Usage:
TH62 (3LN, 4TM) TH63 (3NN, 5WM) TH82 (3JN, 3KN) TH83 (3RN) TH103 (3PN) Telehandlers
Reference: Service Magazine Article: September 2, 1996; Page 24; "Service Parts Available for Hydraulic Controller".
Reference: SENR5835, Service Manual, TH62, TH63, TH82, TH83 Telehandlers; SEBU6865-02, March 20, 1997, and SEBU7112, September 19, 1997, Operation and Maintenance Manuals.
Reference: SENR1230 Service Manual, TH103 Telehandler; SEBU7017, August 23, 1996, and SEBU7111, September 23, 1997, Operation and Maintenance Manuals.
This article replaces the article "Service Parts Available for Hydraulic Controller" on Page 24 of the September 2, 1996, issue of Service Magazine.
Three different hydraulic controllers have been used on the machines, 8I-3632 Hand Control , 133-0956 Pilot Operated Hydraulic Control, and 140-1721 Hydraulic Hand Control. 8I-3632 Hand Control was used first. It was canceled and replaced by 133-0956 Pilot Operated Hydraulic Control. The 133-0956 Pilot Operated Hydraulic Control was replace by 140-1721 Hydraulic Hand Control.
The 133-0956 Pilot Operated Hydraulic Control was serviced by two service kits. The 143-9264 Repair Kit applies to COSA or Type 1 control arrangement machines. The 143-9603 Repair Kit applies to NACD or Type 2 control arrangement machines.
Illustration 1.
COSA or Type 1 Control Arrangement machines.
Illustration 2.
NACD or Type 2 Control Arrangement machines.
Refer to SENR5835, Service Manual, TH62, TH63, TH82, TH83 Telehandlers; SEBU6865-02, March 20, 1997, and SEBU7112, September 19, 1997, Operation and Maintenance Manuals, to identify the control arrangement decal in the TH62, TH63, TH82, and TH83 machines.
Refer to SENR1230 Service Manual, TH103 Telehandler; SEBU7017, August 23, 1996, and SEBU7111, September 23, 1997, Operation and Maintenance Manuals, to identify the control arrangement decal in the TH103 machines.
8I-3632 Hand Control and 133-0956 Pilot Operated Hydraulic Control can be reworked to meet current control configurations. The following steps are the rework procedures for both to meet current control configurations using the above repair kits.
1. Remove the panel from the side of the joystick console. Separate the joystick harness from the cab harness.
NOTE: For machines with COSA or Type 1 control arrangement only: if a short harness with two relays was connected between the joystick harness and the cab harness, it must be removed and discarded. The two relays may be reused with item (5) from the repair kits.
Illustration 3. View of the joystick showing the gaiter
2. Roll up joystick gaiter (1) in Illustration (3).
3. Remove connector (2) from the section of the harness connected through the joystick. Refer to Illustration 3.
Illustration 4.
Cut away view of the joystick
4. Pull harness (1) up through the joystick base. See Illustration 4.
5. Unscrew the joystick handle at nut (2). Do not turn plunger operating plate (3). Refer to Illustration 4.
Illustration 5.
New joystick installation
6. Refer to Illustration 5. Install adapter (1). It should contact plunger operating plate (2). Tighten adapter (1). Install 143-3904 Hydraulic Hand Control (3) into adapter (1). Tighten lock nut (4).
7. Route the attached harness through the joystick base. Install 8T-8730 Connector Sockets to the wires in the harness. Install the wires and sockets to the numbered plug positions in 102-8811 Plug Kit in the following order: 1. red, 2. black, 3. gray, 4. blue, 5. yellow, 6. green, 7. white, 8. brown. Install wedge (4) to the plug.
8. Install item (5) from the appropriate repair kit between the joystick and cab harness. Install 3E-9362 Relay and secure it to the main harness with cable ties.
9. Connect the black cable to a suitable ground.
10. Install the console panel.
11. Replace the existing joystick decal with item (6) from the appropriate repair kit to reflect the correct control pattern.
12. Check all operations controlled by the joystick. The operations controlled by the joystick must match item (6).
Both repair kits have been canceled. Parts for both kits must be ordered as separate items but both kits can be serviced with parts for 140-1721 Hydraulic Hand Control. Serviced parts for 140-1721 Hydraulic Hand Control are listed in Chart 11.
Illustration 6.
Serviced parts of 140-1721 Hydraulic Hand Control. See Chart 11.
