JLG SkyTrak Telehandlers 8042,10042,10054 ANSI Service & Repair Manual

8990396 C Printed in U.S.A. 02/07 SERVICE MANUAL Models: 8042, 10042, 10054 S/N 13198 thru 19987 and 0160002332 thru 0160029592 OH2462

SECTION CONTENTS Section Subject Page  2003 JLG Industries, Inc. Model 8042, 10042, 10054 Legacy Rev. 10/03 i 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 Subject Page ii Model 8042, 10042, 10054 Legacy Rev. 10/03 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 Subject Page iii Model 8042, 10042, 10054 Legacy Rev. 10/03 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 Subject Page iv Model 8042, 10042, 10054 Legacy Rev. 10/03 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 Accident Prevention Tags

1.1 Model 8042, 10042, 10054 Legacy Rev. 10/03 Section 1 Safety Practices Contents PARAGRAPH TITLE PAGE 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 1.4.1 Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 1.4.2 Hazard Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 1.5 Accident Prevention Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 1.7 Emergency Exit Rear Window (Enclosed Cabs Only) . . . . . . . . . . . . . . . . . . . . . 1.6 1.8 Hazard/Emergency Information Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . 1.8

Safety Practices 1.2 Model 8042, 10042, 10054 Legacy Rev. 10/03 1.1 INTRODUCTION 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-by- step 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. This service manual provides general directions for accomplishing service and repair procedures with tested, effective techniques. Following the procedures in this manual will help assure safety and equipment reliability. Read, understand and follow the information in this manual, and obey all locally approved safety practices, procedures, rules, codes, regulations and laws. Prior to performing any maintenance on the vehicle, consider all factors, circumstances and conditions which can have an effect upon the safety of personnel and equipment, and take appropriate action to ensure the safety of all involved. These instructions cannot cover all details or variations in the equipment, procedures, or processes described, nor provide directions for meeting every possible contingency during operation, maintenance, or testing. When additional information is desired to satisfy a situation not covered sufficiently, consult the local Sky Trak distributor or the JLG Service Department at 1-877-554-5438 or 1-717-485-6657. Many factors contribute to unsafe conditions: carelessness, fatigue, overload, inattentiveness, unfamiliarity, even drugs and alcohol, among others. Although equipment damage can usually be repaired in a brief period of time, death and irreparable injury are permanent. For optimal safety, encourage everyone to think, and to act, safely. Appropriate service methods and proper repair procedures are essential for the safety of the individual doing the work, for the safety of the operator, and for the safe, reliable operation of the vehicle. All references to the right side, left side, front and rear are given from the operator’s seat looking in a forward direction. Provisions for supplementary information are made by JLG in the form of Service Bulletins, Service Campaigns, Service Training Schools, the JLG website, other literature, and through updates to the manual itself. Comments and suggestions for improvement are welcome and encouraged. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication approval. JLG reserves the right to make changes and improvements to its products, and to discontinue the manufacture of any product, at its discretion at any time without public notice or obligation. 1.2 OWNERS/OPERATORS MANUAL The vehicle must be driven and operated as a consequence of, or when performing, service, maintenance and test procedures. The service technician must, therefore, thoroughly read, understand, and follow the Sky Trak 8042, 10042 and 10054 Legacy Telescopic Material Handler Owners/Operators Manual. An owners/operators manual is supplied with each vehicle and must be kept in the owners/operators manual holder (1). In the event that the owners/operators manual is missing, consult the local Sky Trak distributor or the JLG Service Department before proceeding. MH0770 1

1.3 Model 8042, 10042, 10054 Legacy Rev. 10/03 Safety Practices 1.3 TRAINING MECHANICS AS OPERATORS Because it is necessary to move the vehicle to service or maintain the vehicle, it is necessary that all mechanics are OSHA trained and certified as operators. A mechanic trained in the proper operation of the vehicle can better determine whether all functions are operating correctly. At the time of original purchase, the purchaser of this vehicle was instructed by the seller on its proper use. When this vehicle is to be serviced or maintained by someone other than the purchaser, make certain that the mechanic is trained, in accordance with the OSHA regulations listed in the NOTICE below, and reads and understands the SKY TRAK Model 8042, 10042 and 10054 Legacy Telescopic Material Handler Owners/ Operators Manual before operating or maintaining the vehicle. NOTICE: Under OSHA rules, it is the responsibility of the employer to provide operator training. Successful completion and certification of Safety Training for Rough Terrain Forklifts is required. Operator Training Kits are available by calling the Ken Cook Company at 414-466-6060. An order form for these kits is available through our website, http://www.jlg.com. In addition, make sure that the mechanic has completed a walk-around inspection of the vehicle, is familiar with all decals and/or decal plates on the vehicle, and has demonstrated the correct use of all controls. 1.4 SAFETY INFORMATION The following information provides general safety instructions, including examples of hazard statements with signal words, notification of hazards, methods to help avoid hazards, and the consequences of failing to follow the safety information. To avoid possible death or injury, carefully read and follow all safety messages. Fully understand the potential causes of death and injury. In the event of an accident, know where to obtain medical assistance and how to use a first-aid kit and fire extinguisher/fire suppression system. Keep emergency telephone numbers (fire department, ambulance, rescue squad/paramedics, police department, etc.) nearby. If working alone, check with another person routinely to help assure personal safety. The information in this manual does not replace any other safety rules or proper judgement. Governmental authorities and employers also have their own sets of rules, codes, regulations and laws. Before starting work at a site, check with the supervisor or safety coordinator and ask about the safety policy. Learn the safety requirements in effect before operating, maintaining, testing or servicing the vehicle. Safety depends on following safety requirements. 1.4.1 Safety Alert Symbol The exclamation mark within a triangle is the Safety Alert Symbol. This symbol is used to indicate a potential personal injury hazard only. The symbol will not be used to indicate property-damage-only hazards. This symbol means “Attention! Become Alert! Your Safety is Involved!” The symbol is used to attract attention to safety hazards found on the vehicle safety decals and throughout this manual. MC0700

Safety Practices 1.4 Model 8042, 10042, 10054 Legacy Rev. 10/03 1.4.2 Hazard Statements Signal words and messages are used in conjunction with the safety alert symbol to create hazard statements. These hazard statements convey important information about SAFETY. Four types of hazard statements are used within this manual. Each statement indicates the existence and degree of relative risk of the hazard described within the statement that follows a signal word. Explanations of the types of hazard statements are as follows: The signal word “DANGER” indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. The signal word “WARNING” indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. The signal word “CAUTION” indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. The signal word “CAUTION,” used without the safety alert symbol, indicates a potentially hazardous situation which, if not avoided, may result in property damage. For safe maintenance of the vehicle, read, understand and follow all DANGER, WARNING and CAUTION information. 1.5 ACCIDENT PREVENTION TAGS Before beginning any maintenance or service, place an Accident Prevention Tag (1) on both the starter key switch (2) and the steering wheel (3), stating that the vehicle should not be operated. Actual Accident Prevention Tags, which can be punched out and used, are included as the last page in this manual. Retain these Accident Prevention Tags for reuse at a later date. DANGER: WARNING: CAUTION: CAUTION: MC0690   OH1720 1 2 3

1.5 Model 8042, 10042, 10054 Legacy Rev. 10/03 Safety Practices 1.6 SAFETY INSTRUCTIONS Following are general safety statements to consider before performing maintenance procedures on a vehicle. Additional statements related to specific tasks and procedures are located throughout this manual and are listed prior to any work instructions to provide safety information before the potential of a hazard occurs. For all safety messages, carefully read, understand and follow the instructions before proceeding. 1.6.1 Personal Hazards HAIR and CLOTHING: DO NOT wear loose clothing or jewelry. Tie up or restrain hair. Wear the correct safety equipment for the job (including, but not limited to: hard hat; safety shoes; safety glasses, goggles, or face shield; heavy gloves; hearing protection; reflective clothing; wet- weather gear; respirator or filter mask). EYE PROTECTION: Always wear appropriate eye protection when chiseling, grinding, sanding, welding, painting, repairing hydraulic systems, or checking, testing or charging the battery. BREATHING PROTECTION: Wear respiratory protection when grinding or painting. HEARING PROTECTION: Always wear hearing protection in a high noise area. FOOT PROTECTION: Wear protective footwear with reinforced toe caps and slip-resistant soles. LIFTING: NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist. 1.6.2 Equipment Hazards OWNERS/OPERATORS MANUAL: Before operating the vehicle, carefully read, understand and follow the owners/ operators manual. OPERATIONAL PROTECTION: Before operating the vehicle, or returning it for operational use, check that the Operator’s Protective Structure is intact, undamaged, unmodified and secure. LIFTING OF EQUIPMENT: Before using any lifting equipment (chains, slings, brackets, hooks, etc.), verify that it is of the proper capacity, in good working order, and is properly attached. NEVER stand or otherwise become positioned under a suspended load or under raised equipment. The load or equipment could fall or tip. DO NOT use a hoist, jack or jack stands only to support equipment. Always support equipment with the proper capacity blocks or stands properly rated for the load. A hoist or jack failure can allow the equipment to tip or fall. COMPRESSED AIR: Before and during the use of compressed air, wear eye protection and advise all other personnel in the work area that compressed air is about to be used. HAND TOOLS: Always use the proper tool for the job; keep tools clean and in good working order, and use special service tools only as recommended.

JLG SkyTrak Telehandlers 8042,10042,10054 ANSI Service & Repair Manual

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