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162
SECTION 6
SECTION
6
HYDRAULIC
COMPONENTS
HYDRAULIC RESERVOIR
1
8
3
4
5
6
9
7
11
12
26
14
23
9
17
18
19
21
13
Torque to 4 - 5 lb/ft
(5 - 7 Nm)
Hydraulic
Reservoir
To
Brake Valve
To Main
Pump Inlet
See
“Fuel Tank”
In
Drain
Out
PH0103
16
2
22
6
24
25
2
2
16
10
20
18
19
17
1
13
15
14
13
12
11
S/N 9499 & Before
13
8042/10042/10054 Rev. 2/00
- Illustrated Parts Manual 1
- Table of Contents 3
- T of C 2 4
- 2000JLG Industries, Inc 4
- MAIN FRAME 6
- HOODS AND GUARDS 8
- OPERATOR’S CAB - OPEN 10
- OPERATOR’S CAB - CLOSED 12
- CAB DOOR 14
- OPERATOR’S SEAT 16
- CONTROL CONSOLE 18
- TRANSMISSION SHIFT CONTROLS 20
- SECTION 2 25
- THROTTLE PEDAL CONTROL 28
- SERVICE BRAKE PEDAL CONTROL 30
- FRONT WINDSHIELD WIPER 32
- CAB HEATER 34
- AUX. HYDRAULIC CONTROL 36
- SKYLIGHT WINDSHIELD WIPER 40
- SOFT CAB ENCLOSURE 42
- CONVERTER GROUP 46
- FORWARD, REVERSE, LOW AND 2ND 48
- OUTPUT, IDLER AND THIRD 50
- TRANSMISSION CLUTCH GROUPS 52
- CONTROL VALVE ASSEMBLY 54
- EMERGENCY BRAKE 56
- TRANSMISSION MOUNTING 58
- ENGINE CONNECT 60
- CONVERTER AND LAYSHAFT 62
- OIL PRESSURE PUMP 64
- INPUT SHAFT 66
- OIL LEVEL 68
- GEARBOX HOUSING 69
- CLUTCH PACK 1ST GEAR - 1 OF 2 70
- CLUTCH PACK 1ST GEAR - 2 OF 2 72
- CLUTCH PACK 2ND GEAR - 1 OF 2 74
- CLUTCH PACK 2ND GEAR - 2 OF 2 76
- CLUTCH PACK 3RD GEAR - 1 OF 2 78
- CLUTCH PACK 3RD GEAR - 2 OF 2 80
- OUTPUT SHAFT 83
- PARKING BRAKE 84
- POWER TAKE-OFF SHAFT 86
- GEARSHIFT SYSTEM 88
- CONTROL VALVE 90
- OIL TUBES 94
- (S/N 9909 & After) 100
- DRIVE SHAFT - FRONT AND REAR 102
- DIFFERENTIAL CARRIER ASSEMBLY 106
- AXLE STEERING JOINTS 108
- AXLE WHEEL ENDS 110
- 8042/10042/10054 Rev. 2/00 114
- SECTION 3 115
- WHEELS AND TIRES - 8042 116
- (S/N 0118 & Before) 120
- (S/N 0119 thru 1598) 122
- (S/N 1599 & After) 124
- TORSION COUPLER 126
- EXHAUST SYSTEM 128
- AIR CLEANER 130
- FUEL SYSTEM 132
- FUEL SYSTEM (EPA) 134
- POWER STEERING CIRCUIT 136
- CONTROL VALVES CIRCUIT 140
- (S/N 9908 & Before) 144
- SECTION 5 149
- VALVE PLATE ASSEMBLY 154
- TRANSMISSION COOLING CIRCUIT 158
- AUXILIARY HYDRAULIC CIRCUIT 162
- OUTRIGGER HYDRAULIC CIRCUIT 164
- HYDRAULIC RESERVOIR 166
- MAIN PUMP 168
- IMPORTANT: 172
- BOOM EXTEND CYLINDER 173
- BOOM HOIST CYLINDER 176
- FRAME TILT CYLINDER 180
- STABILIZER CYLINDER 182
- SLAVE CYLINDER 185
- ATTACHMENT TILT CYLINDER 188
- OUTRIGGER CYLINDER 190
- SWING CARRIAGE CYLINDER 194
- SIDE TILT CARRIAGE CYLINDER 196
- STEERING CYLINDER 198
- MAIN CONTROL VALVE 202
- SECONDARY CONTROL VALVE 204
- SECTION 6 206
- (S/N 0291 & Before) 210
- (S/N 0292 thru 9908) 212
- (S/N 9909 and After) 214
- SECTION 7 216
- LIGHTING SYSTEM 226
- OUTRIGGER ELECTRICAL HARNESS 228
- DECALS AND PAINT 231
- OUTER BOOM 232
- S/N 0884 & Before Only 232
- SECTION 9 234
- INNER BOOM - 8042 AND 10042 236
- QUICK ATTACH 238
- CARRIAGE 48" 240
- CARRIAGE 60" 242
- CARRIAGE 72" 244
- (Optional) 247
- OUTRIGGERS 250
- SWING CARRIAGE 252
- SHEET MATERIAL HANDLER 254
- UTILITY BUCKET 256
- 31 ± 3 lb/ft (42 ± 4 Nm) 258
- Hose Carrier 260
- (Reference Only) 260
- INNER BOOM - 10054 262
- 8042/10042 Rev. 2/00 264
- (S/N 1084 & Before) 266
- (S/N 1085 & After) 268
- BOOM EXTEND CHAINS - 10054 270
- BOOM RETRACT CHAINS - 10054 272
- TRUSS BOOM 12 AND 15 FT 278
- SECTION 10 281
- GENERAL TROUBLESHOOTING 281
- STABIL-TRAK SYSTEM 282
- Pressure Test Kit 283
- Flowmeter Kit 283
- 8042 Hydraulic Diagram 284
- (S/N 1167 & Before) 284
- From Kit P/N 7118782 285
- Hydraulic Pump Flow Test 285
- (S/N 1168 thru 2194) 286
- (S/N 2195 thru 9908) 288
- From Kit P/N 7133413 291
- TRANSMISSION 298
- (S/N 9908 & Before) 308
- (S/N 9909 & After) 309
- (S/N 8540 & Before) 310
- (S/N 8541 thru 9908) 312
- Auxiliary Circuits 322
- (S/N 2194 & Before) 322
- Auxiliary Schematic 323
- (S/N 10881 & Before) 336
- (S/N 10882 & After) 337
- 10054 Electrical Schematic 341
- 10042 Outrigger Logic Circuit 343
- 10054 Outrigger Logic Circuit 344
- (S/N 0292 & After) 351
- 8042/10042 Stabilizer Circuit 352
- (S/N 0292 thru S/N 9908) 353
- 10054 Stabilizer Circuit 355
- Stabil-TRAK System 358
- Angle Of 359
- Stabil-TRAK 359
- Activation 359
- 8042/10042 362
- Free Pivot Mode 365
- Final Positioning Mode 367
- Locked Mode 369
- Relay Block located 380
- Relays located in Kick Panel 380
- Boom Extend Lockout Relay 390
- Outrigger Pressure Switches 390
- Extend Circuit Solenoid Valve 390
- Park Brake Disconnect Relay 390
- PART NUMBER INDEX 401
- JLG Worldwide Locations 412
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