 NEUTRAL
87A 87 A2 A2
40.0 27 27D 113A START
MAIN
100 RELAY
2 85
D 41 113B
41B 107A 107B 2EE 113 87A 87
1
113 2FF
3A 153A
7.5 2HH 20 20 20
9 9
B+ 153 CAB
GEAR 150 STUD BULKHEAD HARNESS
3 Gear
rd
7 7 CONNECTORS
GEAR 103
F 6 6
GEAR 105
5 5
2 N GEAR
3 112A
4 4
4 R NEUTRAL 112 112
112
3 3
REVERSE 102A 102A 102B 102B 24
SHIFTER 102
ZF TRANSMISSION 2
FORWARD
2
102
REVERSE 30
1 1 86 BACK-UP
B+ 113 ALARM
RELAY
85
87A 87
2BB 31
20
2DD 20
31 20
31 31 + 2X
A5 A5 2G
2H
B2 B2 - 2D 2J
2X
B1 B1 2J 7 7
Y1 Y3 Y2
C4 C4 1 1
DE E E
103 103 103B Y1 Y3 Y2
C3 C3 103 3 3
102 102 102B 2 2

C2 C2 102
UPPER
TRANSMISSION COILS
(VIEWED FROM
105
C5 C5
105
105
105B 4 4 Valve Valve
Body Body
C1 C1 5 5 Y6 Y5 Y4
E DE E Driving Speed
150
B3 B3
150
150
102A 103A 105A 2H 7 7
MALE AND FEMALE
BULKHEAD HARNESS
2DD 150A 2D Forward 1
Forward 3
Forward 4
Y6 Y5 Y4
Reverse 1
2G Reverse 2
LOWER
TRANS. (VIEWED FROM
MH5390
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.181

Electrical System
9.8.26 Transmission, Reverse Third Gear Circuit, (SN 10054, 13198 - 19079)
3A

1
8 7
6
3C
2 PARK
26A E BRAKE
SWITCH
A B C D E 5
D
A B C D E 4
E 3
TO
S 2 PARK
B
P D 41
19
R
41 52 BRAKE
1
58 INTERLOCK
IGNITION
O
SWITCH P
R TO
O
15
26A IGNITION
30 S 52 SWITCH
10.0
HORN/HEATER 24 P
26
R
50 86
30 PARK
O BRAKE
INTERLOCK
85
87A 87 RELAY 40.0
A B C 7.5
MAIN
7.5 LIGHT SWITCH
51A RELAY
LIGHT SWITCH
RELAY
3C 1 8
1
7
2HH 3
TO See page 9.84.
111 IGNITION
26
6 SWITCH
PARK 51A
E 2
BRAKE
SWITCH 51
26A 1 153A
5 51B 111
D 107B 153
4
26 113A
30 111
26 E 3 86 PARK
BRAKE 112A 111A
26B DIS. 30 A1 A1
27C 2
RELAY
B
D 41 86
1 87A 87 A2 A2
40.0 27 27D 113A START
MAIN
100 RELAY
107A NOT USED
85
113B 87A 87
C 2EE 113
51B 107B 113 2FF
3A 153A
7.5 2HH 20 20 20
9 9 CAB
B+ 153
GROUND MALE AND FEMALE
8 8 STUD BULKHEAD HARNESS
GEAR 150
3rd Gear 7 7
CONNECTORS
GEAR 103
F 6 6
GEAR 105
5 5
2 N GEAR 112A
3
4 4
4 R NEUTRAL 112 112
112
3 3 24
SHIFTER 102
ZF TRANSMISSION 2
FORWARD
2
30
102
REVERSE 86 BACK-UP
1 1
B+ 113 ALARM
RELAY
85
87A 87
2BB 31
20
2DD 20
31 20
31 31 + 2X
A5 A5 2G
2H
B2 B2 - 2D 2J
2X
B1 B1 2J 7 7
Y1 Y3 Y2
C4 C4 1 1
DE E E
103 103 103B Y1 Y3 Y2
C3 C3 103 3 3
102 102 102B 2 2

C2 C2 102
UPPER
TRANSMISSION COILS
(VIEWED FROM
105
C5 C5
105
105
105B 4 4 Valve Valve
Body Body
C1 C1 5 5 Y6 Y5 Y4
Driving Speed
150
B3 B3
150
150
150B 6 6
E DE E
102A 103A 105A 2H 7 7
MALE AND FEMALE 2DD 150A 2D Forward 1
BULKHEAD HARNESS
Forward 3
Forward 4
Y6 Y5 Y4
Reverse 1
2G Reverse 2
LOWER
= See Page 9.92, 9.93, 9.94 TRANSMISSION COILS Reverse 3

TRANS. (VIEWED FROM
MH5540
9.182 Model 8042, 10042, 10054 Legacy Rev. 10/03

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
102B 24
30
S 86 BACK-UP
19 P
R ALARM
O
58
RELAY
85
10.0 S
87A 87
HORN/HEATER 24 P
R
O
15
2BB 31
30 S IGNITION
P SWITCH
R
50
7.5 O
LIGHT SWITCH
RELAY
3C A B C 153A
1 2HH
8 7
111
6
1
PARK 107B
26A 26 E 2 153
BRAKE
1 SWITCH 30
PARK
5 86
26 D BRAKE
26 4 DIS.
85
RELAY
26B 27C
E 3 87A 87
TO STARTER
40.0 27 27D 2
100 D 113B
MAIN 107A 107B 2EE
1 2BB
3A 153A 2HH 20A 20A 20B 20C
7.5 20A 20A A4 A4 20A 20B
TRANSMISSION 9 9
B+ 153 2MM
2X
8 8 FEMALE AND MALE
GEAR 150 BULKHEAD HARNESS -
CAB BACK-UP
3 Gear
rd 7
GEAR
7
103 GROUND
CONNECTORS
ALARM
+
STUD
6 6 113B 111
F GEAR 105 31
5 5
113A 113A
113 111
2 N GEAR
3 113
4 4 111A
4 R NEUTRAL 112 112 112A
112
3 3 30
SHIFTER REVERSE 102A 86 NEUTRAL
102
2 2 102
85
1 1 87A 87
B+ 113
2FF
20 20 20 20D
20 A3 A3 20 20D
2LL 20E
MALE AND FEMALE
BULKHEAD HARNESS
CAB CONNECTORS
GROUND STUD
31
31
A5 A5
20
B2 B2 2DD 20
2G 2H
2D 2J
B1 B1
7 7
Y1 Y3 Y2
C4 C4 1 1
DE E E
103 103 103B Y1 Y3 Y2
C3 C3 103 3 3
20E 20C
102 102 102B 2 2
C2 C2 102
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
4 4
C5 C5 105
Valve Valve
C1 C1 5 5 Y6 Y5 Y4
Body Body
150 150 150B E DE E Driving Speed
B3 B3 150 6 6
102A 103A 105A 2H 7 7
Forward 2
Forward 3
Y6 Y5 Y4 Forward 4
2G
LOWER Reverse 2
TRANSMISSION COILS
TRANS.
FRONT OF VEHICLE)
GRND
MH5400
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.183

Electrical System

(SN 10054, 19080 - 19987 And 0160002332 & After)
3A
3C
26A
A B C D E
A B C D E
S
19 P 102B 24
R
58
O
52 30
S 86
P BACK-UP
R 30 PARK ALARM
15 86
O BRAKE RELAY
30 S IGNITION INTERLOCK 85
10.0 87A 87
HORN/HEATER 24 P
SWITCH 85
87A 87 RELAY
R
50
O 2BB 31
51A
A B C
7.5 1 2HH
LIGHT SWITCH 8 7
RELAY 111
6
3C 1
51A
2
26 E
51
1 153A
5
D
51B
26A 4
107B 153
PARK 30
BRAKE E 3 86 PARK
26 SWITCH BRAKE
26 DIS.
2
RELAY
26B 27C
D
1
41B B 52 85
87A 87
40.0 27 27D 113B
100
MAIN
51B C 107B
2EE 2BB
3A 153A 2HH 20A 20A 20B
7.5 20A 20A A4 A4 20A 20B
TRANSMISSION 9 9
B+ 153 2MM 20C
2X
8 8 FEMALE AND MALE
GEAR 150 BULKHEAD HARNESS -
CAB
3rd Gear 7
GEAR
7
103 GROUND
CONNECTORS
+
STUD BACK-UP
6 6 113B 111 ALARM 31
F GEAR 105
5 5
113A 113A
113 111
2 N GEAR
3 113
4 4 111A
4 R NEUTRAL 112 112 112A
112
3 3 30
SHIFTER REVERSE 102A 86 NEUTRAL
102
2 2 102
85
1 1 87A 87
B+ 113
2FF
20 20 20 20D
20 A3 A3 20 20D
2LL 20E
MALE AND FEMALE
BULKHEAD HARNESS
CAB CONNECTORS
GROUND STUD
31
31
A5 A5
20
B2 B2 2DD 20
2G 2H
2D 2J
B1 B1
7 7
Y1 Y3 Y2
C4 C4 1 1
DE E E
103 103 103B Y1 Y3 Y2
C3 C3 103 3 3
20E 20C
102 102 102B 2 2
C2 C2 102
TRANSMISSION COILS
(VIEWED FROM
FRONT OF VEHICLE)
4 4
C5 C5 105
Valve Valve
C1 C1 5 5 Y6 Y5 Y4
Body Body
150 150 150B E DE E Driving Speed
B3 B3 150 6 6
102A 103A 105A 2H 7 7
Forward 2
Forward 3
Y6 Y5 Y4 Forward 4
2G
LOWER Reverse 2
= See Page 9.107 TRANSMISSION COILS
GRND
MH5550
9.184 Model 8042, 10042, 10054 Legacy Rev. 10/03

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.”
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.185

Electrical System
9.8.30 Engine Alternator Charging Warning Indicator Troubleshooting
Engine Alternator
Charging Warning
P
Indicator
0000 00
MA7560
Engine alternator charging

warning indicator stays ON
while operating.
begin by checking the Check alternator belt tension.
following:
If OK
1. Fuses.
2. Battery for proper charge. Check terminal “D+” Check for proper ground at
Not
on alternator for alternator. Repair as
3. All connections relating to 13.8 to 14.2 volts.
OK
necessary.
4. Check instrument cluster Light Still On
bulb for proper function.
Replace alternator.
If OK
Replace instrument cluster.
9.186 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
9.8.31 Engine Coolant Temperature Warning Indicator Troubleshooting
Engine Coolant Temperature

Warning Indicator
0000 00
MA7570
Engine coolant temperature

while operating.
Check radiator coolant level,

fan belt tension, radiator
Not
Before troubleshooting any cap, thermostat, and for OK
Repair as needed.
electrical circuit, ALWAYS plugged condition or debris
begin by checking the on radiator.
following:
If OK
1. Fuses.
2. Battery for proper charge.
Check connections at
Not
3. All connections relating to temperature switch and back OK
Repair as needed.
circuit are clean and tight. of instrument cluster.
4. Check instrument cluster

If OK
Check circuit for grounded

wire 15 (LT BLU).
Disconnect harness at If grounded, repair wire. Refer
Not
temperature switch. Indicator OK
to pages 9.38, 9.39, 9.40,
light should go out. 9.41, 9.50, 9.51, 9.62, 9.63,
9.64, 9.65,9.74, 9.75, 9.84,
If OK 9.85, 9.86, 9.87, 9.102 or
9.103.
Replace engine coolant
temperature switch and If circuit tests OK
retest system.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.187

Electrical System
9.8.32 Transmission Temperature Warning Indicator Troubleshooting
P
Transmission Temperature
Warning Indicator
0000 00
MA7580
Transmission temperature
while operating and alarm
sounds.

Stop and idle vehicle for
begin by checking the 1 minute to allow
following: transmission oil to cool.
1. Fuses.
Not OK
Check transmission fluid
circuit are clean and tight. level. Check radiator for Not
Repair as needed.
OK
4. Check instrument cluster plugged condition or debris.
If OK
Check connections and

Not
circuit at switch OK
Repair as needed.
on transmission.
If OK

wire 18 (GRN). If grounded,
Disconnect harness at
repair wire. Refer to pages
transmission temperature Not
9.38, 9.39, 9.40, 9.41, 9.50,
switch. Indicator light OK
9.51, 9.62, 9.63, 9.64,
should go out.
9.65,9.74, 9.75, 9.84, 9.85,
9.86, 9.87, 9.102 or 9.103.
If OK
If circuit tests OK
Replace transmission
temperature switch and Replace instrument cluster.
retest system.
9.188 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
9.8.33 Hydraulic Oil Temperature Warning Indicator Troubleshooting
Hydraulic Oil Temperature

Warning Indicator
0000 00
MA7590
Hydraulic oil temperature

warning indicator stays
ON while operating.
begin by checking the Stop and idle engine for
5 minutes to allow
following: hydraulic oil to cool.
1. Fuses.
Not OK
Check hydraulic fluid level.
circuit are clean and tight. Check for plugged condition Not
Repair as needed.
OK
4. Check instrument cluster or debris on oil cooler.
If OK
Check connections and circuit Not

Repair as needed.
at switch. OK
If OK

wire 151 (YEL/GRN).
Disconnect harness at switch. If grounded, repair wire.
Not
Indicator light should go out. OK
Refer to pages 9.38, 9.39,
9.40, 9.41, 9.50, 9.51, 9.62,
9.63, 9.64, 9.65,9.74, 9.75,
If OK 9.84, 9.85, 9.86, 9.87, 9.102
or 9.103.
Replace hydraulic oil If circuit tests OK

temperature switch and
retest system.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.189

Electrical System
9.8.34 Park Brake Warning Indicator Troubleshooting
Park Brake
Warning Indicator
0000 00
MA7600
Park brake warning

indicator stays ON
with park brake
Before troubleshooting any disengaged.
following:
Check light bulb.
1. Fuses.
2. Battery for proper charge. If OK

circuit are clean and tight. Check park brake switch for
battery voltage at
4. Check instrument cluster Pin 3 of the 8 pin connector.
If OK
Check park brake switch for

Not
battery voltage at OK
Check fuses.
Pin 2 of the 8 pin connector.
If OK
Replace park brake switch.

Retest switch.
9.190 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
9.8.35 Engine Oil Pressure Warning Indicator Troubleshooting
P
Engine Oil Pressure
Warning Indicator
following:
1. Fuses.
2. Battery for proper charge. 0000 00
MA7610
Engine oil pressure

warning indicator stays
ON while operating.
Check connections at oil

Check engine for If Not Repair connections
pressure switch and
oil pressure. OK OK as needed.
instrument cluster.
Not OK
If OK Not OK
Disconnect oil pressure
switch at harness. Turn
Disconnect wire Repair engine ignition ON and check for
16 (BLU) from oil component. grounded circuit. If Indicator
pressure switch and light is still on, check wire 16
verify that switch (BLU). Refer to pages 9.38,
contact is open. 9.39, 9.40, 9.41, 9.50, 9.51,
9.62, 9.63, 9.64, 9.65,9.74,
Not OK 9.75, 9.84, 9.85, 9.86, 9.87,
9.102 or 9.103.
Replace oil pressure

switch. If OK
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.191

Electrical System
9.8.36 Fuel Level Indicator Troubleshooting
P
following:
1. Fuses.
Fuel Level
Indicator 0000 00
MA7620
Fuel level indicator reads

EMPTY while operating.
Verify fuel quantity Not

Fill fuel tank.
level in tank. OK
If OK
Check ground wire 2A (BLK) wire for continuity:
Full = 31 ohms
Disconnect fuel level sender
Not One-Half = 101 ohms
and check resistance at OK Empty = 255 ohms
fuel level sender.
Refer to pages 9.38, 9.39, 9.40, 9.41, 9.50, 9.51,
9.62, 9.63, 9.64, 9.65,9.74, 9.75, 9.84, 9.85, 9.86,
If OK
9.87, 9.102 or 9.103.
Verify battery voltage on If OK

wire 17 (GRY). Refer to
pages 9.38, 9.39, 9.40, 9.41,
9.50, 9.51, 9.62, 9.63, 9.64, Replace switch in tank.
9.65,9.74, 9.75, 9.84, 9.85,
9.86, 9.87, 9.102 or 9.103.
Not OK
9.192 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
9.8.37 Hourmeter Indicator Troubleshooting
P
following:
1. Fuses.
2. Battery for proper charge. 0000 00
4. Check instrument cluster MA7640

Hourmeter
Indicator
Hourmeter indicator does

not register
operating hours.
Check for proper ground at
alternator. Refer to pages
Check wire 38 (ORG) for 9.38, 9.39, 9.40, 9.41, 9.50,
Not If Check alternator terminal
battery voltage to instrument 9.51, 9.62, 9.63, 9.64,
OK OK “D+” for battery voltage.
panel connector. 9.65,9.74, 9.75, 9.84, 9.85,
9.86, 9.87, 9.102 or 9.103.
Not OK
Not OK
Replace alternator.
Repair ground wires as

necessary.
If OK
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.193

Electrical System
9.8.38 Stabil-TRAK™ Indicator Troubleshooting
0000 00
Stabil-TRAK™
Indicator MH3430
Stabil-TRAK™ indicator
stays ON with boom
below 40°.
Before troubleshooting this
begin by checking the Check circuit 40 (BRN/BLK)
following: at solenoid 3 on Stabil-TRAK
cylinder for battery voltage.
1. Boom below 40°.
2. Transmission shifter in If OK
NEUTRAL.
3. Park Brake OFF. Check Stabil-Lock relay
circuit 114B (BLU/ORG) for
battery voltage.
If OK
Check for “0” volts on circuit

Not
48 (PUR/BLK) at OK
Replace boom relay.
Stabil-Lock relay.
If OK Check for battery voltage on

circuit 46 (WHT/ORG) and
45B (DK BLU/ORG) at brake
Not
Replace service brake switch. OK
pedal switch. If battery
voltage is found on circuit
If OK 45B, replace brake
pedal switch.
Check for “0” battery voltage

Not
at Pin 3 of the 8 pin park OK
Replace park brake switch.
brake switch connector.
9.194 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
9.9 ENGINE START CIRCUIT 4. If the park brake is set, current flows through
contacts in the brake switch to the neutral start
The purpose of the engine start circuit is to energize the circuit.
starter solenoid and engage the starter motor to start the 5. If the transmission select lever is in (N) NEUTRAL,
engine. To start the engine, the ignition key switch must current flows through the neutral start circuit to
be in the START (1) position, the park brake switch must energize the coil of the starter relay. The relay closes
be in the ON position and the transmission shift control internal contacts that allow current to flow to the
switch (travel select lever) must be in the NEUTRAL starter solenoid and starter.
(center) position.
6. The starter solenoid engages a gear on the starter
When the ignition key switch is turned to the START (1) pinion shaft to mesh with the flywheel. The starter
position, and with the transmission in (N) NEUTRAL, the pinion and gear begin to spin, in turn, rotating the
starting circuit activates the starter relay, starter solenoid flywheel, crankshaft and related components within
and fuel shut-off solenoid. The fuel shut-off solenoid the engine.
opens a valve that supplies fuel to the injection pump.
7. When the ignition key switch is initially turned, the
fuel shut-off solenoid opens a valve to supply power
9.9.1 Starting Circuit
to the fuel injection pump. As the starter rotates the
The starting circuit functions as follows: engine components, the fuel injection pump, and
1. Current from the battery flows through the positive related lines and injectors supply fuel to the
(+) battery cable to the starter solenoid. cylinders.
2. Current then flows to the fuse box, through the main 8. When the pistons compress the injected fuel, ignition
fuse and to the ignition key switch. occurs, the engine starts and the starter pinion
retracts.
3. When the key switch is turned to the START (1)
position, current flows through contacts in the 9. As the engine runs, it drives the alternator that
ignition key switch to the park brake switch. recharges the battery used during the starting cycle.
10. When the ignition key switch is released, it returns to
2 the RUN (2) position where it directs current to the
fuse panel that, in turn, distributes electrical current
1 for the operation of vehicle controls, gauges and
other equipment.
MA10,0010
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.195

Electrical System
9.9.2 Starter The starter operates when the attached starter solenoid
engages a gear on the starter pinion shaft to mesh with
The starter (1 or 15) is located on the left side of the
the flywheel, and the starter pinion and gear begin to spin,
engine (the left side of the vehicle).
in turn rotating the flywheel, crankshaft and related
components within the engine.
SN 8042, 13198 - 18990, 10042 13198 - 19030,
The starter is grounded indirectly via the negative (-)
10054, 13198 - 19079
battery cable. The cable (2 or 13) is routed from the
3 battery to the starter housing where it attaches to the
6 engine.
1
a. Testing the Starter on the Engine
7
If the starter does not engage when the ignition key
4 switch is turned, check the following:
5 1. The main fuse may be blown, requiring replacement.
Check for the cause of the blown fuse.
2. There may be a defect in the ignition key switch,
ignition wiring or starter solenoid.
3. Check battery condition. Clean the battery posts and
2 the connectors at each end of the battery cables.
MA8420 4. Check for broken wiring and damaged insulation on
the wiring. Replace all broken or damaged wiring.
5. Check all connections at the starter solenoid, key
SN 8042, 18991 - 19987, 10042 19031 - 19987,
switch and wiring harness plugs. Clean and tighten
10054, 19080 - 19987 And
all connections.
8042/10042/10054, 0160002332 & After
6. If the starter still does not operate after these checks
have been performed, check the starting circuit.
15
b. Starter Circuit Checks
8
14 1. Check wires and connections for looseness,
corrosion, damage, etc.
10
12 2. If a “whirring” noise is heard but the engine does not
turn over, the starter is spinning but not engaging the
flywheel. The starter drive or solenoid that pushes
11
the drive forward to engage the flywheel may be
14 defective. Missing or damaged teeth on the flywheel
can also prevent the starter from cranking the
engine.
3. If the starter only “clicks” it may indicate that the
battery is discharged, or that there is a loose or
corroded battery cable connection. Check the
battery state of charge and battery condition first,
9 then check the cables and cable connections.
4. For additional information on the starting circuit, refer
to Section 9.7.36, “Engine Start Circuit and
13 Troubleshooting.”
15 MH5680
9.196 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
c. Starter Removal 3. For jump start protection, a protective plastic

cover (18) is installed around the starter solenoid
Remove the starter only if it fails. To remove the starter:
terminal and mounting screw. A removable, tethered
cap (19) allows access to the terminal mounting
screw.
20
16
MH4890
17
18
1. Unlock and open the rear engine door. 21
negative (-) battery cable at the negative (-) battery 19 MU1351
terminal (16).
If the vehicle has dual batteries, disconnect both 4. Use a small, flat knife blade (20), inserted next to the
negative battery cables from both negative (-) battery cap (19), so that the cap pops out of the protective
terminals (17). cover.
SN 8042, 13198 - 18990, 10042 13198 - 19030, 5. Label the blue/orange wire (21) from the starter
10054, 13198 - 19079 solenoid terminal. Use a small phillips screwdriver to
loosen the screw far enough to allow the blue wire to
3. Remove the red wires (3) from the solenoid stud (4). be removed from the terminal.
Remove the red, positive (+) battery cable (5) from
6. Loosen, but DO NOT remove, the two fasteners (14)
the starter. Label and disconnect the blue/orange
securing the starter (15) to the flywheel housing.
wire (6) from the starter solenoid housing stud.
Support the starter securely, as it is relatively heavy
Record how the wires are installed to ensure correct
and will fall if not supported.
installation later.
7. Remove the fasteners (14) securing the starter to
4. Loosen, but DO NOT remove, the three fasteners (7)
the engine.
securing the starter to the flywheel housing. Support
the starter securely, as it is relatively heavy and will 8. Remove the starter (15) from the vehicle.
fall if not supported.
d. Starter Cleaning and Drying
5. Support the starter and remove the fasteners
securing the starter to the engine. Remove the 1. While the starter is being removed, wipe away any
negative (-) ground cable from its starter mounting grease or dirt that has accumulated around the
bolt (7). starter mounting opening.
6. Remove the starter (1) from the vehicle. 2. If reinstalling the starter, clean the exterior of the
starter with an approved solvent. DO NOT submerse
SN 8042, 18991 - 19987, 10042 19031 - 19987, the starter or allow the solvent to contact the starter
10054, 19080 - 19987 And bushings.
8042/10042/10054, 0160002332 & After 3. Dry the starter with a clean, lint-free cloth.
1. At the positive starter stud (8), label and disconnect
the positive (+) battery cable (9) and starter positive e. Starter Periodic Maintenance
buss bar (10). Leave the wires (11) connected to the A starter requires no routine maintenance beyond the
starter positive buss bar. occasional inspection of the electrical connections, which
2. At the negative starter stud (12), label and must be clean and tight. The starter is not serviceable;
disconnect the negative (-) battery cable (13). replace a defective starter with a new unit.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.197

Electrical System
f. Starter Installation Applies To Serial Numbers: 8042, 18991 - 19987,

10042 19031 - 19987, 10054, 19080 - 19987 And
Applies To Serial Numbers: 8042, 13198 - 18990, 8042/10042/10054, 0160002332 & After
10042 13198 - 19030, 10054, 13198 - 19079
1. Position the starter (8) in its mounting opening on
1. Position the starter (1) in its mounting opening on the flywheel housing. Secure the starter with two
the flywheel housing. Position the ground cable (2) fasteners (9). Torque fasteners to 32 lb-ft (43 Nm).
over the correct starter mounting bolt (3). Secure the 2. At the negative starter stud (10), connect the
starter with the three fasteners (3). Torque fasteners negative (-) battery cable (11). Torque mounting
to 32 lb-ft (43 Nm). hardware to 3.7 lb-ft (5 Nm).
3. Connect the positive (+) battery cable (12) and
SN 8042, 13198 - 18990, 10042 13198 - 19030,
starter positive buss bar (13), with the wires (14) still
10054, 13198 - 19079
connected, at the positive starter stud (15). Torque
mounting hardware to 3.7 lb-ft (5 Nm).
6
7
1 SN 8042, 18991 - 19987, 10042 19031 - 19987,
10054, 19080 - 19987 And
3
8042/10042/10054, 0160002332 & After
5
4 8
15
9
13
10
2
MA8420
14
2. Connect the red, positive (+) battery cable (4) to the 9
upper solenoid stud (5). Install the two red wires (6)
to the upper solenoid stud, and secure with
lockwasher and nut. Torque nuts to 3.4 lb-ft
(4,6 Nm).
3. Connect the blue/orange wire (7) to the solenoid
mounting stud.
12
11
8 MH5680
9.198 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
4. Insert the fork terminal of the blue/orange wire (16) 9.10 CHARGING CIRCUIT
into the protective cover (17) on the starter solenoid
terminal. Use a small phillips screwdriver to tighten The purpose of the charging circuit is to maintain battery
the screw (18) securely. voltage between 13.8 and 14.2 volts. The key switch
5. Snap the tethered cap back in place over the screw must be in the RUN position with the engine running in
in the protective cover. order for the charging system to operate.
The charging circuit consists of the battery and a
belt-driven alternator with an internal voltage regulator.
These components work together to provide electrical
power for the vehicle, including the starting system,
18 operator’s instrument cluster, horn, solenoids, back-up
alarm and all accessories.
Current flows from the positive post of the battery to the
battery terminal on the starter motor solenoid.
16 When the ignition key switch is in the RUN position,
17 current flows from the instrument cluster to the alternator
D+ terminal, and is used to excite the field windings; The
alternator begins emitting a charge. Current flows from
the alternator B+ terminal to the starter motor B terminal,
MU6190 then through the positive (+) battery cable to the battery.
The circuit in the instrument panel connects to the battery
Applies To All Vehicles positive terminal through the fuse panel and detects field
6. If the vehicle has one battery, connect the voltages in excess of 16 volts or system voltages that are
negative (-) battery cable to the negative (-) battery less than 2-4 volts below battery voltage. Either of these
terminal (19). conditions will cause the warning light on the operator’s
instrument cluster to illuminate.
negative battery cables to both negative (-) battery The alternator charging warning indicator (21), a battery-
terminals (20). shaped icon on the instrument cluster panel, illuminates
for three seconds when the engine is started and will
remain illuminated if the engine is not running. The
alternator charging warning indicator illuminates when
the battery is at a low state of charge, and when the
alternator is no longer able to charge the battery.
21
19
MH4890
20
0000 00
MA7560
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.199

Electrical System
The negative (-) post of the battery is connected to the

starter ground, a stud located on the starter housing. 3
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.
The alternator includes an internal voltage regulator that
limits alternator voltage to a preset value and helps
prevent circuit overloads, power surges, etc. during peak- 2
voltage output.
1
Beyond inspecting the fan belt every 1,000 hours of MH4890
4
engine operation, there is no periodic maintenance
required for the charging circuit. When inspecting the fan
belt, also check the electrical wiring and connectors. Applies To Serial Numbers: 8042, 18991 - 19987,
10042 19031 - 19987, 10054, 19080 - 19987 And
Under normal conditions the alternator will have no 8042/10042/10054, 0160002332 & After
problem keeping the battery charged. The only condition
in which the battery may cause a problem is when it has
been completely discharged for an extended period of CAUTION: When doing welding
time. In this condition, the alternator may be unable to anywhere on the vehicle disconnect the wire
recharge the battery, and a battery charger will be harness (5 and 6) from the Engine Control
required for recharging. Module (ECM) (7) on the engine.
Before using a battery charger, an attempt can be made
to recharge the battery by jump-starting the vehicle.
(Refer to the appropriate Owners/Operators Manual.)
Allow the engine to run, which will enable the alternator to
charge the battery. 5
WARNING: DO NOT charge a frozen

battery. A frozen battery may explode and
cause serious personal injury. Allow the
battery to thaw before “jump-starting” the
vehicle or connecting a battery charger. 7
CAUTION: Before performing ANY

welding on vehicle: 6
MU5510
If the vehicle has one battery, disconnect the
negative (-) battery cable at the negative (-)
Applies To All Vehicles
battery terminal (1).
If the vehicle has dual batteries, disconnect If the engine alternator charging warning indicator
both negative battery cables from both negative illuminates, perform the following checks:
(-) battery terminals (4). 1. Check the all battery cable connections at the
Failure to disconnect the negative (-) battery battery (1, 2, 3 and 4), and verify that they are clean
cable will result in damage to vehicle electronic and tight.
systems. 2. Check the external alternator wiring and
connections, and verify that they are in good
condition.
3. Check the fan belt condition and tension. (Refer to
the appropriate Legacy Owners/Operators Manual.)
9.200 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
4. Verify that the alternator mounting hardware is tight.

5. Run the engine and check the alternator for noise. A SN 8042, 18991 - 19987, 10042 19031 - 19987,
loose drive pulley, loose mounting hardware, worn or 10054, 19080 - 19987 And
dirty internal alternator bearings, a defective stator 8042/10042/10054, 0160002332 & After
or defective diodes can cause noise. Replace a worn
or defective alternator.
6. For additional information on the charging circuit
refer to Section 9.7.38, “Charging Circuit and
Troubleshooting.”
9.10.1 Alternator
a. Alternator Removal
negative (-) battery cable at the negative (-) battery 9
terminal (1).
8
terminals (4).
3. Install a 1/2" square drive ratchet into the square MH4560
hole (8) in the tensioner bracket (9).

4. While lifting the automatic belt tensioner (9) away
Note: Record how the alternator are installed to ensure
from the belt, remove the fan drive belt (10).
correct installation later.
SN 8042, 13198 - 18990, 10042 13198 - 19030, Applies To Serial Numbers: 8042, 13198 - 18990,
10054, 13198 - 19079 10042 13198 - 19030, 10054, 13198 - 19079
10 5. Label and disconnect the alternator ground wire

9
8 (11), D+ (12) and B+ (13) wire leads.
5
11 13
RE
D
2W
BL
K
38 ORG
B+
D+
12
6 YEL
D-
MT1840
MA8400
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.201

Electrical System
Applies To Serial Numbers: 8042, 18991 - 19987,

10042 19031 - 19987, 10054, 19080 - 19987 And SN 8042, 13198 - 18990, 10042 13198 - 19030,
8042/10042/10054, 0160002332 & After 10054, 13198 - 19079
6. Label and disconnect the alternator wires:
• AG1 and AG2 from G terminal (1)
• AB1 and AB2 from B+ terminal (2) 7
• 38 and 6 from D+ terminal (3)
6
MA61902
SN 8042, 18991 - 19987, 10042 19031 - 19987,

MH5670
10054, 19080 - 19987 And
1 3 2 8042/10042/10054, 0160002332 & After
Applies To All Vehicles 7

7. Remove the lower mounting capscrew (4) securing 6
the alternator to the lower mounting hole (5) on the 4
engine.
8. While supporting the alternator with one hand,
remove the upper (longer) mounting hardware (6)
from the upper alternator mount (7). Remove the
alternator from the vehicle.
MH5670
9.202 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
b. Alternator Installation Applies To All Vehicles

1. Position the alternator and align with the upper 5. Place a 1/2" square drive ratchet into the square
alternator mount (7) on the engine bracket. Insert hole (11) on the tensioner bracket (12). Apply
the upper (longer) mounting hardware (6) through pressure against the tensioner bracket (12) and
the alternator mount. Thread the longer capscrew route the fan belt (13) onto the alternator and engine
into the alternator front mount. DO NOT tighten pulleys. Release and check the tensioner pulley to
completely at this time. verify that it is pivoting freely in order to provide the
2. Align the lower alternator mount hole (5) with the proper tension on the belt. Check for proper fan belt
lower mounting bracket on the engine, and insert the deflection. (Refer to the appropriate Legacy Owners/
lower mounting capscrew (4). Tighten the lower Operators Manual.)
capscrew (4) and upper capscrew (6) securely.
SN 8042, 13198 - 18990, 10042 13198 - 19030,
Applies To Serial Numbers: 8042, 13198 - 18990, 10054, 13198 - 19079
10042 13198 - 19030, 10054, 13198 - 19079
13
12
3. At the rear of the alternator, connect the alternator 11
ground wire (8), D+ (9) and B+ (10) wire leads.
5
8 10
RE
D
2W
BL
K
38 ORG
B+
D+
9
6 YEL
MT1840
D-
SN 8042, 18991 - 19987, 10042 19031 - 19987,

10054, 19080 - 19987 And
8042/10042/10054, 0160002332 & After
MA8400

10042 19031 - 19987, 10054, 19080 - 19987 And
8042/10042/10054, 0160002332 & After
4. At the rear of the alternator, connect the alternator
wires:
• AG1 and AG2 to G terminal (1)
• AB1 and AB2 to B+ terminal (2)
13
• 38 and 6 to D+ terminal (2) 12
11
MH4560
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.203

Electrical System
6. If the vehicle has one battery, connect the a. Battery Description

The battery supplies power to the starter and ignition
terminal (1).
system to crank the engine, and it provides extra power
If the vehicle has dual batteries, connect both when the electrical load requirements of the vehicle
negative battery cables to both negative (-) battery exceed the supply from the charging system in the event
terminals (4). of an alternator or charging-system failure. The battery
also acts as a voltage stabilizer in the electrical system,
3 smoothing out or reducing temporarily high voltage.
With the correct battery cables properly attached and with
the battery properly mounted, the battery does not
require periodic maintenance.
When starting the engine, allow the starter to crank for a
maximum of 15 seconds only, then wait a minimum of two
minutes to help avoid burning out the starter. Also, DO
2 NOT let the engine idle excessively, as low engine rpm
1 can also lead to battery discharge.
4 MH4890 Keep the battery from freezing by maintaining a full

charge. A completely discharged battery will freeze at
18° F (8° C).
9.10.2 Battery
Due to the maintenance-free design, water NEVER has
WARNING: All lead-acid batteries
to be added to the battery, so there are no filler caps.
Each battery is sealed, except for small vent holes in the
generate hydrogen gas, which is highly
cover. The vent holes allow gas and pressure produced
flammable. If ignited by a spark or flame, the
in the battery during charging to escape. The special
gas may explode violently, causing spraying of
chemical composition inside the battery reduces gassing
acid, fragmentation of the battery, and cause
to a very small amount at normal charging voltages. The
possible severe personal injuries. Wear safety
special chemistry also greatly reduces the possibility of
glasses when working near batteries. In case
overcharge damage.
of contact with acid, flush area immediately
with water. The vents require that the battery be kept in an upright
position, to help prevent electrolyte leakage. Tipping the
Note: For Serial Numbers 8042, 13198 - 18990, battery beyond a 45° angle in any direction can allow a
10042 13198 - 19030, 10054, 13198 - 19079, a single, small amount of electrolyte to leak out of the vent hole.
lead-acid type, 12-volt, negative (-) ground, DO NOT exceed this 45° angle when carrying or installing
maintenance-free battery rated at 1000 cold-cranking a battery.
amps is used in this vehicle. For Serial Numbers
8042, 18991 - 19987, 10042 19031 - 19987, The battery has top-post terminals. Keep the terminals
10054, 19080 - 19987 And clean, and securely tighten clean cable clamps onto the
8042/10042/10054, 0160002332 & After, two, lead-acid posts. Grease or special spray sealers may be applied
type, 12-volt, negative (-) ground, maintenance-free over the connections.
batteries rated at 850 cold-cranking amps each are used
in this vehicle. (Refer to the appropriate Owners/
Operators Manual for general information.)
9.204 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
b. Visual Inspection of the Battery 8. If voltage is at or above the value determined in

Step 6, the battery is good and may be returned to
Inspect for damage such as a cracked or broken case, or
service.
cover, that could permit loss of electrolyte. If obvious
physical damage is noticed, replace the battery. Handle 9. If voltage is below the value determined in Step 6,
the battery with care. Determine the cause of battery check the charge acceptance of the battery one
damage and correct as needed before installing the new more time before discarding it. If the voltage
battery. continues to read below the value determined in
Step 6, replace the battery.
c. Battery Load Test Note: The accuracy of this test procedure depends on
1. If the vehicle has one battery, disconnect the closely following the load, time and temperature
negative (-) battery cable at the negative (-) battery specifications.
terminal (1).
Relation of Battery Temperature
If the vehicle has dual batteries, disconnect both to Minimum Voltage
negative (-) battery cables from both negative (-)
Temperature Minimum Voltage
battery terminals (4).
70° F (21° C) and above 9.6
positive (+) battery cable at the positive (+) battery 50° F (10° C) 9.4
terminal (2). 30° F (-1° C) 9.1
If the vehicle has dual batteries, disconnect both 15° F (-10° C) 8.8
positive (+) battery cables from both positive (+) 0° F (-18° C) 8.5
battery terminals (3).
3. Make sure that the negative and positive battery d. Battery Charging
terminal posts are clean to help assure a good
Charge rates between three and 50 amperes are
electrical connection.
generally satisfactory as long as spewing of electrolyte
4. Attach voltmeter and battery load tester clamps to does not occur, or that the battery does not feel
the battery terminal posts. excessively hot (over 125° F [52° C]). Battery
5. Remove the surface charge from any battery that temperature can be estimated by touching or feeling the
has just been charged (by a battery charger or by battery case. If spewing of electrolyte occurs or
the vehicle alternator). DO NOT remove the surface temperature exceeds 125° F (52° C), commonly referred
charge from a battery that has been in storage. To to as “boiling” the battery, the charging rate must be
remove the surface charge, apply a 300-ampere reduced or temporarily halted to permit cooling. Failure to
load across the terminals for 15 seconds. Then turn do so will destroy the battery.
off the load and wait for 15 seconds to allow the When charging a battery, keep this point in mind:
battery to recover and normalize. • Battery charging consists of a charge current in
6. Battery temperature should be estimated by touch amperes for a period of time in hours. Thus, a
and also by the surrounding temperature it was 25-ampere charging rate for two hours would
exposed to during the preceding few hours before result in a 50-ampere, hour charge to the battery.
testing. Select the nearest estimated temperature
from the following chart, and determine the minimum
voltage that must be maintained while the battery
supplies a specified electrical load.
7. Apply a 260-ampere load test to check the charge
acceptance of the battery. Observe the voltage after
15 seconds with the load connected, and then
remove the load.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.205

Electrical System
The time required for a charge will vary due to the 5. Extended slow speed driving with many accessories
following conditions: on and excessive engine idling. (Both cases DO
• Size of battery: For example, a completely NOT allow engine rpm to reach a sufficient speed to
discharged, large, heavy-duty battery requires enable alternator output to sufficiently charge the
more than twice the recharging as a completely battery.)
discharged small passenger car battery. 6. Loose or poor battery cable-to-post connections,
• Temperature: For example, more time will be previous improper charging of a run-down battery or
required to charge a battery at 0° F than at 80° F. loose battery hold-down hardware.
When a fast charger is connected to a cold 7. High resistance connections or defects in the
battery, the current accepted by the battery will starting system.
be very low at first, then, in time, the battery will 8. Failure to disconnect the battery before long periods
accept a higher rate as the battery warms. of vehicle storage. Small current drains of vehicle
• State of Charge: A completely discharged accessories that are connected all of the time can
battery requires more than twice as much charge also discharge the battery in a six to eight-week
as a half-charged battery. Because the period. A battery left in a discharged condition for a
electrolyte is nearly pure water and therefore a prolonged period of time is subject to freezing and
poor conductor in a completely discharged can become difficult to recharge.
battery, the current accepted is very low at first.
Later, as the charging current causes the f. Jump-Starting with an Auxiliary (“Booster”)
electrolyte acid content to increase, the charging Battery
current will likewise increase.
Note: Use this information in addition to that found in the
• Charger Capacity: A charger that can only appropriate Legacy Owners/Operators Manual.
supply 5 amperes will require a much longer
period of charging than a charger that can supply Both the auxiliary or “booster” battery and the discharged
30 amperes or more. battery should be treated carefully when using jumper
cables. Follow the following procedure exactly, and DO
e. Battery Troubleshooting NOT cause sparks to occur:
1. Engage the park brake of the booster vehicle and
If a battery has tested satisfactorily but then fails to
place its transmission in (N) NEUTRAL. DO NOT
perform satisfactorily for no apparent reason, the
allow both vehicles to touch each other in any
following items are among the more common factors that
manner, as this could establish a ground connection
may help understand the cause:
and counteract the jump-starting process.
1. Vehicle accessories left on, causing battery
discharge. WARNING: Any other procedure other
2. Charging system defect such as slipping fan belt, than that outlined in these instructions could
high wiring resistance or a faulty alternator. result in:
3. A vehicle electrical load exceeds alternator output • Personal injury caused by electrolyte
capacity (common with the addition of electrical spewing out of the top vent holes on
accessories such as radio equipment, lights, air the battery.
conditioning or window defogging/de-misting • Personal injury or property damage
devices). due to battery explosion.
4. Electrical system defects, such as shorted wires. • Damage to the starting systems of both
vehicles.
2. Continue with the jump-starting instructions found in

the appropriate Legacy Owners/Operators Manual.
9.206 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
g. Battery Removal h. Battery Inspection, Cleaning and Drying

Note: The best time to clean the battery compartment is
when the battery is removed from the vehicle.
10042 13198 - 19030, 10054, 13198 - 19079
1. Periodically inspect the battery for accumulation of
1. Disconnect the negative (-) battery cable (1), from the
dirt or corrosion on the battery, terminals, cable ends
battery (2). Disconnect the positive (+) battery
and battery retaining hardware. Also, check that the
cable (3) from the battery.
battery case and cover are not cracked or leaking,
2. Remove the battery retaining (hold-down) strap and that the terminal posts are not broken or loose.
hardware (4 and 5) and the retaining strap (6).
2. Prepare a mixture of baking soda and water, and
3. Carefully slide the battery (2) out of the battery tray, obtain a non-metallic scrub brush. Dip the brush in
and remove the battery from the vehicle. the mixture, and scrub the battery and cable
terminals. Also, clean the battery mounting area on
the vehicle frame before replacing the battery.
3. Dry the battery with a clean, lint-free cloth.
i. Battery Installation

10042 13198 - 19030, 10054, 13198 - 19079
1. Carefully slide the battery (2) in the battery
compartment.
2. Install the battery retaining (hold-down) strap (6) and
3 the retaining strap hardware (4 and 5). Attach the
strap properly to help prevent the battery from
4 1 6
2 5 shifting, moving and vibrating. Vibration is harmful to
MA8410
a battery. DO NOT overtighten the fasteners.
Applies To Serial Numbers: 8042, 18991 - 19987, 3. Connect the positive (+) cable (3) to the positive
10042 19031 - 19987, 10054, 19080 - 19987 And battery terminal post.
8042/10042/10054, 0160002332 & After 4. Connect the negative (-) cable (1) to the negative
1. Disconnect the battery negative (-) ground cables (7) battery terminal post.
and positive (+) cables (8) from the batteries (12).
2. Remove the battery hold-down nuts (9), threaded 10042 19031 - 19987, 10054, 19080 - 19987 And
hold-down rods (10), and hold-down bracket (11). 8042/10042/10054, 0160002332 & After
Remove batteries (12) from the vehicle. Store
batteries in a cool dry area. 1. Install the batteries (12), hold-down bracket (11),
threaded hold-down rods (10) and hold-down
nuts (9).
negative (-) battery cables (7) to the batteries (12).
9
7 7
8 11 10 8 12
12 MH4210
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.207

Electrical System
9.11 ELECTRICAL SYSTEM b. Warning Indicator Lights

COMPONENTS (In Operator’s Instrument Cluster)
Electrical components include warning devices such as 8

7
the indicators in the operator’s instrument cluster, horn,
back-up alarm, and other components such as the
4 6
various solenoids and all accessories.
P
Examine the appropriate wiring diagrams and schematics
earlier in this section, to help understand the wiring
3
circuits involved.
9.11.1 Warning Devices

Vehicle warning devices include the horn, instrument
cluster warning lights and the back-up alarm. 0000 00
5
a. Horn
OH1810
The horn (1) is mounted on the vehicle frame.

There are five subdued or “hidden” warning indicator
lights present in the instrument cluster (3). These warning
indicators illuminate during critical circumstances.
IMPORTANT: All five warning indicator lights demand
immediate attention and vehicle service. In many cases,
the vehicle should be shut down as soon as practical to
help prevent serious mechanical failure. Appropriate
service procedures for each circuit, as applicable,
2 appear elsewhere in this section of the manual.
c. Engine Coolant Temperature Warning Indicator

1
This indicator (4) is illuminated when the engine
coolant temperature is above 210° F (99° C).
MA7960 An audible alarm will sound, and the engine
OH25202 must be shut down as soon as practical to help
The horn sounds when the momentary-contact horn avoid engine damage. For additional information refer to
button on the center of the steering wheel is pressed. Section 9.8.31, “Engine Coolant Temperature Warning
Removal of the horn button is discussed in Section 4.3.2, Indicator Troubleshooting.”
a. “Steering Wheel Removal” of this manual.
The horn sound is produced by a solenoid-actuated d. Transmission Temperature Warning Indicator
diaphragm in the horn that develops a resonating air This indicator (5) illuminates when the
column in the horn trumpet, which is shaped to project the transmission fluid temperature exceeds 250° F
sound. If the horn does not sound when the horn button (121° C). An audible alarm will sound, and the
is pressed, check that the fuse is not blown. OH25302
vehicle should be stopped and the engine
Check for corrosion on the horn mounting that may be allowed to run at high idle for five minutes.
preventing a solid ground, and check for a loose horn If the light and alarm DO NOT cease after five minutes,
wire. Test the horn switch for continuity when the horn the engine must be shut down to help avoid transmission
button is pressed. damage. For additional information refer to Section
If the problem is still not located, unplug the horn 9.8.32, “Transmission Temperature Warning Indicator
connector (2), remove the nut attaching the horn to frame Troubleshooting.”
(not shown) and test the horn using short, heavy-gauge
wires connected to a fused or otherwise protected 6-amp
minimum output, 12-volt DC power supply. If the horn
does not sound, replace the horn.
9.208 Model 8042, 10042, 10054 Legacy Rev. 10/03
Electrical System
e. Hydraulic Oil Temperature Warning Indicator

This warning light (6) will activate when the
hydraulic oil temperature is above 195° F (91°
C). The vehicle should be stopped and the 10
MA8290 engine allowed to idle at high idle for five
minutes. 9
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 9.8.33, “Hydraulic Oil Temperature Warning
Indicator Troubleshooting.”
f. Alternator Charging Warning Indicator

MH2940
This light (7) illuminates when the charging
system is not working properly. Check and
The back-up alarm is energized via current from the
service the alternator and battery as required.
OH25602
transmission shift control switch, part of the travel select
For additional information refer to Section
lever, mounted within the steering column. See the
9.7.38, “Charging Circuit and Troubleshooting.”
appropriate wiring schematic and diagram in this section
to help understand the back-up alarm circuit. Refer to
g. Engine Oil Pressure Warning Indicator
Section 4.3.2, c. “Transmission Travel and Gear Select
This indicator (8) illuminates and an audible Lever Removal,” for information on removing and
alarm sounds after 15 seconds if the engine is replacing the transmission shift control switch.
not started; this is normal. When the ignition key
OH25502
switch is turned to the OFF position, the a. Back-Up Alarm Removal
indicator is reset.
Should the light and alarm begin during engine operation, negative (-) battery cable at the negative (-) battery
the engine oil pressure is too low. The engine must be terminal (11).
shut down as soon as practical to help avoid engine
damage. For additional information refer to Section
9.8.35, “Engine Oil Pressure Warning Indicator
terminals (12).
Troubleshooting.”
9.11.2 Back-up Alarm

The back-up alarm (9) is located at the rear of the vehicle.
When the transmission shift control switch (travel select
lever) is shifted to the (R) REVERSE position, the back-
up alarm will automatically sound.
Place the travel select lever in (R) REVERSE to test the
back-up alarm. The back-up alarm must not sound when
the travel select lever is in (N) NEUTRAL or (F) 11
FORWARD. Also, with the ignition key switch in the RUN MH4890
12
position, the back-up alarm will sound when the travel
select lever is shifted into the (R) REVERSE position. 2. Label and disconnect the wiring from the back-up
alarm (10).
3. Remove the two 1/4-20 nuts and lockwashers
securing the back-up alarm to the vehicle frame.
Remove the alarm from the vehicle.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.209

Electrical System
b. Disassembly 9.11.3 Instrument Cluster

DO NOT disassemble the back-up alarm. Replace a The information under this heading deals mainly with the
defective or faulty alarm with a new part. description and function of each indicator in the
operator’s instrument cluster. Appropriate service
c. Inspection and Replacement procedures for each circuit, as applicable, appear
elsewhere in this section of the manual.
Inspect the wiring harness connector and alarm terminals
for continuity and shorting. Replace a defective or faulty The instrument cluster is of solid-state, printed circuit
alarm with a new part. design, and contains one wiring terminal and a display
panel that provides overall monitoring of vehicle functions
d. Installation and Testing and status.
1. Position the back-up alarm (1) onto the 1/4-20 studs
located on the inside frame wall at the rear of the
CAUTION: Before performing ANY
welding on vehicle, disconnect the negative (-)
vehicle. Secure with two lockwashers and 1/4-20 battery cable at the negative (-) battery terminal.
nuts. Failure to remove the negative (-) battery cable
will result in damage to vehicle electronic systems.
Prevent the instrument cluster from coming into contact

2 with static or other electrical sources. When washing the
1 vehicle, keep spray away from the operator’s display
panel. Replace a defective, malfunctioning or faulty panel
with a new unit.
The operator’s display panel provides important
information in a “user friendly” design with easily
recognizable graphic and alpha-numeric indicators. The
panel provides information the operator needs to know
about vehicle and engine functions.
MH29402
When testing circuits connected to the instrument cluster,
disconnect the harness connector and test the harness
2. Connect the wiring harness connector lead (2) to the
side only.
back-up alarm.
3. If the vehicle has one battery, connect the a. Power-Up Lights
terminal (3). When the ignition key switch is turned to power up the
vehicle, all lights in the instrument cluster (5 and 6) will
If the vehicle has dual batteries, connect both illuminate for three seconds as a test function.
terminals (4).
6
5
P
3
MH4890
4 0000 00
4. Test the alarm by turning the ignition key switch to

the RUN position and shifting the travel select lever OH1810
into the REVERSE position. The back-up alarm

should sound.
9.210 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
b. Normal Operating Lights High-Beam Indicator (Optional)

After the engine starts, the operator’s instrument The high-beam indicator (12) illuminates when
cluster (7) provides information via the following the optional headlight switch is placed in the
indicators: HIGH-BEAM position.
MA8260
Fuel Level Indicator Directional Light Indicator (Optional)

The fuel level indicator (8) represents the The directional light (turn signal) indicator (13)
quantity of fuel remaining in the fuel tank. For illuminates when the optional directional light
additional information, refer to Section 9.8.36, lever is moved either to the LEFT or RIGHT turn
OH24703 MA8270
“Fuel Level Indicator Troubleshooting.” position.
d. Operator’s Instrument Cluster Removal

11
P CAUTION: Static electricity can cause
damage to the operator’s instrument cluster.
7 Avoid any manner of touching (hands, tools,
12 etc.) the printed circuit boards and terminals.
Disconnect the negative (-) battery cable at its
battery terminal (3 or 4) before beginning this
8 procedure. Failure to comply can result in
13
0000 00 damage to the operator’s instrument cluster
10 and malfunction of the instruments and
9 indicator lights.
MH3970

Hourmeter Indicator
The hourmeter indicator (9) displays the total terminal (3).
number of running hours of the vehicle. The If the vehicle has dual batteries, disconnect both
hourmeter only functions when the engine is negative battery cables from both negative (-) battery
OS02602
running. terminals (4).
c. Function Indicator Lights 2. Remove the four fasteners (14) securing the right
side access panel (15).
There are three subdued or “hidden” function indicator
lights on the display panel that illuminate only when a
specific function is activated. They are: 16
Stabil-Trak™ Indicator
The Stabil-Trak™ indicator (10) illuminates with
the boom above 40° and the parking brake
engaged, travel select lever in (N) Neutral or the
OH2500
service brake pedal depressed and held.
Park Brake Indicator

14
The park brake indicator (11) illuminates anytime
P the park brake switch is applied, and the ignition
key switch is in the RUN position. 15
OH24802 OH2430
3. Unscrew the locking ring from below the instrument

cluster (16). Pull the instrument cluster up and away
from the cut-out, and unplug the harness connector.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.211

Electrical System
e. Operator’s Instrument Cluster Bulb Removal

15
negative (-) battery cable at the negative (-) battery 14
terminal (1).
12 16
terminals (2). 11 17
10
1
MH4890
2 7
2. Unscrew the plastic ring retainer from the back of the 9

8 MA7940
instrument cluster. Disconnect the harness plug
connector from the back of the instrument
cluster (3). Remove three screws, (4) securing the f. Operator’s Instrument Cluster Installation
instrument cluster rear access plate (5). Remove the 1. Install the instrument cluster rear access plate (5)
cover plate. using three screws (4).
3 2. Connect the harness plug terminal into the
5 instrument cluster terminal (3).
3. Place the instrument cluster (18) into the cut-out,
and install the plastic retaining ring and secure.
4 18
MA7930
3. Rotate the suspect bulb assembly (6) 1/4- turn

counterclockwise and remove bulb.
Item Description
20
7 Transmission Temperature
8 Stabil-TRAK™
9 Turn Signal (Optional) 19 OH2430
10 Main Beam (Optional)
11 Fuel Level 4. Install the right side access panel (19) using four
12 Hydraulic Oil Temperature screws (20).
13 Engine Oil 5. If the vehicle has one battery, connect the
14 Alternator negative (-) battery cable to the negative (-) battery
terminal (1).
15 Park Brake
16 Engine Coolant Temperature If the vehicle has dual batteries, connect both
17 Fuel Level
terminals (2).
9.212 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
Operator’s Display Panel Test a. Removal

Check the following, as the key switch is placed in the 1. If the vehicle has one battery, disconnect the
RUN position (21): negative (-) battery cable at the negative (-) battery
terminal (1).
21 If the vehicle has dual batteries, disconnect both
terminals (2).
2. Carefully pry the windshield wiper switch (22) and
wire connector out of the mounting hole.
3. Disconnect the windshield wiper switch with bezel
from the cab wiring harness connector.
b. Disassembly
MA10,0010 DO NOT disassemble the switch. The switch is not
serviceable. Replace the switch if found to be defective.
1. All lights must illuminate for a minimum of 3 seconds.
Note: If the park brake switch is engaged, the park
brake instrument cluster light will also stay illuminated. Without submerging the switch, clean the switch with an
approved solvent and dry with a clean, lint-free cloth.
2. Alternator warning and engine oil pressure light must
stay illuminated after three seconds. d. Inspection and Replacement
9.12 WINDOW WIPER/WASHER (OPTION) 1. Inspect the switch terminals for continuity with the
switch in the OFF, LOW speed and HIGH speed
positions. (Refer to Section 9.7.44, “Front
9.12.1 Windshield Wiper Switch Windshield Wiper Circuit and Troubleshooting
(Option).”)
2. Replace the switch if it fails any of the tests in Step 1.
e. Installation and Testing

1. Connect the windshield wiper switch to the cab
harness connector.
2. Position the switch over the rectangular switch bezel,
22 OH18502
and snap into position.
Figure 9-2 Windshield Wiper Switch Location
terminal (1).
The windshield wiper switch (22) is supplied on If the vehicle has dual batteries, connect both
enclosed cab models only. The front windshield negative battery cables to both negative (-) battery
wiper is located on the dash panel to the right of terminals (2).
OS19302
the steering column and is pressed or
“snapped” into a rectangular switch bezel. It is a three- 4. Turn the ignition key switch to the RUN position and
position switch providing OFF (upper position), center for test the windshield wiper LOW speed and HIGH
LOW speed and lower position for HIGH speed speed functions.
operation.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.213

Electrical System
9.12.2 Windshield Wiper Motor 7. Disconnect the washer hose (19) from hose
connector (20).
a. Removal 8. Remove the wiper arms (8), knurled driver (9) and
Note: It may be necessary to remove several hydraulic rubber cap (10) from the motor shaft (7).
hoses from under the dash in order to remove and install 9. Remove the metal hex jam nut (11) and metal
the wiper motor housing. (Refer to Section 4.3.3, washer (12) from the motor shaft.
“Steering Column/Valve Replacement.”)
10. Remove the motor mounting bolts (13), panto adapter
1. If the vehicle has one battery, disconnect the (14) and gasket (15) from the motor shaft.
Note: Retain all hardware removed from the wiper
terminal (1).
assembly for possible reuse on the replacement motor
If the vehicle has dual batteries, disconnect both housing.
terminals (2). 11. Remove the motor (3) from the inside of the cab.
b. Disassembly
DO NOT disassemble the motor. The motor is not
serviceable. Replace motor if found to be defective.

Without submerging the motor, clean the motor with an
1 approved solvent and dry with a clean, lint-free cloth.
MH4890
2
d. Inspection and Replacement
2. Remove the right side instrument panel.
Inspect the motor terminals for continuity. Replace motor
3. Remove the lower access panel below the
if continuity is not found. (Refer to Section 9.7.44, “Front
instrument panel.
Windshield Wiper Circuit and Troubleshooting (Option).”)
4. Disconnect the right side defroster hose from dash
panel hose connector. e. Installation and Testing
5. Disconnect the cab harness connectors from the Note: An assistant will be required for the installation of
wiper motor (3). the windshield motor.
3 18
1 16
8 17
14 7
5
15
12 13 MA8440
10 11
6
1. Install all required hardware to the motor assembly.
4 9 MA8430
Align spacer (16) and wiper motor bracket, (17) and
6. From the outside and front of the cab, remove the apply masking tape (18) in order to hold the two
windshield wiper blade arm nuts (4 and 5) and components together during installation.
washer (6) from the motor shaft (7). 2. Align motor (3) with cab mounting holes and insert
motor through cab.
9.214 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
3. Have an assistant insert gasket (15), panto adapter 9.12.3 Skylight Wiper Switch
(14) onto to the motor shaft (7). Insert bolts (13)
through front cab holes and thread into motor
housing. Tighten bolts.
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.
Note: Align the wiper blade arm with the flat on the
motor shaft to ensure wiper stroke covers window area,
and it does not swipe past the glass area. 24 OH18502
Figure 9-3 Skylight Wiper Switch Location

The skylight wiper switch (24) is supplied on
21 enclosed cab models only. The skylight wiper
switch is located on the dash to the right of the
OH19002
steering column and is pressed or “snapped”
into a rectangular switch bezel. It is a three-position
22 switch providing OFF (upper), center (not used) and
19 lower (one speed) positions.
20
a. Removal
90°
terminal (1).
23
MA8450 negative battery cables from both negative (-) battery
terminals (2).
5. Install wiper blade arm (21) at 90° (22) from the
motor shaft flat (23). 2. Carefully pry the skylight wiper switch (24), bezel
and wiring out of the mounting hole.
6. Install internal-tooth lockwasher (6), 1/4" (5) and
3/8" (4) acorn nuts, and tighten. 3. Disconnect the skylight wiper switch from the cab
harness connector.
7. Connect the cab harness connectors to windshield
wiper motor connectors. b. Disassembly
DO NOT disassemble the switch. The switch is not
serviceable. Replace switch if found to be defective.
terminal (1).
If the vehicle has dual batteries, connect both c. Cleaning and Drying
terminals (2). Without submerging the switch, clean the switch with an
9. Turn ignition key switch to the RUN position, and
operate windshield wiper in both LOW and HIGH d. Inspection and Replacement
speeds to ensure proper operation and that correct
wiper travel is achieved. 1. Inspect the switch terminals for continuity with the
switch in the OFF and ON positions. (Refer to
10. Install right side defroster hose to the dash panel
Section 9.7.45, “Skylight Wiper Circuit and
hose connector.
Troubleshooting (Option).”)
11. If previously removed, install hydraulic hoses under
the dash. (Refer to Section 4.3.3, “Steering Column/
Valve Replacement.”)
12. Install the top right dash panel and lower dash panel.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.215

Electrical System
e. Installation and Testing a. Removal

1. Connect the skylight wiper switch to the cab harness 1. If the vehicle has one battery, disconnect the
connector. negative (-) battery cable at the negative (-) battery
2. Position the switch over the rectangular switch bezel terminal (1).
and snap into position. If the vehicle has dual batteries, disconnect both
3. If the vehicle has one battery, connect the negative battery cables from both negative (-) battery
negative (-) battery cable to the negative (-) battery terminals (2).
terminal (1). 2. Remove the wiper arm (3) from the wiper motor
If the vehicle has dual batteries, connect both shaft (4).
negative battery cables to both negative (-) battery 3. Disconnect the washer hose from the top hose
terminals (2). fitting (5).
4. From inside the cab, remove screws (6) from top
locknut plate (9).
5. Unclip the plastic motor cover (7) and remove.
6. From the top of the cab, remove the hex nut (8) from
the wiper motor shaft (4).
7. From inside the cab, pull the wiper motor down and
1 away from the roof.
MH4890
2 8. Label and disconnect the cab harness connectors
from the wiper motor.
4. Turn the ignition key switch to the RUN position and
test the skylight wiper functions. b. Disassembly
9.12.4 Skylight Wiper Motor DO NOT disassemble the motor. The motor is not
serviceable. Replace motor if found to be defective.

Without submerging the motor, clean the motor with an

Refer to Section 9.7.45, “Skylight Wiper Circuit and
3
Troubleshooting (Option).”
8 e. Installation and Testing

9 5
1. Hold wiper motor up toward cab top and install the
7 cab harness connectors.
4 2. With the help of an assistant, insert the wiper motor
through the roof hole and have the assistant thread
the hex nut (8) onto the wiper motor shaft (4). Insure
that the motor housing is facing the front of the cab.
6
MA8360
9.216 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
3. Install the wiper arm (3) onto the wiper motor a. Removal
shaft (4).
4. Install the screws (6) through the plastic motor negative (-) battery cable at the negative (-) battery
cover (7) and into the top locknut plate (9), and terminal (1).
tighten.
5. Connect washer hose to top hose fitting (5). negative battery cables from both negative (-) battery
6. If the vehicle has one battery, connect the terminals (2).
negative (-) battery cable to the negative (-) battery 2. Carefully pry the windshield washer switch (10),
terminal (1). bezel and wiring out of the mounting hole.
If the vehicle has dual batteries, connect both 3. Disconnect the switch from the cab harness
negative battery cables to both negative (-) battery connector.
terminals (2).
7. Turn ignition key switch to the RUN position and turn b. Disassembly
skylight wiper switch to the ON position. Ensure DO NOT disassemble the switch. The switch is not
wiper stays on the window through a full stroke. Turn serviceable. Replace switch if found to be defective.
the skylight wiper switch to the OFF position.
8. Engage the washer switch and ensure washer fluid c. Cleaning and Drying
is sprayed on the skylight window. Turn the ignition
Without submerging the switch, clean the switch with an
key switch to the OFF position.
9.12.5 Windshield/Skylight Washer Switch d. Inspection and Replacement
1. Inspect the switch terminals for continuity with the
switch in the OFF and ON positions. For additional
information, refer to Section 9.7.46, “Front
Windshield & Skylight Washer Circuit and

OH18502
10 1. Connect the windshield washer switch to the cab
harness connector.
The windshield washer switch (10) is supplied
on enclosed cab models only. The switch is 2. Position the switch over the rectangular switch bezel
located on the dash to the right of the steering and snap into position.
OS19402
column and is pressed or “snapped” into a 3. If the vehicle has one battery, connect the
rectangular switch bezel. It is a spring-loaded negative (-) battery cable to the negative (-) battery
momentary, two-position switch providing OFF (upper) terminal (1).
and ON (lower). The switch will return to the OFF position
when released. When pressed, washer fluid is sprayed
on both the front windshield and roof glass.
terminals (2).
4. Check the washer reservoir for fluid; fill if needed.
test the windshield washer functions. Verify that fluid
is being pumped to both the front and top
windshields.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.217

Electrical System
9.12.6 Windshield/Skylight Washer Reservoir 3. Pull the washer reservoir (6) out and away from the
and Pump mounting studs.
The windshield washer motor and reservoir is a unit and 4. Rotate the washer reservoir, label and remove the
cannot be serviced separately. cab harness connectors (7) from the washer
reservoir connectors (8).
a. Removal 5. Remove the windshield washer hose (9) from the
1. If the vehicle has one battery, disconnect the reservoir.
terminal (1). b. Disassembly
If the vehicle has dual batteries, disconnect both DO NOT disassemble the pump. The pump is not
negative battery cables from both negative (-) battery serviceable. Replace pump if found to be defective.
terminals (2).
Without submerging the pump, clean the pump and
reservoir with an approved solvent and dry with a clean,
lint-free cloth.

Inspect the electrical terminals for continuity. For
1 additional information, refer to Section 9.7.46, “Front
MH4890
2 Windshield & Skylight Washer Circuit and
2. Remove the nuts (3) and the lockwashers (4) from
the washer mounting studs (5).
1. Connect the windshield washer hose (9) to the
reservoir.
5
6 2. Connect the cab wiring harness connectors (7) to
the reservoir connectors (8).
4
3. Install the reservoir tank (6) onto the welded
studs (5).
4. Install the lockwashers (4) and nuts (3) and secure.
5. Fill the washer fluid reservoir with washer fluid.
9 7
3 terminal (1).
8
MA8350 negative battery cables to both negative (-) battery
terminals (2).
press the washer switch. Verify that fluid is sprayed
on both the windshield and roof glass.
9.218 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
9.13 CAB HEATER AND FAN (OPTION) 7. Remove the hex locknut from the suspect control
shaft.
9.13.1 Cab Heater Controls 8. Remove the control from the panel.
Note: If the suspect component is found to be within the b. Disassembly

heater box, the heater box must be removed as a
complete unit and replaced. For additional information DO NOT disassemble the cab heater and fan controls.
on the removal and installation of the heater box, refer to The controls are not serviceable. Replace controls if
Section 4.4.4, a. “Heater Assembly Removal.” found to be defective.

18
15 12 10 14 Without submerging the variable speed fan control, clean
11
the control with an approved solvent and dry with a clean,
lint-free cloth.

For additional information refer to Section 9.7.47, “Heater
13 Circuit and Troubleshooting (Option).”
16 17 MA8700

The cab heater controls are located directly below the
1. Check that the variable speed fan control (11) is in
switch banks on the right side dash panel. The control
the OFF position.
panel (10) consists of a variable speed fan control
knob (11) and a temperature control knob (12). 2. If installing the temperature control (12), attach the
control cable (not shown) to the back of the control.
a. Cab Heater Controls Removal 3. Insert the control shaft through the panel, ensuring
Note: After determining which control knob is not that the knob is in the VERTICAL position.
functioning, remove only the suspect control knob. In 4. Install the hex locknut on the shaft and tighten.
order to remove either knob, the cab heater and fan 5. Connect the cab harness connector to the variable
control panel must be removed from the dash panel. speed fan control.
1. If the vehicle has one battery, disconnect the 6. Install the screws and backing locknuts (14, 15, 16
negative (-) battery cable at the negative (-) battery and 17), securing the control panel to the dash
terminal (1). panel.
If the vehicle has dual batteries, disconnect both 7. Install the setscrew (13), securing the knob to the
negative battery cables from both negative (-) battery control.
terminals (2).
8. Install the right side control panel screws (18).
2. Remove the setscrew (13) from the variable speed
fan control knob (11) or temperature control
knob (12).
terminal (1).
3. Remove the right side control panel (18) screws.
4. Remove the screws and backing locknuts (14, 15, 16 negative battery cables to both negative (-) battery
and 17) from the cab heater and fan control terminals (2).
panel (10).
5. Pull the control panel out from the dash panel, and if
removing variable speed fan control, remove the cab
harness connector.
6. If removing the temperature control knob, disconnect
the cable connector and remove control knob.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.219

Electrical System
9.14 SWITCHES AND SOLENOIDS Apply powdered graphite to the key, and insert and
withdraw the key from the switch several times to
Note: For information on the front windshield wiper, distribute the graphite into the switch-lock mechanism.
skylight wiper and windshield washer systems, refer to During freezing temperatures, if the ignition key switch
Section 9.12, “Window Wiper/Washer (Option).” fails to turn, or does not allow the key to be inserted,
warm the switch with a heat gun (blow-dryer), or use
9.14.1 Ignition Key Switch liquid lock deicer to help evaporate frozen moisture from
The ignition key switch (1) is located on the lower right within the switch.
side of the front dash. It is a key-operated switch used to IMPORTANT: Only use graphite or a liquid lock deicer
start the engine and to run the vehicle. within the switch. Replace a defective switch.
2 3 a. Ignition Switch Removal
4 1. If the vehicle has one battery, disconnect the

terminal (5).
1 If the vehicle has dual batteries, disconnect both
terminals (6).
MA10,0010
When the key is inserted into the ignition key switch, the
switch can be turned clockwise from the OFF position (2)
to the RUN (3) and START (4) positions. The START
position is spring-loaded to return the switch to the RUN 5
MH4890
position. This position must be manually held in place for 6
normal starting and for ether (cold start option) to be
2. Remove lower access panel (7).
injected into the cylinders.
3. Remove the hex nut securing the ignition key
In the OFF position (2), the entire electrical system is shut
switch (8) to the dash.
down, with power at the ignition switch terminals and the
starter solenoid only.
In the RUN position (3), all controls and indicators are
operable.
When the park brake switch is ON and the transmission
is in (N) NEUTRAL, turning the ignition switch to the
START position (4) engages the starter to start the
engine and injects fuel into the cylinders.
If the key binds in the switch, check the key for defects
and the switch for foreign objects. Clean or remove foreign
material from the key as required. Check that the key is 8
not bent or excessively worn; replace a bent or worn key
with a new key.
OH1760
9.220 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
4. Reach up and under the dash to work the ignition d. Ignition Switch Installation
switch and wiring out of the mounting hole.
1. Connect the ignition key switch to the cab harness
5. Disconnect the ignition switch connectors from the connectors.
cab harness connectors, and remove the switch
2. Reach up and under the dash to work the ignition
from the vehicle.
switch into the ignition switch-mounting hole on the
lower right side of the dash (8).
b. Disassembly
3. Align the ignition switch so that when it is in the OFF
DO NOT disassemble the ignition switch. Replace a position (2), the key slot is positioned vertically (straight
defective switch with a new part. up and down). Install the hex nut securing the
ignition switch to the dash. DO NOT overtighten.
c. Inspection and Replacement
4. Install the lower access panel (7).
To determine the proper operation of the ignition key
switch, using the following charts, test the wires on the
back of the switch for continuity with an ohmmeter.
terminal (5).
Test the ignition key switch for continuity, by checking
from the ignition (BLUE) wire to each of the following
wires in each switch position. Continuity (X) should be
terminals (6).
present as indicated in the following chart:
Switch Position
Test from BLUE wire to: OFF RUN START
WHT Wire (10 Gauge) X
Pin B on 3-Pin Connector
Test the ignition key switch for continuity, by checking

from the ignition (RED) wire to each of the following wires
in each switch position. Continuity (X) should be present
as indicated in the following chart:
Switch Position
Test from RED wire to: OFF RUN START
PUR Wire (10 Gauge) X X
Pin B on 5 Pin Connector
RED/BLK Wire (16 Gauge) X X
Pin C on 5 Pin Connector
If all wires do not show proper continuity, replace the

ignition switch.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.221

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
9.14.2 Fuel Shut-off Solenoid

(SN 8042, 13198 - 18990, 10042, 13198
- 19030, 10054, 13198 - 19079)
The fuel shut-off solenoid (5), located on the rear of the
fuel injection pump, is a solenoid that lets fuel enter the
injection pump when the ignition key switch is turned to
the START or RUN positions. The fuel shut-off solenoid
2 is connected to mechanical linkage (6).
MH4840
7
Test the transmission neutral start circuit as follows:
6
• The starter MUST NOT operate with the travel
select lever in (F) FORWARD or (R) REVERSE.
• The starter MUST NOT operate when the park
brake is OFF (disengaged).
• The starter MUST operate with the travel select 5
lever in (N) NEUTRAL.
If the starter fails to turn the engine with the travel select
lever (3) in (N) NEUTRAL (4) and the ignition key switch MS16902
is in the START position, refer to Section 9.7.36, “Engine

Start Circuit and Troubleshooting.” The NEUTRAL a. Fuel Shut-off Solenoid Removal
position contacts in the travel select lever (3) are 1. If the vehicle has one battery, disconnect the
non-repairable. Replace the travel select lever if negative (-) battery cable at the negative (-) battery
defective. terminal (8).
terminals (9).
9.222 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
2. Disconnect the wiring connector at the fuel shut-off 6. Start the engine. If the engine starts, the fuel shut-off
solenoid lead (7), then remove the fuel shut-off solenoid is functioning. If the engine fails to start, the
solenoid (5) from the fuel injector pump. fuel shut-off run solenoid may have a poor ground
3. Remove the two bolts securing the solenoid to the connection. Visually check the wiring at the fuel
mounting plate. Remove the nut holding the linkage shut-off solenoid leads and/or check for continuity
to the arm on the fuel injection pump. Save the with a voltmeter as required.
hardware for later reuse. 7. Check for fuel and/or oil leakage around the solenoid.
9.14.3 Hydraulic Oil Temperature Switch
The hydraulic oil temperature switch (10) is threaded into
a fitting (11) at the lower inside wall of the hydraulic oil
tank.
8
MH4890
9
b. Fuel Shut-off Solenoid Disassembly

DO NOT disassemble a fuel shut-off solenoid. Replace a
defective fuel shut-off solenoid with a new part.
c. Fuel Shut-off Solenoid Inspection and

Replacement
Use a 12-volt DC source and ground to test the solenoid.
Energize the solenoid, and watch for the plunger to
retract. If the plunger does not retract, replace the fuel
shut-off solenoid with a new part.
d. Fuel Shut-off Solenoid Installation

1. Clean the exterior of the fuel injector pump.
2. Using the hardware removed earlier, install the nut 12
holding the linkage to the arm on the fuel injection pump.
Install the two bolts to secure the solenoid to the
mounting plate.
3. Connect the wiring connector at the fuel shut-off 11
solenoid lead (7). 10 MA7670
negative (-) battery cable to the negative (-) battery The hydraulic tank oil temperature switch connector (12)
terminal (8). attaches to the wiring harness and operator’s instrument
If the vehicle has dual batteries, connect both cluster. When the hydraulic oil temperature is above
negative battery cables to both negative (-) battery 195° F (91° C), the hydraulic oil temperature warning
terminals (9). indicator on the operator’s instrument cluster illuminates.
The vehicle should be stopped and the engine allowed to
5. Clear personnel and any obstructions from the area run at high idle for five minutes.
around the vehicle.
If the warning indicator continues to illuminate after five
minutes, the engine must be shut down to help avoid
damage to the hydraulic system.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.223

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 9.8.33, “Hydraulic Oil Temperature
Warning Indicator Troubleshooting.”)
1 OH2340
a. Hydraulic Tank Oil Temperature Switch Removal 6

5
1. If the vehicle has one battery, disconnect the MA7670
terminal (2).
3. Label and disconnect the temperature switch wiring
If the vehicle has dual batteries, disconnect both connector (4) from the harness connector.
4. Unthread the switch (5) from the hydraulic reservoir
terminals (3).
welded fitting (6).
b. Hydraulic Oil Temperature Switch Disassembly

DO NOT disassemble the hydraulic oil temperature
switch. Replace a defective or faulty switch with a new
switch.
2
MH4890
3
2. Drain oil from the hydraulic tank reservoir into a

clean container for reuse.
9.224 Model 8042, 10042, 10054 Legacy Rev. 10/03

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
OH18502
a defective or faulty switch with a new switch.

8 10
1. Thread the switch (5) into its fitting (6) on the P
hydraulic reservoir. Tighten securely.
2. Fill hydraulic oil reservoir with hydraulic oil.
P 11
3. Connect the switch wiring connector lead (4) to the 9
OS1323 OS0121
harness connector.
4. If the vehicle has one battery, connect the The park brake solenoids on the secondary function
negative (-) battery cable to the negative (-) battery valve (12) are normally de-energized, allowing the park
terminal (2). brake to engage. When the park brake solenoids are
If the vehicle has dual batteries, connect both energized, the park brake is disengaged. The system is
negative battery cables to both negative (-) battery designed so that, when electrical power is OFF, the park
terminals (3). brake is engaged. (Refer to Section 10.7, “Stabil-TRAK™
Electrical Circuit Operation and Troubleshooting (8042/
5. Clear the area around the vehicle of personnel and
10042),” or Section 10.9, “Stabil-TRAK™ Boom Interlock
any obstructions to vehicle travel.
Electrical Circuit Operation and Troubleshooting
6. Start the engine, check for hydraulic fluid leaking at (10054, 13198-17984),” or Section 10.10, “Stabil-
the hydraulic oil temperature switch and allow the TRAK™ Boom Interlock Electrical Circuit Operation and
hydraulic fluid to reach operating temperature. Cycle Troubleshooting (10054, 17985-19987 and 0160002332
the boom several times and check whether the & After).”)
hydraulic oil temperature warning indicator
illuminates on the operator’s display panel.
9.14.4 Park Brake Switch 12

The park brake switch (7) is located on the dash to the left
of the steering column and is pressed or “snapped” into a
rectangular switch bezel. The park brake switch must be
ENGAGED to permit engine starting.
Note: The park brake may be used to stop in an
EMERGENCY situation; however, notify the operator to
use caution as the stop will be abrupt and the operator
and the load may be jolted forward unexpectedly.
The park brake switch is a two-position toggle switch; the
two positions are ENGAGED (8) and DISENGAGED (9).
The switch is marked with an engaged (10) and Front
disengaged (11) symbol. When engaged, the park brake
switch completes the park brake circuit.
MA8300
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.225

Electrical System
a. Park Brake Switch Removal

terminal (1).
terminals (2).
1 3
MH4890
2
4
2. Carefully pry the park brake switch (3) and wiring out
of the mounting hole. P
3. Label and disconnect the wiring from the park brake MA76802
switch. Remove the switch from the vehicle.
2. Properly position the “P” on the switch (4) to the
b. Park Brake Switch Disassembly bottom, then press or “snap” the switch into place in
the bezel.
DO NOT disassemble the park brake switch. Replace a
defective or faulty switch with a new switch. 3. If the vehicle has one battery, connect the
c. Park Brake Switch Inspection and Replacement terminal (1).
Inspect the switch terminals for continuity and shorting in If the vehicle has dual batteries, connect both
both the ENGAGED and DISENGAGED positions. negative battery cables to both negative (-) battery
Replace a defective or faulty switch with a new switch. terminals (2).
d. Park Brake Switch Installation and Testing any obstructions to vehicle travel.
1. Route the wiring from the dash through the bezel, 5. Start the engine, engage the park brake switch,
then connect the wiring to the park brake switch (3) place the travel select lever in (F) FORWARD or (R)
as labeled during switch removal. REVERSE and in second gear and apply full throttle.
The vehicle should remain motionless in both (F)
FORWARD and (R) REVERSE positions.
6. To test for proper park brake switch disengagement,
firmly depress the service brake pedal, disengage
the park brake switch, place the travel select lever in
either (F) FORWARD or (R) REVERSE and in first
gear, and slowly press the throttle pedal while
releasing the service brake pedal. The park brake
should release, and the vehicle should travel freely.
Note: The park brake indicator on the operator’s instrument
cluster must illuminate when the park brake switch is
engaged, and not illuminate when the park brake switch
is disengaged.
9.226 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
9.14.5 Outrigger Switches (10042/10054 Only) 2. Remove the four fasteners (9) securing the right side
Inspect the switch terminals for continuity and shorting in access panel (10), and remove the panel.
both the non-depressed and depressed positions.
Replace a defective or faulty switch with a new switch.
a. Left and Right Outrigger Switches

The left and right outrigger switches (5 and 6) control the
RAISE and LOWER movements of both outriggers. The
rocker switches are spring-loaded to return to the center
(STOP) position when released.
10
OH2430
3. Carefully pry the outrigger switch (5 or 6) and wiring

out of the mounting hole.
4. Label and disconnect the wiring from the outrigger
6 switch. Remove the switch from the vehicle.
5
c. Outrigger Switch Disassembly
OH1700 DO NOT disassemble the outrigger switch. Replace a
defective or faulty switch with a new switch.
Both outriggers are wired in series and have pressure
d. Outrigger Switch Inspection
switches (10054 only) that detect a pressure difference
when one of the outriggers contacts the ground. Both Inspect the switch terminals for continuity and shorting in
outriggers must make contact with the earth (10054 only) both the RAISE and LOWER positions. Replace a
before the boom will be allowed to fully extend. defective or faulty switch with a new switch.
e. Outrigger Switch Installation and Testing
b. Outrigger Switch Removal
1. Route the wiring connectors through the bezel, then
Note: The LEFT and RIGHT outrigger switches function connect the wiring to the outrigger switch (5 or 6) as
the same but have the LEFT (7) or RIGHT (8) icon on labeled during switch removal.
each switch. If removing both switches, ensure that you
install each switch in the proper bezel location. 2. Properly position the symbol (7 and 8) on the switch
to the bottom, then press or “snap” the switch into
place in the bezel.
3. Install the right side access panel (10), four fasteners
(9) and tighten.
7 8 4. If the vehicle has one battery, connect the
terminal (1).
MH3920 MH3930
1. If the vehicle has one battery, disconnect the negative battery cables to both negative (-) battery
negative (-) battery cable at the negative (-) battery terminals (2).
terminal (1). 5. Clear the area around the vehicle of personnel and
If the vehicle has dual batteries, disconnect both any obstructions to vehicle travel.
negative battery cables from both negative (-) battery 6. Start the vehicle, and lower or raise effected
terminals (2). outrigger through full travel.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.227

Electrical System
9.14.6 Transmission Shift Control Switch b. Gear Select Lever

The gear select lever (5) is part of the transmission shift
a. Travel Select Lever
control switch (travel select lever). The lever has a twist-
The transmission shift control switch (travel select grip handle with four positions.
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.
2
3 5
4
MA7710
The vehicle has four forward gears and three reverse

gears.
1 First gear is used for the highest torque and pulling
OH17902
power, and the higher-numbered gears are for increasing
vehicle travel speed.
Moving the lever (1) opens and closes electrical contacts
in the switch, allowing electricity to flow to the appropriate Refer to Section 4.3.2, c. “Transmission Travel and Gear
relays and onto the transmission shift solenoids. Select Lever Removal,” and Section 4.3.2, d.
“Transmission Travel and Gear Select Lever Installation,”
Travel selections are changed by grasping the lever, for removal and installation instructions.
pulling it toward the steering wheel, then up or down to
the desired selection, (F) FORWARD (2) or
(R) REVERSE (4).
When the switch is shifted to the (R) REVERSE (4)
position, the back-up alarm will automatically sound.
(Refer to circuit diagrams in Section 9.8, “Transmission
Gear Selection Troubleshooting,” and also, Section
9.14.7, a. “Travel Select Lever and Wiring Harness
Testing.”)
Refer to Section 4.3.2, c. “Transmission Travel and Gear
Select Lever Removal,” and Section 4.3.2, d.
“Transmission Travel and Gear Select Lever Installation,”
for removal and installation instructions.
9.228 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
9.14.7 Transmission Solenoid Valves The remaining three solenoid valves (Y4, Y5 and Y6) are
contained in the LOWER spool-type solenoid cartridge
The transmission is shifted via six solenoids. Three
assembly (valve body) (7). While each 12-volt solenoid
solenoid valves (Y1, Y2 and Y3) are contained in an
coil at the transmission is the same, the internal wiring to
UPPER spool-type solenoid cartridge assembly (valve
the solenoids is different and connected so that the
body) (6).
various transmission clutches can be actuated via input
from the transmission shift control switch (travel select
6 lever).
By placing the transmission shift control switch (travel
select lever) in any given position, a combination of
solenoids are activated, which, in turn, engage a
combination of internal clutches. (Refer to Section 9.14.7,
a. “Travel Select Lever and Wiring Harness Testing,” and
Section 9.14.7, b. “Upper and Lower Transmission Valve
Body Solenoid Testing.”)
If the transmission is not shifting properly, the
transmission shift control switch (travel select lever),
wiring harness or transmission shift solenoids should be
checked in order to determine which component is
defective. Specific information to determine which travel
position and corresponding component is not responding
can be found by referring to the circuit diagrams in
Section 9.8, “Transmission Gear Selection
Troubleshooting,”. Replace a defective component.
MA7720
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.229

Electrical System
a. Travel Select Lever and Wiring Harness Testing 3. Check the harness side pin connections with a DMM
for battery voltage corresponding to the direction
Note: An assistant will be required to operate the travel
and gear that has been selected. Refer to the chart
select lever, in order to perform the following test.
that follows. Place the negative (-) lead on pin 7
1. Remove the plug from the UPPER (1 and 3) and (ground) (4 or 6) and the positive (+) lead on the pin
LOWER (2 and 5) transmission solenoid valve to be tested; test for battery voltage.
bodies. Turn the ignition key switch to the RUN If battery voltage is not present on any of the pins
position. that have been tested, the wiring harness is suspect
and should be replaced.
1
If battery voltage is present, the harness is
functioning properly.
Y4
5
Y6
Y5
6
2
MT1120
Note: The following chart shows which solenoids are

MA7720 active with any given selection of the transmission shift
control switch (travel select lever) and gear select position.
Note: In order to perform the solenoid test, the park
brake switch must be in the OFF position. Upper Valve Lower Valve
Body Body
2. Have an assistant place the travel select lever in the
position that is not functioning correctly. Driving
Speed Y1 Y2 Y3 Y4 Y5 Y6
Direction
Forward 1 • • • •
Y1
Y2 Forward 2 • • • •
3 Forward 3 • • • •
Y3
Forward 4 • • •
Reverse 1 • • • •
4
MT1110
9.230 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
b. Upper and Lower Transmission Valve Body

Solenoid Testing 14 13
Inspect the solenoid connector plugs (7 and 12).
16
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 15
valve. (Refer to Section 9.14.7, c. “Transmission Upper
Valve Body Solenoid Removal.”
12
Solenoid Pin Active Callout
Position Solenoid
MT1100
1 Y1 8
2 Y2 9 c. Transmission Upper Valve Body Solenoid
3 Y3 10 Removal
7 Ground 11 Note: Before removing the valve body protective cover,
4 Y4 13 clean the area around the housing to prevent
5 Y5 14 contamination.
6 Y6 15 1. If the vehicle has one battery, disconnect the
7 Ground 16 negative (-) battery cable at the negative (-) battery
terminal (17).
Note: All six solenoids within both upper and lower If the vehicle has dual batteries, disconnect both
solenoid valve body housings are of the same design. negative battery cables from both negative (-) battery
terminals (18).
9
8
10
17
7 MH4890
18
11
MT1090
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.231

Electrical System
2. Remove the six capscrews (1) four hex-head 2. Install the solenoid capscrew (9) and torque to
capscrews (2), ten lockwashers (3 and 4) and 53 lb-in (6 Nm).
protective cover plate (5) secured over the 3. Install the protective cover gasket (7) on the valve
transmission solenoid cartridge valve (6). Inspect the body. Position the protective cover plate (5) over the
protective cover gasket (7); replace if torn or gasket. Install six lockwashers (3) and
missing. capscrews (1), and tighten until the valve body
spring (14) (upper valve body only) is compressed
8 and the cover plate sits flush over the gasket.
4. Install the four lockwashers (4) and four
1
capscrews (2). Torque to 84 lb-in (9,5 Nm).
3 5
2 negative (-) battery cable to the negative (-) battery
terminal (15).
4 If the vehicle has dual batteries, connect both
terminals (16).
7
6 9
10
14
12 15
MH4890
11 16
13
6. Test the operation of the transmission. Put the
transmission through its entire range of gears
(speeds) in both (F) FORWARD and (R) REVERSE,
and check that the transmission also shifts into
MT2300
(N) NEUTRAL.
3. Disconnect the internal wire connector (8) from the 7. Verify that each function works properly and that the
solenoid valve that is being removed. Label the transmission does not engage when in (N) NEUTRAL.
internal wire connections if removing more than one For further information, refer to the Transmission Service
solenoid valve. Manual, Model ZF 4 WG-98 TC P/N 8990455 (ZF P/N
4. Remove the solenoid capscrew (9), retaining 5871 135 002).
plate (10) and flat washer (11) securing the solenoid
valve (6) to the transmission. e. Transmission Lower Valve Body Solenoid Removal
5. Remove the solenoid valve (6) and replace. Note: In order to service the lower valve body housing,
the upper valve body housing MUST be removed to allow
d. Transmission Upper Valve Body Solenoid access to the lower housing protective cover. The area
Installation around the upper and lower valve body housing must be
thoroughly cleaned to avoid contamination of internal
Note: When installing the solenoid valve into the valve
transmission components.
body, position the solenoid valve wires so that they do
not interfere with the protective cover plate. 1. If the vehicle has one battery, disconnect the
1. Install the flat washer (11) and solenoid valve (6) terminal (15).
along with the retaining plate (10). Connect the
internal wire connector to solenoid. Insure that the If the vehicle has dual batteries, disconnect both
claw side (12) of the retaining plate is facing down negative battery cables from both negative (-) battery
toward the valve body surface (13). terminals (16).
9.232 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
2. Thoroughly clean the area around the upper and f. Transmission Lower Valve Body Solenoid
lower valve body housing. Installation
3. Remove screws securing the upper valve housing to Note: When installing the solenoid valve into the valve
the transmission. body, position the solenoid valve wires so they do not
4. Remove upper valve body housing from transmission, interfere with the protective cover plate.
and set aside in a clean area, free of dirt, grease and oil. 1. Install the solenoid valve (24) and retaining plate
5. Remove the upper valve housing flat gasket. (23). Connect the internal wire connector (21) to the
6. Remove the nine lower valve body protective cover solenoid. Insure that the claw side of the retaining
screws (17), lockwashers (18) protective cover (19) plate (23) is facing down toward the valve body
and gasket (20) surface.
2. Install the solenoid capscrew (22) and torque to
53 lb-in (6 Nm).
17
3. Install the protective cover gasket (20 onto the valve
18 body. Position the protective cover (19) over the
gasket. Install lockwashers (18) and capscrews (17),
19 and tighten until the cover plate is compressed and it
sits flush over the gasket. Torque to 84 lb-in
(9,5 Nm).
20
4. Install the upper transmission valve body gasket and
22 upper valve body assembly to transmission.
5. Install the lockwashers and capscrews, and torque
screws to 84 lb-in (9,5 Nm).
24
terminal (15).
terminals (16).
7. Test the operation of the transmission. Put the
transmission through its entire range of gears (speeds)
in both (F) FORWARD and (R) REVERSE, and
check that the transmission also shifts into
(N) NEUTRAL.
21 8. Verify that each function works properly and that the
transmission does not engage when in (N) NEUTRAL.
For further information, refer to the Transmission Service
Manual, Model ZF 4 WG-98 TC, P/N 8990455 (ZF P/N
5871 135 002).
MT2480
7. Disconnect the internal wire connector (21) from the

solenoid valve that is being removed. Label the
internal wire connections if removing more than one
solenoid valve.
8. Remove the solenoid capscrew (22) and retaining
plate (23), securing the solenoid valve (24) to the
transmission.
9. Remove the solenoid valve (24) and replace.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.233

Electrical System
9.14.8 Steering Steer select solenoids are energized or de-energized

accordingly to provide the type of steering selected. The
Certain steering functions are dependent upon electrical
switch allows four-wheel steer (2) (the rear wheels turn
operations as described below. Consult the Owners/
opposite the front wheels), two-wheel steer (3) (the front
Operators Manual for further information related to steering.
wheels only) or crab steer (4) (the rear wheels turn in the
same direction as the front wheels).
a. Steer Select Switch
The steer select switch (1) is located on the right side of b. Steer Modes and Conditions
the operator’s control panel. It is a three-position switch
that is pressed or “snapped” into a rectangular switch Four-Wheel Steer Mode
bezel.
With the steer select switch (1) in the lower
position (2), the following conditions must be
1 met:
OH2611
1. Front wheels (5) must steer in the direction that the

steering wheel is turned.
5 6
4
3 OH1660
2 2. Rear wheels (6) must steer in the opposite direction

from which the steering wheel is turned. Refer to
Section 9.7.40, “Four-Wheel Steer Circuit and
Troubleshooting.”
OH19412
The three-position switch (1) is a single-pole, double

throw toggle switch that has three positions. It has a
multiple-connector plug on its underside that connects to
the cab wiring harness. Wiring from the plug connects the
switch with power from the fuse panel bus bar, and to the
operator’s instrument cluster and the steer select
solenoids on the vehicle.
9.234 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
Front-Wheel Steer Mode c. Four-Wheel Steer Indexing

With the steer select switch (1) in the center If the vehicle does not drive “straight,” the steering may
position (3), the following condition must be not be synchronized or is “out of phase.” Perform the four-
met: wheel steer indexing procedure to synchronize the steering.
OH2601
1. With the steer select switch (1) in the four- wheel
steer position (2), turn the steering wheel fully left.
1. The front wheels (7) must steer in the direction that
the steering wheel is turned. 2. While holding the steering wheel fully left, toggle the
steer select switch to the front-wheel steer
position (3).
8
7 3. Steer the front wheels back to center.
4. Toggle the steer select switch back to four-wheel
steer position (2).
5. Turn the steering wheel fully left.
6. Toggle the steer select switch back to the front-wheel
steer position (3).
7. Steer the front wheels fully left.
OH1670
8. Toggle the switch to the four-wheel steer position (2)
and return to center.
2. Rear wheels (8) must remain in a fixed FORWARD
position and not move. (Refer to Section 9.7.39, The vehicle should now be properly indexed in four-wheel
“Front Steer Circuit and Troubleshooting.”) steer. If the steering is still not synchronized, repeat the
procedure. (Refer to Section 9.7.39, “Front Steer Circuit
Crab-Steer Mode and Troubleshooting” and subsequent circuits and
troubleshooting charts.)
With the steer select switch (1) in the upper
most position (4), the following conditions must
be met:
OH2591
1. Front wheels (9) must steer in the direction that the

steering wheel is turned.
9
10
OH1680
2. Rear wheels (10) must steer in the direction that the

steering wheel is turned. (Refer to Section 9.7.41,
“Crab Steer Circuit and Troubleshooting.”)
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.235

Electrical System
9.14.9 Steer Select Switches b. Steer Select Switch Disassembly, Inspection and
Replacement
For additional information, refer to Section 9.7.39, “Front
Steer Circuit and Troubleshooting.” DO NOT disassemble the switch. Replace a defective or
faulty switch with a new part.
a. Steer Select Switch Removal
Inspect the switch and the wiring harness connector terminals
1. If the vehicle has one battery, disconnect the for continuity and shorting in all three switch positions.
negative (-) battery cable at the negative (-) battery Inspect the switch terminals for continuity in the “UP” and
terminal (1). “DOWN” positions and for shorting in the “MIDDLE” position.
If the vehicle has dual batteries, disconnect both Replace a defective or faulty switch with a new part.
c. Steer Select Switch Installation and Testing
terminals (2).
1. Route the wiring through the dash and switch bezel,
then connect the wiring to the switch (3) (the pin
connector only goes on one way).
2. Properly position the “front” and top of the switch as
noted during removal, then press or “snap” the
switch into place in the bezel.
MH4890
2 terminal (1).
2. Carefully pry the switch (3) and wiring out of the If the vehicle has dual batteries, connect both
mounting hole in the switch bezel. negative battery cables to both negative (-) battery
terminals (2).
5
5. Start the engine and check the operation of the steer
3 select switch functions with the switch in all three
positions. If the vehicle has the rear steer option,
also test the rear steer mode for proper operation.
MH6100
3. Note and mark the "front" or top of the switch as

positioned in the dash.
4. Disconnect the wiring harness connector (4) from
the steering select switch (3) by pressing down on
the tab (5) on the harness connector. Remove the
switch from the vehicle
9.236 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
9.14.10 Steer Select Valve When the solenoid is de-energized, the control spool (10)
is returned to its normal (centered) condition by the
The steer select valve (6), is secured to the steer select
centering springs (11).
manifold and frame with four capscrews and o-rings (7)
on the inside wall of the vehicle frame.
7
6
9 11 8 9 11
10
12 12
MA8370
MA8320
The steer select valve contains two solenoids that direct

hydraulic fluid through hoses and ultimately help operate
the steering. The valve is a direct dual-solenoid operated,
spool-type directional control valve. The steer select
valve controls the start, stop and direction of hydraulic 6
fluid flow to the steering cylinders mounted on each axle.
The valve consists of a housing (8), two solenoids (9), a
control spool (10) and two return springs (11).
14 13
MA8310
In the de-energized state, the spool (10) is held by the
return springs (11) in the center position. The spool is
shifted through the action of the two wet-pin type Check the steer select valve solenoids (13 and 14) for
solenoids (9). proper operation, and check the wiring for continuity or
shorts. When energized/de-energized, the solenoid
The force of an acting solenoid works against the push
should move and/or an audible “click” should be heard;
pin (12) on the end of the spool (10). The spool is shifted
check for the presence of voltage with a voltmeter.
from its normal position to the end position for the
selected flow. The selected flow pattern is covered in Replace a defective or faulty steer select valve with a new
Section 8, “Hydraulic System.” unit. (Refer to Section 9.7.39, “Front Steer Circuit and
Troubleshooting.”)
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.237

Electrical System
9.14.11 Engine Low Oil Pressure Sender a. Engine Oil Pressure Sender Removal
The engine oil pressure sender (1) is located on the 1. If the vehicle has one battery, disconnect the
engine and is connected via the engine wiring harness, negative (-) battery cable at the negative (-) battery
bulkhead connector and cab wiring harness to the front terminal (4).
dash panel. If the vehicle has dual batteries, disconnect both
terminals (5).
2 4
MH4890
5
2. Unplug the engine low oil pressure sender

MU4500 connector (2) from the wiring harness connector.
3. The sender (1) is threaded into the engine block.
The engine oil pressure indicator is located in the Remove the sender.
operator’s instrument cluster (3) and illuminates when
engine oil pressure is too low to properly lubricate the b. Engine Oil Pressure Sender Disassembly
engine. The warning indicator illuminates when oil
pressure is below 8.7 psi (0,6 bar). DO NOT disassemble the sender. Replace a defective or
faulty sender.
When the engine has attained normal oil pressure, the
sender opens and the indicator on the operator’s instrument c. Engine Oil Pressure Sender Inspection and
cluster turns OFF. (Refer to Section 9.8.35, “Engine Oil Replacement
Pressure Warning Indicator Troubleshooting.”)
Inspect the sender and the wiring harness connector
terminals for continuity. Replace a defective or faulty
3
sender with a new part.
P
d. Engine Oil Pressure Sender Installation and
Testing
1. Thread the sender (1) into the engine block snugly.
2. Connect the wiring harness connector lead to the
engine low oil pressure sender connector (2).
0000 00
terminal (4).
MA7610
terminals (5).
4. Check for proper oil level.
6. Start the engine, allow it to reach operating
temperature, and observe the operator’s instrument
cluster for warning indication.
9.238 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
9.14.12 Engine Coolant High Temperature When the engine coolant temperature is below 210° F
Sender (99° C), the contacts within the sending unit open and the
instrument cluster indicator turns OFF. (Refer to Section
The engine coolant high temperature sender (6) is
9.8.31, “Engine Coolant Temperature Warning Indicator
threaded into the engine block (7) and is connected to the
Troubleshooting.”)
operator’s instrument cluster via the engine wiring
harness, bulkhead connector and cab wiring harness.
9
(SN 8042-13198 through 18990, 8 7 P
10042-13198 through 19030, 6
10054-13198 through 19079)
0000 00
MA7570
a. Engine Coolant High Temperature Sender Removal

terminal (4).
MA9010 terminals (5).
2. Unplug the engine coolant high temperature sender
connector (8) from the wiring harness connector.
(SN 8042, 18991 - 19987, 8 7
10042 19031 - 19987, 6 3. The sender (6) is threaded into the engine block (7).
10054, 19080 - 19987 And Remove the sender.
8042/10042/10054,
0160002332 & After b. Engine Coolant High Temperature Sender
Disassembly
DO NOT disassemble the sender. Replace a defective or
faulty sender.
c. Engine Coolant High Temperature Sender

Inspection and Replacement
sender with a new part.
d. Engine Coolant High Temperature Sender

MH5240 Installation and Testing
1. Thread the engine coolant high temperature
When the engine coolant temperature exceeds normal sender (6) into the engine block (7) snugly, then
operating limits and rises above 210° F (99° C), the connect the sender connector (8) to the wiring harness
contacts close within the sending unit. The operator’s connector.
instrument cluster indicator (9) illuminates.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.239

Electrical System

negative (-) battery cable to the negative (-) battery (SN 8042-13198 through 18990,
terminal (1). 10042-13198 through 19030,
10054-13198 through 19079)
terminals (2).
3. Check for proper coolant level. 3
1
MH4890 MA9010
2
5. Start the engine, allow it to reach operating (SN 8042, 18991 - 19987,
temperature and observe the operator’s instrument 10042 19031 - 19987,
cluster for warning indication. If the sender is not 10054, 19080 - 19987 And
defective, the problem could be elsewhere; possibly 8042/10042/10054,
in a shorted wire, improper-running engine, improper 0160002332 & After
or low coolant, obstructed or faulty radiator, coolant
pump, loose fan belt, defective instrument cluster,
etc.
3
9.14.13 Transmission Temperature Sender
The transmission temperature sender (3) is threaded into
the transmission housing (4) and is connected to the 4
operator’s instrument cluster via the engine wiring
When the transmission fluid temperature rises above
250° F (121° C), the contacts close within the sending
unit. The operator’s instrument cluster indicator (5)
MH5240
illuminates.
When the transmission temperature is below 250° F
(121° C), the contacts within the sending unit open and
the operator’s instrument cluster indicator turns off.
(Refer to Section 9.8.32, “Transmission Temperature P
Warning Indicator Troubleshooting.”)
5
0000 00
MA7580
9.240 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
a. Transmission Temperature Sender Removal 9.14.14 Engine Block Heater

1. If the vehicle has one battery, disconnect the The engine is equipped with an engine block heater (6)
negative (-) battery cable at the negative (-) battery that can be plugged into a standard 110/120V A.C.
terminal (1). grounded outlet, to heat the engine coolant.
If the vehicle has dual batteries, disconnect both When temperatures are below 10° F (-12° C), the block
negative battery cables from both negative (-) battery heater should be used to aid in starting.
terminals (2).
2. Unplug the sender connector (3) from the cab (SN 8042, 18991 - 19987, 10042 19031 - 19987,
harness connector. 10054, 19080 - 19987 And
8042/10042/10054, 0160002332 & After
3. The sender (3) is threaded into the transmission
housing or case (4). Remove the sender.
b. Transmission Temperature Sender Disassembly

DO NOT disassemble the sender. Replace a defective or Front
faulty sender with a new part.
c. Transmission Temperature Sender Inspection

and Replacement
sender.
d. Transmission Temperature Sender Installation

6
and Testing (SN 8042-13198 through 18990,
1. Thread the sender (3) into the transmission housing 10042-13198 through 19030,
(4) snugly. 10054-13198 through 19079)
2. Connect the sender connector (3) to the wiring
harness connector.
terminal (1).
Front
terminals (2).
MH6070
5. Start the engine, allow all systems to reach
operating temperature and observe the operator’s
instrument cluster for transmission temperature
sender indication.
6. If the sender is not defective, the problem could be
elsewhere; possibly in a shorted wire, clogged or
defective transmission cooler, defective display, etc.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.241

Electrical System

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, 5. Place a suitable container beneath the radiator drain
“Accident Prevention Tags.”) plug or petcock (3) on the bottom, right side of the
radiator. Slowly turn the radiator cap (not shown) to
the first stop and allow any pressure to escape.
Remove the radiator cap.
engine, muffler and tailpipes to cool down
in severe burns.

terminal (1). 3
terminals (2). OH2640

radiator drain plug or petcock (3) and allow the
coolant to drain into the funnel. Close the radiator
drain plug or petcock.
7. Transfer the coolant into a properly labeled container.
Dispose of properly if coolant needs to be replaced.
1
MH4890
2 8. Remove plastic retainer (4) from around engine
block heater element (5) and 110-volt cord (6).
4. Unlatch, unlock and open the engine right and left 9. Using a 29 mm socket, remove heating element from
engine access doors. Allow the engine to cool before engine block.
proceeding. Draining the cooling system while the
engine is hot can cause cracks in the engine block.
9.242 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
d. Engine Block Heater Testing

(SN 8042, 18991 - 19987, 10042 19031 - 19987,
10054, 19080 - 19987 And Note: The following test should be performed with a
8042/10042/10054, 0160002332 & After) 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
Front functioning properly, you will feel the heat at that location.
If the block is cold, the heater element is defective and
should be replaced.
e. Engine Block Heater Installation

1. Apply Teflon tape to coolant heater element
threads (9) and install element. DO NOT
over-tighten.
2. Plug-in 110-volt cord (6) into heater element and
5 install plastic retainer (4) around coolant heater
(SN 8042-13198 through 18990, 8 9 element and 110-volt cord.
10042-13198 through 19030, 3. Fill radiator with coolant. Refer to the appropriate
10054-13198 through 19079) Legacy Owners/Operators Manual.
7 terminal (1).
4
6
terminals (2).
Front
Note: When the coolant heater is not in use, secure the
110-volt cord with a wire tie to prevent damage to cord.
MH6060
b. Engine Block Heater Disassembly

DO NOT disassemble the heater element. Replace a
defective or faulty heater with a new part.
c. Engine Block Heater Inspection and

Replacement
Inspect the block heater element and the 110-volt cord for
cuts or exposed wires. Replace a defective or faulty block
heater.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.243

Electrical System
9.14.15 Fuel Level Indicator and Fuel Level The operator’s instrument cluster fuel level indicator (1)
Sender shows the level of fuel remaining in the fuel tank. The fuel
level sender wiring harness connector can be accessed
The fuel level indicator (1) can be found on the operator’s
from the top of the fuel tank.
instrument cluster.
The fuel level sender (2) consists of a resistance, float-
type 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. The fuel level indicator gauge in the
operator’s instrument cluster receives a signal from the
fuel level float sender corresponding to the remaining
1 amount of fuel in the tank. Examine the fuel level sender
0000 00 circuit in Section 9.8.36, “Fuel Level Indicator
Troubleshooting.”
MA7620
a. Fuel Level Indicator Testing
The fuel level indicator (1) works in conjunction with the 1. Remove fuel tank cover.
fuel level sender (2). The submerged, coil-type fuel level
2. The fuel level sender wiring harness leads (5) can
sender is secured to the fuel tank (3) and is connected to
be accessed from the top of the fuel tank.
the operator’s instrument cluster via the engine wiring
Disconnect the fuel level sender wiring harness
leads. With the help of an assistant, touch both
harness leads together.
3. From the operator’s cab, have the assistant turn the
4 ignition key switch to the RUN (6) position. DO NOT
start the engine. Observe the fuel level indicator
2 needle on the operator’s instrument cluster. The
5 reading must be at the FULL mark after the engine
startup bulb test is completed.
7 6
MA10,0010
MA7750
4. Turn the ignition key switch to the OFF (7) position.
The fuel level indicator needle should return to the
EMPTY position.
9.244 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
b. Fuel Level Circuit Tests 4. Check for broken, shorted, frayed, disconnected or
damaged wiring between the fuel level indicator
For additional information refer to Section 9.8.36, “Fuel
wiring at the operator’s instrument cluster, fuse and
Level Indicator Troubleshooting.”
relay panel, ignition key switch, and from the fuel
If the fuel level indicator is suspected of giving a false level sender on the fuel tank through the wiring in the
reading, perform the following checks: cab.
1. Check for loose or defective wiring, faulty ground 5. Check the fuel level sender. The resistance of the
connections, and corrosion on the fuel tank sender fuel level sender is 31 ohms for a full tank of fuel,
and wiring lead. 101 ohms for 1/2 tank and 255 ohms for an empty
2. If the fuel level indicator needle does not move after tank. A defective fuel level sender in the fuel tank
the ignition key switch is turned to the RUN (6) may also prevent the fuel level indicator from
position, use a test lamp to determine whether moving.
current is flowing from the ignition switch to the fuel Excessive fuel level indicator “fluctuation” may be caused
level indicator wiring connector behind the operator’s by loose wire connections or a defective fuel level sender
instrument cluster. (The instrument cluster locking in the fuel tank.
ring can be unfastened and raised slightly to do this.)
A full tank reading at all times may occur if the wiring to
the fuel level sender in the tank is broken, if the sender is
If the fuel level indicator needle (1) does not move, not properly grounded or if the sender is defective.
check the fuel tank for fuel. If the fuel level indicator appears to be inaccurate, the fuel
level sender in the tank may be defective, or there may be
If the fuel level indicator does not move and a faulty
low voltage at the fuel level indicator connector to the
or defective fuel level sender in the fuel tank has
operator’s instrument cluster.
been ruled out, and in addition, wiring and
connectors have been checked and ruled out, the If the fuel level indicator fluctuates when other electrical
operator’s instrument cluster is defective and must items are used, there may be a defective, corroded or
be replaced. improper ground. Check the cab harness ground stud
under the dash, the engine to chassis ground, and the
3. Check that the ignition terminal has current and that
negative (-) battery cable and ground stud cable.
the fuse in the fuse panel is not blown.
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.245

Electrical System
9.14.16 Hourmeter a. Boom Angle Sensor Removal

The hourmeter (1) is a non-repairable instrument that 1. If the vehicle has one battery, disconnect the
records hours of vehicle engine operation in tenth of an negative (-) battery cable at the negative (-) battery
hour increments and is located in the instrument cluster. terminal (4).
The hourmeter is an analog device, similar to an If the vehicle has dual batteries, disconnect both
odometer, and will display 99,999.9 hours before negative battery cables from both negative (-) battery
resetting to zero. terminals (5).
If trouble is suspected, time the hourmeter for six minutes
to verify that a tenth of an hour has been recorded.
The hourmeter is built into the instrument cluster and
cannot be repaired. If the hourmeter is suspect, replace
the instrument cluster.
4
MH4890
P 5
2. Disconnect the boom angle sensor electrical

connector (3) from the engine harness connector.
3. Loosen and remove the sensor inside locknut (6)
4. Remove sensor from the outside of boom frame
0000 00
1
MA7640
9.14.17 Boom Angle Sensor Removal and

Replacement 7
The boom angle sensor (2) is located at the rear of, and
on the right side of the vehicle. When the boom is lifted
above 40°, the boom sensor sends a signal to the
Stabil-TRAK indicator on the instrument cluster.
MH2920
3
2
MH2930
9.246 Model 8042, 10042, 10054 Legacy Rev. 10/03

Electrical System
b. Boom Angle Sensor Installation b. Boom Extend Interlock Sensor Installation

1. Install boom angle sensor (2) through outside of 1. Partially install inside locknut (12) onto the sensor.
boom frame. 2. Make sure that there are four to six threads,
2. Install inside locknut (6) onto sensor. approximately .75" and 1.00" (14), between the
3. Measure the clearance between the sensor and outside locknut (15) and the end of the sensor (8).
frame, and adjust sensor distance (7) to .120" 3. Make sure that the wire harness (16) is between the
(3,05 mm) and tighten locknut (6). bracket (13) and the sensor (8), and slide the sensor
4. If the vehicle has one battery, connect the into the bracket (13).
negative (-) battery cable to the negative (-) battery 4. Connect the boom extend interlock sensor
terminal (4). connector (10) to the boom extend harness
If the vehicle has dual batteries, connect both connector (11).
negative battery cables to both negative (-) battery 5. Replace wire ties as necessary.
terminals (5). 6. If the vehicle has one battery, connect the
9.14.18 Boom Extend Interlock Sensor terminal (4).
Removal/Replacement (10054 Only)
The boom extend interlock sensor (8) is located on the negative battery cables to both negative (-) battery
left side of the vehicle, on the outer boom frame (9) and terminals (5).
just behind the cab. The boom extend interlock sensor
prohibits the last boom section from extending unless 16
both outriggers are down and pressure is applied to the
12 13
ground surface.
15
a. Boom Extend Interlock Sensor Removal 8
terminal (4). 9
14
terminals (5).
2. Make note of wire tie locations and clip wire ties
where necessary.
3. Disconnect boom extend interlock sensor (8) 9
electrical connector (10) from the boom extend 15
harness connector (11).
4. Loosen the inside locknut (12) on the sensor.
16
5. Slide the sensor out of the bracket (13) and remove
from vehicle.
11
12 10
8
13 MH6120
Model 8042, 10042, 10054 Legacy Rev. 10/03 9.247

Electrical System
9.14.19 Service Brake Switch 4. Use a wrench and fully tighten the locknut (9)
against the service brake switch bracket (11). There
The service brake switch works in conjunction with the
should now be approximately two or three threads
Stabil-TRAK™ system. With the boom above 40°, the
showing above the locknut.
transmission shifter in either forward or reverse, and the
service brake depressed, the Stabil-TRAK™ system 5. Thread the bottom lip (13) of the switch plunger
engages. If the Service Brake Switch is suspect in the through the hole in the bottom of the dust cover (12).
proper operation of the Stabil-TRAK™ system, refer to 6. Connect the cab harness electrical connectors (3) to
Section 10.8, “Stabil-TRAK™ System Test.” the service brake switch (4 or 7) connectors.
a. Service Brake Switch Removal
1. If the vehicle has one battery, disconnect the terminal (1).
negative (-) battery cable at the negative (-) battery If the vehicle has dual batteries, connect both
terminal (1). negative battery cables to both negative (-) battery
If the vehicle has dual batteries, disconnect both terminals (2).
negative battery cables from both negative (-) battery 8. Adjust the brake switch. (Refer to Section 9.14.19, c.
terminals (2). “Service Brake Switch Adjustment.”)
4
3
1 5

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Models: 8042, 10042, 10054

S/N 13198 thru 19987 and 0160002332 thru 0160029592

 2003 JLG Industries, Inc.

ii Model 8042, 10042, 10054 Legacy Rev. 10/03

Model 8042, 10042, 10054 Legacy Rev. 10/03 iii

iv Model 8042, 10042, 10054 Legacy Rev. 10/03

PARAGRAPH TITLE PAGE

Model 8042, 10042, 10054 Legacy Rev. 10/03 1.1

1.1 INTRODUCTION Many factors contribute to unsafe conditions: carelessness,

In the event that the owners/operators manual is missing,

1.2 Model 8042, 10042, 10054 Legacy Rev. 10/03

1.3 TRAINING MECHANICS AS 1.4 SAFETY INFORMATION

This symbol means “Attention! Become Alert! Your

Model 8042, 10042, 10054 Legacy Rev. 10/03 1.3

1.4.2 Hazard Statements 1.5 ACCIDENT PREVENTION TAGS

WARNING: Before beginning any maintenance or service, place an

The signal word “CAUTION,” used without the safety DAN

1.4 Model 8042, 10042, 10054 Legacy Rev. 10/03

1.6 SAFETY INSTRUCTIONS 1.6.2 Equipment Hazards

Model 8042, 10042, 10054 Legacy Rev. 10/03 1.5

1.6.3 General Hazards FLUID PRESSURE: Before loosening any hydraulic or

ground or hills). The vehicle must be on a hard level 3.

surface, with the wheels blocked when performing any

service. Obtain assistance, block all wheels, and add

slings or straps beneath or around a component or

1.6 Model 8042, 10042, 10054 Legacy Rev. 10/03

This Page Intentionally Left Blank

Model 8042, 10042, 10054 Legacy Rev. 10/03 1.7

1.8 HAZARD/EMERGENCY clean.

1. Read operator's manual

2. Fasten seat belt.

1. 4110188 No Riders Warning (1)

1.8 Model 8042, 10042, 10054 Legacy Rev. 10/03

8. 4110184 Moving Parts Warning (2)

Model 8042, 10042, 10054 Legacy Rev. 10/03 1.9

Model 10042 (S/N 13198 thru 19030)

1. Read operator's manual

1. 4110188 No Riders Warning (1)

1.10 Model 8042, 10042, 10054 Legacy Rev. 10/03

9. 4110184 Moving Parts Warning (2)

Model 8042, 10042, 10054 Legacy Rev. 10/03 1.11

Model 10054 (S/N 13198 thru 19079)

1. Read operator's manual

1. 4110188 No Riders Warning (1)

1.12 Model 8042, 10042, 10054 Legacy Rev. 10/03

9. 4110184 Moving Parts Warning (2)

Model 8042, 10042, 10054 Legacy Rev. 10/03 1.13

Model 8042 (S/N 18991 & After)

1. 4110188 No Riders Warning (1)

1.14 Model 8042, 10042, 10054 Legacy Rev. 10/03

8. 4110184 Moving Parts Warning (2)

Model 8042, 10042, 10054 Legacy Rev. 10/03 1.15

Model 10042 (S/N 19031 & After)

1. Read operator's manual

1. 4110188 No Riders Warning (1)

1.16 Model 8042, 10042, 10054 Legacy Rev. 10/03

9. 4110184 Moving Parts Warning (2)

Model 8042, 10042, 10054 Legacy Rev. 10/03 1.17

Model 10054 (S/N 19080 & After)

1. Read operator's manual

1. 4110188 No Riders Warning (1)

1.18 Model 8042, 10042, 10054 Legacy Rev. 10/03

9. 4110184 Moving Parts Warning (2)