JLG Telehandler 8042 Parts Manual 3122308800

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JLG Telehandler 8042 Parts Manual 3122308800
Size: 39.04 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Telehandler
Type of Manual: Parts Manual
Model: JLG 8042 Telehandler
Part Number: 3122308800
Publication Date: 2024
Number of Pages: 586 Pages

Contents:
SECTION 1 - FRAME AND ATTACHING PARTS

FIGURE 1-1. FRAME BEARING AND TRIM INSTALLATION​

FIGURE 1-2. FRAME COVERS ASSEMBLY​

FIGURE 1-3. FUEL TANK ASSEMBLY (Prior to SN 0160134196)​

FIGURE 1-4. FUEL TANK ASSEMBLY (SN 0160134443 to Present)​

FIGURE 1-5. FUEL TANK MOUNTING INSTALLATION​

FIGURE 1-6. HYDRAULIC TANK ASSEMBLY​

FIGURE 1-7. HYDRAULIC TANK SUB-ASSEMBLY​

FIGURE 1-8. HYDRAULIC TANK MOUNTING INSTALLATION​

SECTION 2 - BOOM

FIGURE 2-1. BOOM INSTALLATION​

FIGURE 2-2. BOOM ASSEMBLY​

FIGURE 2-3. BOOM BASE ASSEMBLY​

FIGURE 2-4. BOOM MID ASSEMBLY​

FIGURE 2-5. HOSE PULLEY ASSEMBLY​

FIGURE 2-6. BOOM FLY ASSEMBLY​

FIGURE 2-7. BOOM ANGLE INDICATOR​

FIGURE 2-8. BOOM PROP INSTALLATION​

FIGURE 2-9. COUPLER ASSEMBLY​

FIGURE 2-10. LOCK PIN ASSEMBLY​

SECTION 3 - ATTACHMENTS

FIGURE 3-1. BASKET, PERSONNEL (1.2MX2.4M) (DOMESTIC)​

FIGURE 3-2. BASKET, PERSONNEL (1.2MX2.4M) (ISO)​

FIGURE 3-3. BASKET, PERSONNEL (1.2MX2.4M) (FRENCH LANGUAGE)​

FIGURE 3-4. BASKET, PERSONNEL ASSEMBLY​

FIGURE 3-5. BOOM - 3 FOOT WITH WINCH​

FIGURE 3-6. BOOM - 12 FOOT WITH WINCH​

FIGURE 3-7. BOOM - 12FT WITHOUT WINCH​

FIGURE 3-8. BOOM - 15FT WITHOUT WINCH​

FIGURE 3-9. BOOM - ADJUSTABLE (FORK MOUNTED)​

FIGURE 3-10. BUCKET (72 INCH)​

FIGURE 3-11. BUCKET (96 INCH)​

FIGURE 3-12. BUCKET (102 INCH)​

FIGURE 3-13. CARRIAGE ASSEMBLY - 48IN SIDE SHIFT​

FIGURE 3-14. CARRIAGE ASSEMBLY - 50IN​

FIGURE 3-15. CARRIAGE ASSEMBLY - 50IN DUAL FORK POSITIONING​

FIGURE 3-16. CARRIAGE ASSEMBLY - 50IN/12000# CAPICITY SIDE TILT​

FIGURE 3-17. CARRIAGE ASSEMBLY - 60IN​

FIGURE 3-18. CARRIAGE ASSEMBLY - 60IN/12000# CAPACITY SIDE TILT​

FIGURE 3-19. CARRIAGE ASSEMBLY - 72IN​

FIGURE 3-20. CARRIAGE ASSEMBLY - 72IN/12000# CAPACITY SIDE TILT​

FIGURE 3-21. CARRIAGE ASSEMBLY - 72IN SWING​

FIGURE 3-22. FORK 2.36X4X48 PALLET​

FIGURE 3-23. FORK 2.36X5X48 PALLET​

FIGURE 3-24. FORK 2.4X4X48 PALLET​

FIGURE 3-25. FORK 2.4X4X60 PALLET​

FIGURE 3-26. FORK 2.36X5X72 PALLET​

FIGURE 3-27. FORK 2.36X5X60 PALLET​

FIGURE 3-28. FORK 2.36X6X60 PALLET​

FIGURE 3-29. FORK 1.75X7X60 LUMBER​

FIGURE 3-30. FORK 2X6X72 LUMBER​

FIGURE 3-31. FORK 2X2X48 BLOCK​

FIGURE 3-32. HOOK - COUPLER MOUNTED​

FIGURE 3-33. HOOK - 4TON (FORK MOUNTED)​

FIGURE 3-34. LIFTING HOOK​

FIGURE 3-35. PLATFORM (FORK MOUNTED)(4X9.8)​

FIGURE 3-36. PLATFORM (FORK MOUNTED)(4X8 WITH DOORS)​

SECTION 4 - ENGINE AND ATTACHING PARTS

FIGURE 4-1. ENGINE INSTALLATION (HRC)​

FIGURE 4-2. ENGINE INSTALLATION (LRC)​

FIGURE 4-3. ENGINE ASSEMBLY (HRC)​

FIGURE 4-4. ENGINE ASSEMBLY (LRC)​

FIGURE 4-5. ENGINE MOUNTS INSTALLATION​

FIGURE 4-6. ENGINE ELECTRICAL INSTALLATION​

FIGURE 4-7. ENGINE AIR INTAKE INSTALLATION​

FIGURE 4-8. ENGINE FUEL SYSTEM INSTALLATION (HRC ENGINES)​

FIGURE 4-9. ENGINE FUEL SYSTEM INSTALLATION (LRC ENGINES)​

FIGURE 4-10. ENGINE PUMPS INSTALLATION​

FIGURE 4-11. ENGINE COOLING SYSTEM INSTALLATION​

FIGURE 4-12. ENGINE EXHAUST INSTALLATION​

FIGURE 4-13. ENGINE OIL QUICK DRAIN INSTALLATION​

FIGURE 4-14. AC PUMP INSTALLATION​

FIGURE 4-15. AIR SHUT-OFF VALVE (ASOV) INSTALLATION​

FIGURE 4-16. BLOCK HEATER INSTALLATION (ANSI)​

FIGURE 4-17. BREATHER HEATER INSTALLATION​

FIGURE 4-18. COOLING LINES INSTALLATION​

FIGURE 4-19. RADIATOR HOSES INSTALLATION​

FIGURE 4-20. SURGE TANK INSTALLATION​

SECTION 5 - DRIVE TRAIN

FIGURE 5-1. AXLES INSTALLATION​

FIGURE 5-2. FRONT AXLE ASSEMBLY​

FIGURE 5-3. FRONT AXLE, CENTRAL HOUSING​

FIGURE 5-4. FRONT AXLE, DIFFERENTIAL​

FIGURE 5-5. FRONT AXLE, HUB REDUCTION (1)​

FIGURE 5-6. FRONT AXLE, HUB REDUCTION (2)​

FIGURE 5-7. FRONT AXLE, BRAKES​

FIGURE 5-8. FRONT AXLE, STEERING​

FIGURE 5-9. FRONT AXLE, TRUNION​

FIGURE 5-10. REAR AXLE ASSEMBLY​

FIGURE 5-11. REAR AXLE, CENTRAL HOUSING​

FIGURE 5-12. REAR AXLE, DIFFERENTIAL​

FIGURE 5-13. REAR AXLE, HUB REDUCTION (1)​

FIGURE 5-14. REAR AXLE, HUB REDUCTION (2)​

FIGURE 5-15. REAR AXLE, BRAKES​

FIGURE 5-16. REAR AXLE, STEERING​

FIGURE 5-17. REAR AXLE, TRUNION​

FIGURE 5-18. DRIVE MOTOR INSTALLATION​

FIGURE 5-19. DRIVE MOTOR AND FITTINGS ASSEMBLY​

FIGURE 5-20. DRIVE MOTOR ASSEMBLY​

FIGURE 5-21. DRIVESHAFT INSTALLATION​

FIGURE 5-22. DRIVESHAFT ASSEMBLY​

FIGURE 5-23. DRIVESHAFT ASSEMBLY​

FIGURE 5-24. FENDER INSTALLATION​

FIGURE 5-25. FENDER INSTALLATION (ENCLOSED CAB)​

FIGURE 5-26. GEARBOX INSTALLATION​

FIGURE 5-27. GEARBOX ASSEMBLY​

FIGURE 5-28. LUGNUT INSTALLATION​

FIGURE 5-29. TIRE SET - 15.5-25 PNUEMATIC​

FIGURE 5-30. TIRE SET - 15.5-25 FOAM-FILLED​

FIGURE 5-31. TIRE SET - 15.5-25 PNUEMATIC NON-MARKING​

FIGURE 5-32. TIRE SET - 15.5-25 FOAM-FILLED NON-MARKING​

FIGURE 5-33. TIRE SET - 15.5-25 (SUNSTATE) FOAM-FILLED NON-MARKING​

FIGURE 5-34. TIRE SET - 370/75-28 PNEUMATIC​

FIGURE 5-35. TIRE SET - 370/75-28 FOAM​

FIGURE 5-36. TIRE SET - 315/95-28/8.5 SOLID​

FIGURE 5-37. TIRE SET 18 X 625 TURF - AIR​

FIGURE 5-38. TIRE SET -13.00-24 FOAM (E-3) (SUNSTATE ONLY)​

FIGURE 5-39. TIRE AND WHEEL ASSEMBLY - 370/75-28 FOAM​

SECTION 6 - CAB

FIGURE 6-1. CAB INSTALLATION - OPEN​

FIGURE 6-2. CAB INSTALLATION - ENCLOSED WITH HEAT ONLY​

FIGURE 6-3. CAB INSTALLATION - ENCLOSED WITH HEAT/AC​

FIGURE 6-4. CAB INTERIOR INSTALLATION​

FIGURE 6-5. CAB SUB-ASSEMBLY (HEAT ONLY)​

FIGURE 6-6. CAB SUB-ASSEMBLY (HEAT AND AC)​

FIGURE 6-7. CAB ASSEMBLY​

FIGURE 6-8. CAB HEATER INSTALLATION​

FIGURE 6-9. CAB HEATER CONTROLS INSTALLATION​

FIGURE 6-10. CAB HEATER LINES INSTALLATION (Prior to SN 0160136201)​

FIGURE 6-11. CAB HEATER LINES INSTALLATION (SN 0160136404 to Present)​

FIGURE 6-12. CAB HVAC CONTROLS INSTALLATION​

FIGURE 6-13. CAB HVAC LINES INSTALLATION (Prior to SN 0160136201)​

FIGURE 6-14. CAB HVAC LINES INSTALLATION (SN 0160136404 to Present)​

FIGURE 6-15. CAB MOUNTING INSTALLATION​

FIGURE 6-16. DOOR ASSEMBLY (Prior to SN 0160136201)​

FIGURE 6-17. DOOR ASSEMBLY (SN 0160136404 to Present)​

FIGURE 6-18. FIRE EXTINGUISHER INSTALLATION​

FIGURE 6-19. FLOOR HEATER​

FIGURE 6-20. FORWARD/NEUTRAL/REVERSE CONTROL INSTALLATION​

FIGURE 6-21. FORWARD/NEUTRAL/REVERSE AND WIPER/LIGHTS CONTROL​

FIGURE 6-22. HEATER ASSEMBLY​

FIGURE 6-23. HEATER VALVE​

FIGURE 6-24. HVAC ASSEMBLY​

FIGURE 6-25. LOADCHART HOLDER INSTALLATION​

FIGURE 6-26. MIRRORS INSTALLATION​

FIGURE 6-27. BEACON/CLEARSKY INSTALLATION​

FIGURE 6-28. ROOF CLOSURE INSTALLATION​

FIGURE 6-29. SEAT INSTALLATION - STANDARD​

FIGURE 6-30. SEAT INSTALLATION - SEAOP​

FIGURE 6-31. SEAT ASSEMBLY - STANDARD​

FIGURE 6-32. SEAT ASSEMBLY - VINYL​

FIGURE 6-33. SEAT BELT INSTALLATION (3IN WIDTH)​

FIGURE 6-34. STEP INSTALLATION​

FIGURE 6-35. STEERING SYSTEM INSTALLATION​

FIGURE 6-36. WINDOW ASSEMBLY (REAR)​

FIGURE 6-37. WINDOW EXIT INSTALLATION (ANSI SPECS)​

FIGURE 6-38. WINDOW EXIT INSTALLATION (ENGLISH/FRENCH LANGUAGES)​

FIGURE 6-39. WINDOW EXIT INSTALLATION (ISO SPECS)​

FIGURE 6-40. WINDOW EXIT INSTALLATION (ENGLISH/SPANISH LANGUAGES)​

SECTION 7 - CONTROLS

FIGURE 7-1. BRAKE SYSTEM INSTALLATION​

FIGURE 7-2. JOYSTICK INSTALLATION (Prior to SN 0160132449)​

FIGURE 7-3. JOYSTICK INSTALLATION (SN 0160132653 to Present)​

SECTION 8 - HYDRAULIC CIRCUITS

FIGURE 8-1. HOSE INSTALLATION - AXLE​

FIGURE 8-2. HOSE INSTALLATION - AXLE (FRONT)​

FIGURE 8-3. HOSE INSTALLATION - AXLE (REAR)​

FIGURE 8-4. HOSE INSTALLATION - BOOM​

FIGURE 8-5. HOSE INSTALLATION - BRAKE​

FIGURE 8-6. HOSE INSTALLATION - OIL COOLER​

FIGURE 8-7. HOSE INSTALLATION - HYDRASTATIC DRIVE​

FIGURE 8-8. HOSE INSTALLATION - MAIN CONTROL VALVE​

FIGURE 8-9. HOSE INSTALLATION - PUMP/TANK​

FIGURE 8-10. HOSE INSTALLATION - STABILIZER/SWAY​

FIGURE 8-11. HOSE INSTALLATION - STEER​

SECTION 9 - HYDRAULIC COMPONENTS

FIGURE 9-1. BRAKE AND FITTINGS SUB-ASSEMBLY​

FIGURE 9-2. BRAKE ASSEMBLY​

FIGURE 9-3. BRAKE AND STEER VALVES INSTALLATION​

FIGURE 9-4. BRAKE VALVE AND FITTINGS SUB-ASSEMBLY​

FIGURE 9-5. BRAKE VALVE ASSEMBLY​

FIGURE 9-6. CYLINDER INSTALLATION (Prior to SN 0160127545)​

FIGURE 9-7. CYLINDER INSTALLATION (SN 0160129591 to Present)​

FIGURE 9-8. CYLINDER - COMP​

FIGURE 9-9. CYLINDER - EXTEND/RETRACT​

FIGURE 9-10. CYLINDER - FORK POSITIONING​

FIGURE 9-11. CYLINDER - LIFT​

FIGURE 9-12. CYLINDER - SIDE SHIRT CARRAIGE​

FIGURE 9-13. CYLINDER - SIDE TILT​

FIGURE 9-14. CYLINDER - STABLIZER​

FIGURE 9-15. CYLINDER - SWAY​

FIGURE 9-16. CYLINDER - SWING CARRIAGE​

FIGURE 9-17. CYLINDER - TILT​

FIGURE 9-18. DIVERTER VALVE ASSEMBLY​

FIGURE 9-19. DUAL FORK CARRIAGE VALVE ASSEMBLY​

FIGURE 9-20. FLOW DIVIDER VALVE​

FIGURE 9-21. MAIN CONTROL VALVE AND FITTINGS SUB-ASSEMBLY​

FIGURE 9-22. MAIN CONTROL VALVE ASSEMBLY​

FIGURE 9-23. PRIORITY VALVE ASSEMBLY​

FIGURE 9-24. PUMP MOUNTING KIT​

FIGURE 9-25. PUMP ASSEMBLY​

FIGURE 9-26. PUMP AND FITTINGS ASSEMBLY - GEAR PUMP​

FIGURE 9-27. GEAR PUMP​

FIGURE 9-28. STABILIZER VALVE AND FITTINGS SUBASSEMBLY​

FIGURE 9-29. STABILIZER VALVE ASSEMBLY​

FIGURE 9-30. STEER SELECT VALVE AND FITTINGS SUB-ASSEMBLY​

FIGURE 9-31. STEER VALVE AND FITTINGS SUB-ASSEMBLY​

FIGURE 9-32. STEERING SELECT VALVE​

FIGURE 9-33. VALVE INSTALLATION - WATCHDOG​

FIGURE 9-34. VALVE ASSEMBLY - WATCHDOG​

FIGURE 9-35. VALVE, AIR SHUT OFF​

SECTION 10 - ELECTRICAL

FIGURE 10-1. AIR SHUT-OFF VALVE HARNESS - ENGINE​

FIGURE 10-2. AIR SHUT-OFF VALVE HARNESS - POSI​

FIGURE 10-3. ALARM INSTALLATION - BACK UP​

FIGURE 10-4. ALARM INSTALLATION - BACK UP (WHITE NOISE)​

FIGURE 10-5. BEACON INSTALLATION (NO CLEARSKY)​

FIGURE 10-6. BEACON HARNESS (NO CLEARSKY)​

FIGURE 10-7. BATTERY INSTALLATION​

FIGURE 10-8. BOOM SENSOR INSTALLATION (WITHOUT LSI)​

FIGURE 10-9. BOOM SENSOR INSTALLATION (WITH LSI)​

FIGURE 10-10. CAB ELECTRICAL INSTALLATION (Prior to SN 0160135529)​

FIGURE 10-11. CAB ELECTRICAL INSTALLATION (SN 0160135706 to Present)​

FIGURE 10-12. CAB ELECTRICAL INSTALLATION - ENCLOSED CAB​

FIGURE 10-13. CAB DIAGNOSTIC PLUG INSTALLATION​

FIGURE 10-14. CAB HARNESS​

FIGURE 10-15. CAB AC JUMPER HARNESS​

FIGURE 10-16. CAB HVAC/WIPER HARNESS​

FIGURE 10-17. CAMERA INSTALLATION - BACK UP (WITHOUT LIGHTS) (Prior to SN 0160135529)​

FIGURE 10-18. CAMERA INSTALLATION - BACK UP (WITHOUT LIGHTS) (SN 0160135706 to Present)​

FIGURE 10-19. CAMERA INSTALLATION - BACK UP (WITH LIGHTS)​

FIGURE 10-20. CAMERA HARNESS - BACK UP CAMERA​

FIGURE 10-21. ENGINE HARNESS​

FIGURE 10-22. FRAME ELECTRICAL COMPONENTS INSTALLATION​

FIGURE 10-23. FRAME HARNESS INSTALLATION​

FIGURE 10-24. FRAME HARNESS​

FIGURE 10-25. FRAME FUSEBOX ASSEMBLY​

FIGURE 10-26. HEADLIGHT HARNESS​

FIGURE 10-27. HEATER INSTALLATION - BATTERY​

FIGURE 10-28. HEATER INSTALLATION - ENGINE OIL PAN​

FIGURE 10-29. HEATER INSTALLATION - HYDRAULIC TANK​

FIGURE 10-30. LIGHTS - ROADLIGHTS INSTALLATION (Prior to SN 0160127545)​

FIGURE 10-31. LIGHTS - ROADLIGHTS INSTALLATION (SN 0160129591 to Present)​

FIGURE 10-32. LIGHTS - WORKLIGHTS INSTALLATION​

FIGURE 10-33. LIGHTS - BOOM HARNESS​

FIGURE 10-34. LIGHTS – HEADLIGHTS HARNESS​

FIGURE 10-35. LIGHTS – TAILLIGHTS HARNESS​

FIGURE 10-36. LOAD SENSE INDICATOR (LSI) SYSTEM INSTALLATION - CAB​

FIGURE 10-37. LOAD SENSE INDICATOR (LSI) SYSTEM INSTALLATION - AXLE​

FIGURE 10-38. LOAD SENSE INDICATOR (LSI) HARNESS​

FIGURE 10-39. REVERSE SENSOR SYSTEM INSTALLATION (WITHOUT CAMERA)​

FIGURE 10-40. REVERSE SENSOR SYSTEM INSTALLATION (WITH CAMERA)​

FIGURE 10-41. REVERSE SENSOR HARNESS​

FIGURE 10-42. SEAT HARNESS - SEAOP SEAT​

SECTION 11 - DECALS

FIGURE 11-1. DECALS INSTALLATION (ANSI SPECS)​

FIGURE 11-2. DECALS INSTALLATION (ISO SPECS)​

FIGURE 11-3. DECALS INSTALLATION (ENGLISH/FRENCH LANGUAGES)​

FIGURE 11-4. DECALS INSTALLATION (ENGLISH/SPANISH LANGUAGES)​

FIGURE 11-5. DECALS INSTALLATIONS (ISO) (HRC)​

FIGURE 11-6. DECALS INSTALLATION - BRAND​

FIGURE 11-7. DECALS INSTALLATIONS - CLEARSKY​

FIGURE 11-8. DECALS INSTALLATION - SKYTRAK​

FIGURE 11-9. LOAD CHART (ANSI SPECS)​

FIGURE 11-10. LOAD CHART (METRIC SPECS)​

FIGURE 11-11. REVERSE SENSOR SYSTEM DECAL (ENGLISH)​

FIGURE 11-12. REVERSE SENSOR SYSTEM DECAL (ISO)​

FIGURE 11-13. REVERSE SENSING SYSTEM DECAL, (ENGLISH/FRENCH)​

FIGURE 11-14. REVERSE SENSOR SYSTEM DECAL (ENGLISH/SPANISH)​

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