JLG Telehandler 8042 Service Manual 3122349800 2025

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JLG Telehandler 8042 Service Manual 3122349800 2025
Size: 49.88 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Telehandler
Type of Manual: Service Manual, Electrical and Hydraulic Diagrams
Model: JLG 8042 Telehandler
Part Number: 3122349800
Publication Date: 2025
Number of Pages: 700 Pages

Contents:
Safety

General​

1.1.1 Disclaimer​

1.1.2 Operation & Safety Manual​

Safety Information​

1.2.1 Safety Alert System and Signal Words​

Safety Hazards (task)​

1.3.1 Personal Hazards​

1.3.2 Equipment Hazards​

1.3.3 General Hazards​

1.3.4 Operational Hazards​

Safety Decals​

Machine Verification​

General Machine Information & Specifications

Specifications​

2.1.1 Travel Speeds​

2.1.2 Boom Performance​

2.1.3 Cylinder Drift​

2.1.4 Electrical System​

2.1.5 Engine Performance Specifications​

2.1.6 Tires​

Machine Temperature Chart​

Serial Number Location​

Fluids and Lubrication​

2.4.1 General Information​

2.4.2 Hydraulic Oil​

2.4.3 Changing Hydraulic Oil​

2.4.4 Lubrication Specifications​

2.4.5 Fluids​

2.4.6 Capacities​

2.4.7 Lubrication Schedules​

ClearSky Smart Fleet​

2.5.1 General​

2.5.2 ClearSky Smart Fleet™ – Access Control​

Maintenance & Inspection Schedules

Machine Preparation, Inspection, and Maintenance​

3.1.1 Preparation, Inspection, and Maintenance​

3.1.2 Pre-Start Inspection​

3.1.3 Pre-Delivery Inspection​

Service and Guidelines​

3.2.1 General​

3.2.2 Safety and Workmanship​

3.2.3 Cleanliness​

3.2.4 Components Removal and Installation​

3.2.5 Component Disassembly and Reassembly​

3.2.6 Pressure-Fit Parts​

3.2.7 Bearings​

3.2.8 Gaskets​

3.2.9 Bolt Usage and Torque Application​

3.2.10 Hydraulic Lines and Electrical Wiring​

3.2.11 Hydraulic System​

3.2.12 Lubrication​

3.2.13 Battery​

3.2.14 Welding on JLG Equipment​

Preventive Maintenance and Inspection Schedule​

3.3.1 Every 10 Hours​

3.3.2 First 50 Hours​

3.3.3 Every 50 Hours​

3.3.4 First 250 Hours​

3.3.5 Every 250 Hours​

3.3.6 First 500 Hours​

3.3.7 Every 500 Hours​

3.3.8 Every 1000 Hours​

3.3.9 Every 1500 Hours​

3.3.10 Every 2000 Hours​

3.3.11 Every 3000 Hours or 2 Years​

3.3.12 Every 6000 Hours or 4 Years​

Pins and Composite Bearing Repair Guidelines​

3.4.1 Filament Wound Bearings​

Tires and Wheels​

3.5.1 Tire Inflation​

3.5.2 Tire Damage​

Brake Maintenance​

3.6.1 Park Brake Bleeding (Manually)​

3.6.2 Service Brake Bleeding​

DEF Tank Inspection​

Boom Inspection and Maintenance​

3.8.1 Boom Wear Pads​

Hydraulic Filter Replacement​

3.9.1 Removal​

3.9.2 Installation​

Engine General Inspection​

3.10.1 General Maintenance​

3.10.2 Glow Plugs​

3.10.3 Replacing Engine Oil​

3.10.4 Replacing the Oil Filter​

3.10.5 Replacing the Fuel Filters​

3.10.6 Replacing the Fuel Pre-Filter​

3.10.7 Checking Belt Tension​

Testing, Calibrations, & Special Procedures

Special Tools​

4.1.1 Multimeter​

4.1.2 Thread Locking Compound​

4.1.3 Tools Catalog​

Testing Procedures​

4.2.1 Starter​

4.2.2 Park Brake/Maximum Drive Traction Test​

Calibration Procedures​

4.3.1 JLG Analyzer​

4.3.2 Calibration Preparation​

4.3.3 Boom Angle Sensor Calibration​

4.3.4 Load Stability Indicator (LSI) System Calibration​

4.3.5 Brake Pedal Calibration​

Special Procedures​

4.4.1 Emergency Lowering Procedure​

4.4.2 Lowering Procedure​

4.4.3 Towing a Disabled Machine​

4.4.4 Charge Air Cooler (CAC) Hose Draining​

4.4.5 Hydraulic Tank​

4.4.6 Fuel Tank Cleaning and Drying​

4.4.7 Pressure Checks and Adjustments​

4.4.8 Cylinder Checking Procedure​

4.4.9 Cylinder Drift Test​

4.4.10 Hydraulic Circuits​

4.4.11 Pressure Specifications​

4.4.12 Boom Extend and Retract Chains​

4.4.13 Boom Chain Tension Adjustment​

4.4.14 Evacuating and Recharging Air Conditioning (AC) System​

Stabil-Trak™ and Boom Interlock System​

4.5.1 Stabil-Trak™ System Component Terminology​

4.5.2 Stabil-Trak™ Description​

4.5.3 Stabil-Trak™ Operation​

4.5.4 Stabil-Trak™ System Test​

System Software

Load Stability Indicator (LSI) (If Equipped)​

5.1.1 Load Stability Indicator​

5.1.2 LSI Sensor​

Analyzer​

5.2.1 Machine Data Access​

5.2.2 JLG Hand Held Analyzer​

5.2.3 JLG Mobile Analyzer and ClearSky SmartFleet Bluetooth Analyzer​

5.2.4 PC Analyzer/Loglifter​

5.2.5 Analyzer Software (Version P27.0)​

Access Level​

Diagnostics (Software Version P27.0)​

Machine Setup (Software Version P27.0)​

Personalities (Software Version P27.0)​

Operator Tools (Software Version P27.0)​

Calibrations (Software Version P27.0)​

ClearSky (CS550) Configuration and Troubleshooting​

5.9.1 ClearSky Smart FleetTM CS550 Configuration​

5.9.2 Troubleshooting​

Fault Codes

Introduction​

6.1.1 Fault Code Display​

Engine Fault Codes​

6.2.1 TCD 2.9L4 Fault Codes​

Fault Codes - Help Comment (00x)​

Fault Codes - Power-Up (21x)​

Fault Codes - Ground Inputs (23x)​

Fault Codes - Other Inputs (24x)​

Fault Codes - Function Prevented (25x)​

Fault Codes - Line Contactor, Open-Circuit (31x)​

Fault Codes - Line Contactor, Short-Circuit (32x)​

Fault Codes - Output Drivers (33x)​

Fault Codes - Engine (43x)​

Fault Codes - Battery Supply (44x)​

Fault Codes - Transmission and Drive System (46x)​

Fault Codes - Communications (66x)​

Fault Codes - Telematics (68x)​

Fault Codes - Tilt Sensor (81x)​

Fault Codes - Envelope Control (84x)​

Fault Codes - Load Moment (85x)​

Fault Codes - Steering (86x)​

Fault Codes - Service Required (87x)​

Fault Codes - Hardware (99x)​

Air Shutoff Valve (ASOV) Controller​

ClearSky CS550 Troubleshooting Procedures​

Hydraulics

General Information and Safety​

Theories of Operation​

7.2.1 Cylinders​

7.2.2 Valves​

Hydraulic Component​

Torque Values​

7.4.1 Cylinder Torque Specifications​

Electricals

General Information​

8.1.1 Applying Silicone Dielectric Compound to Electrical Connections​

8.1.2 Dielectric Grease Application​

8.1.3 Electrical Connector Examples​

Electrical Connectors​

Electrical Component Terminology​

8.3.1 General Overview​

Harness Layouts​

Board Layouts​

8.5.1 Cab Harness Fuses and Relays​

8.5.2 Power Distribution Board​

Telematics Gateway​

8.6.1 Telematics-Ready (TCU) Plug​

8.6.2 Component Locations​

8.6.3 Telematics Gateway Harness Breakdown​

Removal and Installation

Wheels​

9.1.1 Removing Wheel and Tire Assembly from Machine​

9.1.2 Installing Wheel and Tire Assembly onto Machine​

Drive Assembly​

9.2.1 Axle Assembly And Drive Shaft Troubleshooting​

9.2.2 Axle​

9.2.3 Drive Shafts​

9.2.4 Transmission Components​

Boom​

9.3.1 Boom System Component Terminology​

9.3.2 Troubleshooting​

9.3.3 Boom System​

9.3.4 Quick Coupler​

9.3.5 Forks​

9.3.6 Boom Prop (If Equipped)​

9.3.7 Boom Wear Pad Installation and Lubrication​

9.3.8 Boom Angle Sensor​

Cab​

9.4.1 Serial Number Plate​

9.4.2 Cab Removal/Installation​

9.4.3 Steering Wheel​

9.4.4 Brake System​

9.4.5 Throttle Pedal​

9.4.6 Joystick Assembly​

9.4.7 Ignition Key Switch​

9.4.8 Dash Switches​

9.4.9 Front Wiper Assembly (If Equipped)​

9.4.10 Roof Wiper Assembly (If Equipped)​

9.4.11 Windshield Washer Reservoir (If Equipped)​

9.4.12 Heater System (If Equipped)​

9.4.13 Heater and Air Conditioning System (If Equipped)​

9.4.14 Rear Camera and Reverse Sensor (If Equipped)​

Engine​

9.5.1 Component Terminology​

9.5.2 Diesel Fuel​

9.5.3 Engine Serial Number​

9.5.4 Engine Replacement​

9.5.5 Engine Electrical System​

9.5.6 Surge Tank Cap​

9.5.7 Surge Tank​

9.5.8 Thermostat​

9.5.9 Engine Coolant Temperature Sensor​

9.5.10 Radiator/Oil Cooler Assembly​

9.5.11 Pump Coupling Kit​

9.5.12 Air Filter Assembly​

9.5.13 Relay Assembly​

9.5.14 Alternator​

9.5.15 Starter​

9.5.16 Fuel Tank​

9.5.17 Hydraulic Tank​

9.5.18 Pre-Fuel Filter and Fuel Pump​

9.5.19 Engine Exhaust System​

9.5.20 Air Conditioner (AC) Compressor (If equipped)​

Transmission​

9.6.1 Component Terminology​

9.6.2 Transmission Replacement​

9.6.3 Drive Motor​

9.6.4 Gearbox​

Hydraulic Cylinders​

9.7.1 Sway Cylinder Assembly​

9.7.2 Stabilizer Cylinder Assembly​

9.7.3 Compensator Cylinder Assembly​

9.7.4 Lift Cylinder Assembly​

9.7.5 Tilt Cylinder Assembly​

9.7.6 Extend/Retract Cylinder Assembly​

Hydraulic Valves​

9.8.1 Stabil-Trak Valve​

9.8.2 Steer Select Valve and Park Brake Valve​

9.8.3 Main Control Valve​

9.8.4 WatchDog Valve​

9.8.5 Priority Valve​

9.8.6 Diverter Valve​

Hydraulic Pumps​

9.9.1 Gear Pump​

9.9.2 Drive Pump​

Electrical Components​

9.10.1 Battery​

ClearSky® LED Motion / Amber Beacon (CS550) (if equipped)​

9.11.1 ClearSky® LED Motion / Amber Beacon (CS550) (if equipped)​

Disassembly and Assembly

Drive Assembly​

10.1.1 Axle Assembly​

10.1.2 Transmission Assembly​

Boom​

10.2.1 Disassembly​

10.2.2 Assembly​

Cab​

Engine Components​

10.4.1 Engine Components​

Transmission​

10.5.1 Drive Motor​

10.5.2 Gearbox​

10.5.3 Gear Pump​

10.5.4 Drive Pump​

Hydraulic Cylinders​

10.6.1 Telescope Cylinder​

10.6.2 Lift Cylinder​

10.6.3 Tilt Cylinder​

10.6.4 Compensation Cylinder​

10.6.5 RAS Cylinder​

10.6.6 Sway Cylinder​

Hydraulic Valves​

10.7.1 Main Control Valve​

10.7.2 Watchdog Valve​

10.7.3 Steer Select and Park Brake Valve​

10.7.4 Stabil-Trak Valve​

10.7.5 Priority Valve​

10.7.6 Diverter Valve​

Hydraulic Components​

10.8.1 Hydraulic Oil Reservoir​

Torque/Connection Information

Hydraulic Fittings​

11.1.1 Definitions​

11.1.2 Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections​

11.1.3 Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections​

11.1.4 Assembly Instructions for 37° (JIC) Flare Fittings​

11.1.5 Assembly Instructions for 45° SAE Flare Fittings​

11.1.6 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings​

11.1.7 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)​

11.1.8 Assembly Instructions for Bulkhead (BH) Fittings​

11.1.9 Assembly Instructions for O-Ring Boss (ORB) Fittings​

11.1.10 Assembly Instructions for Adjustable Port End Metric (MFF) Fittings​

11.1.11 Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends​

11.1.12 Assembly Instructions for Adjustable Port End (BSPP) Fittings​

11.1.13 Assembly Instructions for Flange Connections (FL61 and FL62)​

11.1.14 Double Wrench Method​

11.1.15 FFWR and TFFT Methods​

11.1.16 Adjustable Stud End Assembly​

11.1.17 O-ring Installation (Replacement)​

Torque Charts​

11.2.1 SAE​

11.2.2 Metric​

Schematics

Hydraulic Schematics​

Electrical Schematics​