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SECTION 10
8042 Hydraulic Testing (S/N 1167 & Before)
Engine Information
Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,050 ± 50 rpm
Full Speed . . . . . . . . . . . . . . . . . . . . . 2,730 ± 130 rpm
Hydraulic Oil Information
Oil Type - 10W, meets MIL-L-2104C or ISO Grade 46
Capacity - Reservoir . . . . . . . . . . 30.3 gal. (114,7 liter)
Capacity - System . . . . . . . . . . . . . .47.3 gal. (179 liter)
Note 1: To adjust relief settings or pressure reducing
settings, turn the adjustment screw clockwise to
increase pressure or counterclockwise to decrease
pressure.
*Note 2:
On units with S/N 0654 & Before. If the low
brake pressure kit has been installed, as offered in
Service Bulletin STB-2076, issued 5-29-95, refer to test
location .
The hydraulic oil temperature for the pump flow test
should be between 100° F (38° C) and 120° F (49° C)
(tank hot to the touch) during testing.
Equipment Needed To Perform Tests
From Kit P/N 7118782
Circuit Gauge Fittings
4,000 PSI Gauge
(275,6 bar)
#12 Run Tee Swivel Nut
End Reducer #12-8
PD38TX Test Nipple
4,000 PSI Gauge
(275,6 bar)
#8 Run Tee Swivel Nut
PD38TX Test Nipple
1,000 PSI Gauge
(68,9 bar)
#4 Union
PD34BTX Test Nipple
300 PSI Gauge
(20,7 bar)
Connector STR. THD. #4
PD34BTX Test Nipple
1,000 PSI Gauge
(68,9 bar)
#4 Run Tee Swivel Nut
PD34BTX Test Nipple
4,000 PSI Gauge
(275,6 bar)
#6 Elbow 90° Swivel Nut
PD36BTX Test Nipple
TEST
LOCATION
Hydraulic Pump Flow Test
To check flow readings a flow meter capable of measuring 60 GPM (3,8 ltr/sec) and a load valve capable of
6,000 psi (413,4 bar) will be required (not included with kit P/N 7118782).
2,000 psi (137,8 bar) load @ Engine Speed of 2,500 ± 25 rpm — Flow rate should be 39 to 43 GPM (2,5 to 2,7 ltr/sec)
TEST
LOCATION
ADJUST.
LOCATION
COMPONENT
DESCRIPTION
PRESSURE
READINGS
PRESSURE TEST PROCEDURES
Pump Standby
Pressure
550 ± 50 psi
(37,9 ± 3,4 bar)
Loosen load sense line at location to bleed off pressure
and then retighten line. With engine at idle and all hydraulic
functions in neutral position, check pump standby pressure.
Pump Pressure
Compensator
2,950 ± 50 psi
(203,3 ± 3,4 bar)
With engine at idle fully retract boom extend cylinder and hold.
Check pump maximum pressure.
Priority Valve
Steering Relief
2,500 ± 50 psi
(172,3 ± 3,4 bar)
With engine at idle turn the steering wheel all the way to the left
or right and hold while checking pressure. If pressure is not
correct, adjust or replace the relief valve cartridge in the priority
valve (See Note 1).
Attachment Tilt Port
Relief
3,150 ± 50 psi
(217 ± 3,4 bar)
CONSULT FACTORY
Pressure Reducing
Valve In Pressure
Reducing Valve
Block And
Park Brake Release
425 ± 25 psi
(29,3 ± 1,7 bar)
With engine at idle and park brake released check pressure. If
pressure is not correct, adjust or replace the cartridge in the
pressure reducing valve (See Note 1).
Pressure Reducing
Valve In Axle
Stabilizer Valve
Block
60 ± 10 psi
(4,1 ± 0,7 bar)
With engine at idle and boom in the down position check
pressure. If pressure is not correct, adjust or replace the
cartridge in the axle stabilizer valve (See Note 1).
Relief Check Valve
In Axle Stabilizer
Valve Block
100 psi Minimum
(6,9 bar)
With engine at idle and boom down, while frame tilting to the
left check pressure.
Transmission
De-Clutch
425 ± 25 psi
(29,3 ± 1,7 bar)
With engine at idle and park brake engaged check pressure. If
pressure is not correct, adjust or replace the cartridge in the
pressure reducing valve (See Note 1).
Service Brakes
(*See Note 2)
(S/N 0654 & Before)
425 ± 25 psi
(29,3 ± 1,7 bar)
With engine at idle depress the service brakes and check
pressure. If pressure is not correct, adjust or replace the
cartridge in the pressure reducing valve (See Note 1).
Load Sense Variable
0 to 2,950 psi
(0 to 203,3 bar)
With engine at idle operate a specific function (Boom, Frame
Tilt, Attachment Tilt, Auxiliary or Steering) and check pressure.
Service Brakes
(S/N 0655 thru 1167)
350 ± 25 psi
(24,1 ± 1,7 bar)
With engine at idle depress the service brakes and check
pressure. If pressure is not correct, recheck pressure reducing
valve pressure.
9
1
2
3 5
4
6 9
7
8
1
N/A
7
N/A
2
2
N/A N/A
3
3
4
4
N/A
5
5
6
6
7
N/A
9
N/A
Rev. 10/97
- 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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