JLG Telehandler 8042 10042 10054 Parts Manual 31200732

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JLG Telehandler 8042 10042 10054 Parts Manual 31200732
Size: 39.24 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Telehandler
Type of Manual: Parts Manual
Model: JLG 8042 10042 10054 Telehandler
Part Number: 31200732
Publication Date: 2024
Number of Pages: 506 Pages

Contents:
SECTION 1 - FRAME AND ATTACHING PARTS

FIGURE 1-1. FRAME AND ATTACHING PARTS​

FIGURE 1-2. COVERS (Prior to SN 0160053075, Excluding 0160050807, 0160050814 and 0160050815)​

FIGURE 1-3. COVERS (SN 0160053075 to Present, Including 0160050807, 0160050814 and 0160050815)​

FIGURE 1-4. OUTRIGGER INSTALLATION (10042,10054)​

SECTION 2 - BOOM

FIGURE 2-1. BOOM INSTALLATION​

FIGURE 2-2. FIRST BOOM SECTION​

FIGURE 2-3. SECOND BOOM SECTION (10042,8042)​

FIGURE 2-4. THIRD BOOM SECTION (10042,8042)​

FIGURE 2-5. SECOND BOOM SECTION (10054)​

FIGURE 2-6. THIRD BOOM SECTION (10054)​

FIGURE 2-7. FOURTH BOOM SECTION (10054)​

FIGURE 2-8. EXTEND CHAINS (10042,8042)​

FIGURE 2-9. EXTEND CHAINS (10054)​

FIGURE 2-10. RETRACT CHAINS (10042,8042)​

FIGURE 2-11. RETRACT CHAINS (10054)​

FIGURE 2-12. QUICK ATTACH​

SECTION 3 - ATTACHMENTS

FIGURE 3-1. TILT CARRIAGE (Prior to SN 0160051822)​

FIGURE 3-2. TILT CARRIAGE (SN 0160051822 to Present)​

FIGURE 3-3. SIDE TILT CARRIAGE​

FIGURE 3-4. 50IN SIDE SHIFT CARRIAGE​

FIGURE 3-5. 50IN DUAL FORK CARRIAGE​

FIGURE 3-6. 90 SWING CARRIAGE​

FIGURE 3-7. SHEET MATERIAL HANDLER​

FIGURE 3-8. FORKS​

FIGURE 3-9. FORK MOUNTED PLATFORM​

FIGURE 3-10. LIFTING HOOK​

FIGURE 3-11. FORK PIN LOCK INSTALLATION​

FIGURE 3-12. BUCKETS​

FIGURE 3-13. GRAPPLE BUCKET​

FIGURE 3-14. TRUSS BOOM​

FIGURE 3-15. 12FT TRUSS BOOM WITH WINCH​

FIGURE 3-16. 8FT MAST​

FIGURE 3-17. ADJUSTABLE TRUSS BOOM​

SECTION 4 - ENGINE AND ATTACHING PARTS

FIGURE 4-1. ENGINE INSTALLATION IF EQUIPPED FOR ULS​

FIGURE 4-2. ENGINE INSTALLATION IF EQUIPPED FOR LS​

FIGURE 4-3. CUMMINS ENGINE IF EQUIPPED FOR ULS (Prior to SN 0160068606)​

FIGURE 4-4. CUMMINS ENGINE IF EQUIPPED FOR ULS (SN 0160068606 to Present)​

FIGURE 4-5. CUMMINS ENGINE IF EQUIPPED FOR LS​

FIGURE 4-6. FUEL TANK AND LINES IF EQUIPPED FOR ULS​

FIGURE 4-7. FUEL TANK AND LINES IF EQUIPPED FOR ULS​

FIGURE 4-8. FUEL TANK AND LINES IF EQUIPPED FOR LS​

FIGURE 4-9. RADIATOR AND COOLING INSTALLATION IF EQUIPPED FOR ULS​

FIGURE 4-10. RADIATOR AND COOLING INSTALLATION IF EQUIPPED FOR LS​

FIGURE 4-11. AIR CLEANER INSTALLATION IF EQUIPPED FOR ULS​

FIGURE 4-12. AIR CLEANER INSTALLATION IF EQUIPPED FOR LS​

FIGURE 4-13. EXHAUST INSTALLATION IF EQUIPPED FOR ULS​

FIGURE 4-14. EXHAUST INSTALLATION IF EQUIPPED FOR LS​

FIGURE 4-15. ISOLATION COUPLER​

FIGURE 4-16. ISOLATION COUPLER IF EQUIPPED FOR LS​

SECTION 5 - DRIVE TRAIN

FIGURE 5-1. DRIVE TRAIN COMPONENTS​

FIGURE 5-2. AXLE INSTALLATION 110HP (ULS) (8042)​

FIGURE 5-3. AXLE INSTALLATION 74HP (LS) (8042)​

FIGURE 5-4. FRONT AXLE​

FIGURE 5-5. FRONT AXLE - INPUT​

FIGURE 5-6. FRONT AXLE - LIMITED SLIP DIFFERENTIAL​

FIGURE 5-7. FRONT AXLE - AXLE CASING​

FIGURE 5-8. FRONT AXLE - M-DISC BRAKE​

FIGURE 5-9. FRONT AXLE - BRAKE​

FIGURE 5-10. FRONT AXLE - JOINT HOUSING​

FIGURE 5-11. FRONT AXLE - PLANETARY DRIVE​

FIGURE 5-12. FRONT AXLE (110HP) (ULS) (8042)​

FIGURE 5-13. CENTRAL HOUSING, FRONT AXLE (110HP) (ULS) (8042)​

FIGURE 5-14. DIFFERENTIAL, FRONT AXLE (110HP) (ULS) (8042)​

FIGURE 5-15. HUB REDUCTION, FRONT AXLE (110HP) (ULS) (8042)​

FIGURE 5-16. BRAKES, FRONT AXLE (110HP) (ULS) (8042)​

FIGURE 5-17. STEERING, FRONT AXLE (110HP) (8042)​

FIGURE 5-18. FRONT AXLE, DIFFERENTIAL KIT 74HP (8042)​

FIGURE 5-19. FRONT AXLE, STEERING ADJUSTING BOLT KIT 74HP (8042)​

FIGURE 5-20. FRONT AXLE INSTALLATION, 74HP (8042)​

FIGURE 5-21. FRONT AXLE, CENTRAL HOUSING 74HP (8042)​

FIGURE 5-22. FRONT AXLE, DIFFERENTIAL 74HP (8042)​

FIGURE 5-23. FRONT AXLE, HUB REDUCTION 74HP (8042)​

FIGURE 5-24. FRONT AXLE, BRAKES 74HP (8042)​

FIGURE 5-25. FRONT AXLE, STEERING 74HP (8042)​

FIGURE 5-26. REAR AXLE INSTALLATION 74HP (8042)​

FIGURE 5-27. REAR AXLE, CENTRAL HOUSING 74HP (8042)​

FIGURE 5-28. REAR AXLE, DIFFERENTIAL 74HP (8042)​

FIGURE 5-29. REAR AXLE, HUB REDUCTION 74HP (8042)​

FIGURE 5-30. REAR AXLE, BRAKES 74HP (8042)​

FIGURE 5-31. REAR AXLE, STEERING 74HP (8042)​

FIGURE 5-32. REAR AXLE, REDUCTION BUSHING 74HP (8042)​

FIGURE 5-33. REAR AXLE, PLANET GEAR CARRIER 74HP (8042)​

FIGURE 5-34. REAR AXLE, RING GEAR SUPPORT 74HP (8042)​

FIGURE 5-35. REAR AXLE, DIFFERENTIAL KIT 74HP (8042)​

FIGURE 5-36. REAR AXLE​

FIGURE 5-37. REAR AXLE - INPUT​

FIGURE 5-38. REAR AXLE - DIFFERENTIAL​

FIGURE 5-39. REAR AXLE - AXLE CASING​

FIGURE 5-40. REAR AXLE - M-DISC BRAKE​

FIGURE 5-41. REAR AXLE - JOINT HOUSING​

FIGURE 5-42. REAR AXLE - PLANETARY DRIVE​

FIGURE 5-43. REAR AXLE(110HP) (ULS) (8042)​

FIGURE 5-44. CENTRAL HOUSING, REAR AXLE (110HP) (ULS) (8042)​

FIGURE 5-45. DIFFERENTIAL, REAR AXLE (110HP) (ULS) (8042)​

FIGURE 5-46. HUB REDUCTION, REAR AXLE (110HP) (ULS) (8042)​

FIGURE 5-47. BRAKES, REAR AXLE (110HP) (ULS) (8042)​

FIGURE 5-48. STEERING, REAR AXLE (110HP) (ULS) (8042)​

FIGURE 5-49. TRANSMISSION​

FIGURE 5-50. TRANSMISSION, ENGINE CONNECTION AND CONVERTER​

FIGURE 5-51. TRANSMISSION, INPUT SHAFTS​

FIGURE 5-52. TRANSMISSION, GEARBOX HOUSING​

FIGURE 5-53. TRANSMISSION, COUPLING GROUP 1​

FIGURE 5-54. TRANSMISSION, COUPLING GROUP 2​

FIGURE 5-55. TRANSMISSION, COUPLING GROUP 3​

FIGURE 5-56. TRANSMISSION, COUPLING GROUP 4​

FIGURE 5-57. TRANSMISSION, REVERSING GEAR GROUP 1​

FIGURE 5-58. TRANSMISSION, REVERSING GEAR GROUP 2​

FIGURE 5-59. TRANSMISSION, OUTPUT​

FIGURE 5-60. TRANSMISSION, CONTROL UNIT​

FIGURE 5-61. TRANSMISSION, VALVE HOUSING ASSEMBLY​

FIGURE 5-62. TRANSMISSION, VALVE BLOCK ASSEMBLY​

FIGURE 5-63. TRANSMISSION, OIL PUMP AND FILTER​

FIGURE 5-64. FENDER INSTALLATION​

FIGURE 5-65. WHEEL ASSEMBLY (8042)​

FIGURE 5-66. WHEEL ASSEMBLY (10042,10054)​

SECTION 6 - CAB

FIGURE 6-1. CAB INSTALLATION​

FIGURE 6-2. CAB ASSEMBLY​

FIGURE 6-3. CAB DOOR ASSEMBLY (Prior to SN 0160050422, Excluding 0160050419)​

FIGURE 6-4. CAB DOOR ASSEMBLY (SN 0160050422 to Present, Including 0160050419)​

FIGURE 6-5. SOFT CAB ENCLOSURE​

FIGURE 6-6. WIPERS​

FIGURE 6-7. OPERATORS SEAT​

FIGURE 6-8. CAB HEATER​

FIGURE 6-9. REAR DROPOUT WINDOW INSTALLATION​

SECTION 7 - CONTROLS

FIGURE 7-1. BRAKE​

FIGURE 7-2. ACCELERATOR​

FIGURE 7-3. STEERING COLUMN​

FIGURE 7-4. BOOM CONTROL​

FIGURE 7-5. FRAME LEVEL AND ATTACHMENT TILT CONTROL​

FIGURE 7-6. AUXILIARY CONTROL​

SECTION 8 - HYDRAULIC CIRCUITS

FIGURE 8-1. SUPPLY CIRCUIT​

FIGURE 8-2. DUMP CIRCUIT IF EQUIPPED FOR ULS​

FIGURE 8-3. STEER SELECT CIRCUIT​

FIGURE 8-4. SERVICE BRAKE CIRCUIT​

FIGURE 8-5. LIFT CYLINDER CIRCUIT​

FIGURE 8-6. EXTEND/RETRACT CYLINDER CIRCUIT​

FIGURE 8-7. ATTACHMENT TILT AND TILT COMPENSATION CYLINDER CIRCUIT​

FIGURE 8-8. AUXILIARY HYDRAULIC CIRCUIT​

FIGURE 8-9. FRAME LEVEL AND STABIL-TRAK CYLINDER CIRCUIT​

FIGURE 8-10. OUTRIGGER CIRCUIT (10042,10054)​

FIGURE 8-11. TRANSMISSION COOLER​

FIGURE 8-12. MAIN CONTROL VALVE INSTALLATION​

SECTION 9 - HYDRAULIC COMPONENTS

FIGURE 9-1. LIFT CYLINDER​

FIGURE 9-2. EXTEND/RETRACT CYLINDER (10054,8042)​

FIGURE 9-3. EXTEND/RETRACT CYLINDER (10042)​

FIGURE 9-4. ATTACHMENT TILT CYLINDER​

FIGURE 9-5. TILT COMPENSATION CYLINDER​

FIGURE 9-6. FRAME LEVEL CYLINDER (Prior to SN 0160076614, Including 0160076627 and 0160076629)​

FIGURE 9-7. FRAME LEVEL CYLINDER (SN 0160076614 through 0160076626, SN 0160076630 to Present, Including 0160076628, Excluding 0160076627 and 0160076629)​

FIGURE 9-8. STABIL-TRAK CYLINDER​

FIGURE 9-9. OUTRIGGER CYLINDER​

FIGURE 9-10. 50IN SIDE SHIFT CARRIAGE CYLINDER​

FIGURE 9-11. MAIN CONTROL VALVE​

FIGURE 9-12. PISTON PUMP​

FIGURE 9-13. PISTON PUMP​

FIGURE 9-14. PISTON PUMP (Prior to SN 0160059878)​

FIGURE 9-15. PISTON PUMP (SN 0160059878 to Present)​

FIGURE 9-16. FUEL/HYDRAULIC TANK ASSEMBLY​

FIGURE 9-17. DIRECTIONAL CONTROL VALVE​

FIGURE 9-18. BRAKE VALVE​

FIGURE 9-19. SIDE TILT CARRIAGE CYLINDER (Prior to SN 0160066474)​

FIGURE 9-20. SIDE TILT CARRIAGE CYLINDER (SN 0160066474 to Present)​

FIGURE 9-21. 72 INCH 90 SWING CARRIAGE CYLINDER​

FIGURE 9-22. GRAPPLE BUCKET CYLINDER​

FIGURE 9-23. VALVE SECONDARY FUNCTION​

SECTION 10 - ELECTRICAL

FIGURE 10-1. ENGINE COMPARTMENT ELECTRICAL INSTALLATION​

FIGURE 10-2. CAB ELECTRICAL INSTALLATION​

FIGURE 10-3. CAB SWITCHES​

FIGURE 10-4. WORK LIGHTING INSTALLATION​

FIGURE 10-5. ROAD LIGHTING INSTALLATION​

FIGURE 10-6. ROTATING BEACON INSTALLATION​

FIGURE 10-7. ENGINE HARNESS IF EQUIPPED FOR ULS​

FIGURE 10-8. ENGINE HARNESS IF EQUIPPED FOR LS​

FIGURE 10-9. CAB POWER DISTRIBUTION HARNESS (Prior to SN 0160065987)​

FIGURE 10-10. CAB POWER DISTRIBUTION HARNESS (SN 0160065987 to Present)​

FIGURE 10-11. DASH/THROTTLE HARNESS​

FIGURE 10-12. MAF/WATER IN FUEL HARNESS​

FIGURE 10-13. OUTRIGGERS HARNESS (10042) (Prior to SN 0160065987)​

FIGURE 10-14. OUTRIGGERS HARNESS (10042) (SN 0160065987 to Present)​

FIGURE 10-15. GPS JUMPER HARNESS (10042)​

FIGURE 10-16. LOGIC HARNESS (10054) (Prior to SN 0160065987)​

FIGURE 10-17. LOGIC HARNESS (10054) (SN 0160065987 to Present)​

FIGURE 10-18. BOOM EXTEND HARNESS (10054)​

FIGURE 10-19. WORK LIGHTING HARNESS​

FIGURE 10-20. ROAD LIGHTING HARNESS​

FIGURE 10-21. REVERSE SENSING SYSTEM INSTALLATION​

FIGURE 10-22. REVERSE SENSOR HARNESS​

FIGURE 10-23. TELEMATICS INSTALLATION, UNITED RENTALS​

SECTION 11 - DECALS

FIGURE 11-1. CAB AND FRAME DECALS​

FIGURE 11-2. BOOM DECALS​

SECTION 12 - RECOMMENDED SERVICE PARTS STOCK

FIGURE 12-1. RECOMMENDED SERVICE PARTS STOCK​

SECTION 13 - SPECIAL OPTIONS/ACCESSORIES/KITS

FIGURE 13-1. SPECIAL OPTIONS/ACCESSORIES/KITS​

PART NUMBER INDEX