Jlg Skytrak Telehandlers 8042 10042 10054 Ansi Service Repair Manual
FILE DETAILS:
FILE TYPE:PDF
MANUAL LANGUAGE:ENGLISH
PAGES:906
DOWNLOADABLE:YES
DESCRIPTION:
JLG Industries, Inc. (hereafter, JLG) products meet all applicable industry safety standards. JLG actively promotes safe practices in the use and maintenance of its products through training programs, instructional manuals and the pro-active efforts of all employees involved in engineering, design, manufacture, marketing and service. This manual is designed to provide service technicians with complete information on the maintenance and repair of the Sky Trak 8042, 10042 and 10054 Legacy Telescopic Material Handler. Particular effort has been made to produce a manual to serve as a reference handbook for the experienced service technician, but also provides essential step-bystep procedures for the professional development of the less experienced person. Remember, even the best manual in the world is no substitute for an appropriate education, skill development that comes through experience alone, safety, wise and judicious discernment, and ultimately, proper performance of service procedures.
SCREENSHOT OF THE MANUAL:
TABLE OF CONTENTS:
- Jlg Skytrak Telehandlers 8042 10042 10054 Ansi Service Repair Manual
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
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
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
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
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Joe Jabari –
this manual is exactly what I needed. Love the 3D pictures, it has everything I need to do what I need to do and more.