JLG SkyTrak Telehandlers 8042 10042 10054 ANSI Illustrated Master Parts List Manual ! (8990187-003)
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Illustrated Parts Manual
Service and Maintenance Manual
ANSI
Model
8042
10042
10054
8990187-003
FEBRUARY 2000
Page Page
Table of Contents
8042/10042/10054 Origin 2/00
T of C 1
© 2000 JLG Industries, Inc.
SECTION 1 – MAIN FRAME AND GUARDS
Main Frame .................................................................. 2
Hoods and Guards ....................................................... 4
SECTION 2 – OPERATOR’S CAB AND CONTROLS
Operator’s Cab - Open ................................................. 6
Operator’s Cab - Closed (Optional) .............................. 8
Cab Door .................................................................... 10
Operator’s Seat .......................................................... 12
Control Console.......................................................... 14
Transmission Shift Controls (S/N 9908 & Before) ...... 16
Transmission Shift Controls (S/N 9909 & After) ......... 18
Boom Raise/Lower & Extend/Retract Control ............ 20
Frame Level & Attachment Tilt Control ...................... 22
Throttle Pedal Control ................................................ 24
Service Brake Pedal Control ...................................... 26
Front Windshield Wiper .............................................. 28
Cab Heater (Optional) ................................................ 30
Aux. Hydraulic Control (Optional) ............................... 32
Mirrors ........................................................................ 34
Skylight Windshield Wiper (Optional) ......................... 36
Soft Cab Enclosure (Optional) .................................... 38
SECTION 3 – DRIVE TRAIN
Converter and Transmission Housings
(S/N 9908 & Before)............................................. 40
Converter Group (S/N 9908 & Before) ....................... 42
Forward, Reverse, Low and 2nd
(S/N 9908 & Before)............................................. 44
Output, Idler and Third (S/N 9908 & Before) .............. 46
Transmission Clutch Groups (S/N 9908 & Before) ..... 48
Control Valve Assembly (S/N 9908 & Before) ............ 50
Emergency Brake (S/N 9908 & Before) ..................... 52
Transmission Mounting (S/N 9908 & Before) ............. 54
Engine Connect (S/N 9909 & After) ........................... 56
Converter and Layshaft (S/N 9909 & After) ................ 58
Oil Pressure Pump (S/N 9909 & After) ....................... 60
Input Shaft (S/N 9909 & After) .................................... 62
Gearbox Housing (S/N 9909 & After) ......................... 64
Clutch Pack 1st Gear - 1 of 2 (S/N 9909 & After) ....... 66
Clutch Pack 1st Gear - 2 of 2 (S/N 9909 & After) ....... 68
Clutch Pack 2nd Gear - 1 of 2 (S/N 9909 & After) ...... 70
Clutch Pack 2nd Gear - 2 of 2 (S/N 9909 & After) ...... 72
Clutch Pack 3rd Gear - 1 of 2 (S/N 9909 & After) ...... 74
Clutch Pack 3rd Gear - 2 of 2 (S/N 9909 & After) ...... 76
Output Shaft (S/N 9909 & After) ................................. 78
Parking Brake (S/N 9909 & After) .............................. 80
Power Take-Off Shaft (S/N 9909 & After) .................. 82
Gearshift System (S/N 9909 & After) ......................... 84
Control Valve (S/N 9909 & After) ............................... 86
Transmission Filter & Dipstick (S/N 9909 & After) ......88
Oil Tubes (S/N 9909 & After) ......................................90
Transmission Mounting (S/N 9909 & After) ................92
Drive Shaft - Engine to Transmission
(S/N 9908 & Before) .............................................94
Drive Shaft - Engine to Transmission
(S/N 9909 & After) ................................................96
Drive Shaft - Front and Rear (S/N 9908 & Before) .....98
Drive Shaft - Front and Rear (S/N 9909 & After) ......100
Differential Carrier Assembly ....................................102
Axle Steering Joints ..................................................104
Axle Wheel Ends (S/N 0460 & Before) .....................106
Axle Wheel Ends (S/N 0461 & After) ........................108
Tie Rod and Steering Cylinder Mounting ..................110
Wheels and Tires - 8042 ...........................................112
Wheels and Tires - 10042/10054 ..............................114
SECTION 4 – POWER PLANT
Engine, Radiator and Oil Cooler Mounting
(S/N 0118 & Before) ...........................................116
Engine, Radiator and Oil Cooler Mounting
(S/N 0119 thru 1598) ..........................................118
Engine, Radiator and Oil Cooler Mounting (EPA)
(S/N 1599 & After) ..............................................120
Torsion Coupler (S/N 9909 & After) ..........................122
Exhaust System ........................................................124
Air Cleaner ................................................................126
Fuel System (S/N 1598 & Before) .............................128
Fuel System (EPA) (S/N 1599 & After) .....................130
SECTION 5 – HYDRAULIC CIRCUITS
Power Steering Circuit (S/N 9908 & Before) .............132
Power Steering Circuit (S/N 9909 & After) ................134
Control Valves Circuit (S/N 9908 & Before) ..............136
Control Valves Circuit (S/N 9909 & After) .................138
Boom Raise/Lower & Extend/Retract Circuit
(S/N 9908 & Before) ...........................................140
Boom Raise/Lower & Extend/Retract Circuit
(S/N 9909 & After) ..............................................142
Attachment Tilt and Slave Circuit ..............................144
Frame Tilt and Stabilizer Circuit ................................146
Service Brake and De-Clutch Circuit ........................148
Valve Plate Assembly
(Without Outriggers 8042 Only) ..........................150
Valve Plate Assembly
(With Outriggers 10042/10054 Only) ..................152
Transmission Cooling Circuit (S/N 9908 & Before)...154
Transmission Cooling Circuit (S/N 9909 & After) ......156
Auxiliary Hydraulic Circuit (Optional) ........................158
Outrigger Hydraulic Circuit (10042/10054 Only) .......160
8042/10042/10054 Origin 2/00
Page Page
T of C 2
© 2000JLG Industries, Inc.
SECTION 6 – HYDRAULIC COMPONENTS
Hydraulic Reservoir .................................................. 162
Main Pump (S/N 9908 & Before) .............................. 164
Main Pump (S/N 9909 & After) ................................. 166
Boom Extend Cylinder (Early Production) ................ 168
Boom Extend Cylinder (Current Production) ............ 170
Boom Hoist Cylinder (S/N 5818 & Before) ............... 172
Boom Hoist Cylinder (S/N 5819 & After) .................. 174
Frame Tilt Cylinder ................................................... 176
Stabilizer Cylinder..................................................... 178
Slave Cylinder (Early Production)............................. 180
Slave Cylinder (Current Production) ......................... 182
Attachment Tilt Cylinder ........................................... 184
Outrigger Cylinder (S/N 10881 & Before) ................. 186
Outrigger Cylinder (S/N 10882 & After) .................... 188
Swing Carriage Cylinder ........................................... 190
Side Tilt Carriage Cylinder........................................ 192
Steering Cylinder (S/N 1167 & Before)..................... 194
Steering Cylinder (S/N 1168 & After)........................ 196
Main Control Valve ................................................... 198
Secondary Control Valve .......................................... 200
Directional Control Valves 1 of 2 .............................. 202
Directional Control Valves 2 of 2 .............................. 204
SECTION 7 – ELECTRICAL
Electrical System - Cab Harness
(S/N 0291 & Before) ........................................... 206
Electrical System - Cab Harness
(S/N 0292 thru 9908) ......................................... 208
Electrical System - Cab Harness
(S/N 9909 and After) .......................................... 210
Electrical System - Engine Harness
(S/N 8042-0206 & Before and
10042-0211 & Before) ........................................ 212
Electrical System - Engine Harness
(S/N 8042-0207 thru 1598, 10042-0212 thru
1598, 10054-1598 & Before) .............................. 214
Electrical System - Engine Harness
(S/N 8042-1599 to 5234, 10042-1599 to
5250, 10054-1599 to 5274) ................................ 216
Electrical System - Engine Harness (EPA)
(S/N 8042-5235, 10042-5251,
10054-5275 thru 9908) ...................................... 218
Electrical System - Engine Harness (EPA)
(S/N 9909 and After) .......................................... 220
Lighting System ........................................................ 222
Outrigger Electrical Harness (10042/10054 Only) .... 224
SECTION 8 – DECALS AND PAINT
Decals and Paint ...................................................... 226
SECTION 9 – BOOM AND ATTACHMENTS
Outer Boom.............................................................. 228
Intermediate Boom - 8042 and 10042...................... 230
Inner Boom - 8042 and 10042 ................................. 232
Quick Attach ............................................................. 234
Carriage 48" ............................................................. 236
Carriage 60" (Optional) ............................................ 238
Carriage 72" (Optional) ............................................ 240
Side Tilt Carriage - Early Production (Optional) ....... 242
Side Tilt Carriage - Current Production (Optional) ... 244
Outriggers (10042/10054 Only)................................ 246
Swing Carriage (Optional) ........................................ 248
Sheet Material Handler (Optional)............................ 250
Utility Bucket (Optional)............................................ 252
Primary Intermediate Boom - 10054 ........................ 254
Secondary Intermediate Boom - 10054 ................... 256
Inner Boom - 10054 ................................................. 258
Boom Extend Chains - 8042 and 10042 .................. 260
Boom Retract Chain - 8042 and 10042
(S/N 1084 & Before) .......................................... 262
Boom Retract Chain - 8042 and 10042
(S/N 1085 & After) ............................................. 264
Boom Extend Chains - 10054 .................................. 266
Boom Retract Chains - 10054
(S/N 0884 & Before) .......................................... 268
Boom Retract Chains - 10054
(S/N 0885 thru 1084) ......................................... 270
Boom Retract Chains - 10054 (S/N 1085 & After) ... 272
Truss Boom 12 and 15 Ft. (Optional) ....................... 274
PART NUMBER INDEX........................................... 277
SECTION 10 – GENERAL TROUBLESHOOTING . 287
1
The parts information in this publication is based on data available at the time it was
printed. Because of continual improvement and advancing product design, your vehicle
may not be identical to the parts information shown. Whenever there is a question, obtain
the latest parts information available from your local dealer.
SECTION 1 MAIN FRAME AND GUARDS
2
SECTION 1
MAIN FRAME
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
19
20
21
22
23
24
25
26
27
28
21
10
5
5
5
2
3
4
6
6
10
3
2
4
3
2
4
10
6
12
8
8
6
22
19
20
15
14
16
13
3
3
17
4
6
6
2
Boom Pivot
Frame Tilt Cylinder
Stabilizer Cylinder
Hoist Cylinder
Slave Cylinder
12
1
2
3
4
5
6
7
8
9
10
11
Locate the fracture in bearing outer race
at the clock position shown for each
application (Items 5 & 7).
18
18
PH0012
5
10
5
10
PF0791
29
30
31
8042/10042/10054 Rev. 2/00
3
SECTION 1
Item No. Part Number Qty. Description
MAIN FRAME
1 Consult Factory 1 Weldment, Frame
2 7092292 8 Pin, Hoist, Slave, Tilt, and Stabilizer Cylinders
3 8303782 8 HHCS, 1/2-13 x 4"
4 8305644 8 Nut, Hex Lock Elastic 1/2-13
5 8065640 8 Bearing, 2" I.D.’
6 6620531 AR Conduit, 1 x 5' - Cut to Fit
7 8065641 2 Bearing, 2-3/4" I.D.
8 7124331 AR Conduit, 1/2 x 5' - Cut to Fit
9 7125861 AR Conduit, 3/4 x 5' - Cut to Fit
10 8520013 8 Fitting, Grease
11 8520021 2 Fitting, Grease 90°
12 8303724 8 HHCS, 3/4-10 x 3-1/2"
13 8310111 8 Washer, Flat .81 x 2 x .15"
14 8310067 8 Nut, Hex Lock Elastic 3/4-10
15 7079442 2 Pin, Axle Pivot
16 8307913 AR Spacer, Washer .12" Thick
17 8307912 AR Spacer, Washer .06" Thick
18 8310259 AR Spacer, Washer .09" Thick
19 8303655 2 HHCS, 5/8-11 x 4-1/2"
20 8305643 2 Nut, Hex Lock Elastic 5/8-11
21 7099312 2 Anchor, Cylinder
22 8040258 2 Axle
23 7098563 1 Counterweight
24 8305021 4 Nut, Hex 1"-8
25 5724302 2 Washer, Shim .06" Thick
26 8307012 4 Washer, Lock 1"
27 8310066 2 Washer, Flat .134" Thick
28 8310051 4 HHCS, 1-8 x 4"
KITS
29 7138302 1 Kit, Cylinder Anchor (Includes 1 of Item 5, 1 of Item 10 and 1 of Item 21)
30 7129313 1 Kit, Hoist Cylinder Pivot Left Side (Includes 1 of Item 2, 1 of Item 5 and 1 of Item 10)
31 7129323 1 Kit, Hoist Cylinder Pivot Right Side (Includes 1 of Item 2, 1 of Item 5 and 1 of Item 10)
8042/10042/10054 Rev. 2/00
4
SECTION 1
HOODS AND GUARDS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
29
26
28
16
11
12
9
11
12
11
12
18
11
12
17
18
13
14
15
8
8
19
18
If Gap at top
exceeds .06", shim
Lower Pivot with Item 8.
PH1330
20
20
S/N 9908 & Before
Apply Item 33 to Item 10
31
3
12
11
32
7
PF0810
33
8042/10042/10054 Rev. 2/00
5
SECTION 1
Item No. Part Number Qty. Description
HOODS AND GUARDS
1 7098262 1 Cover, Tool Box
2 7084792 1 Cover, Fuel Tank
3 7111164 1 Cover, Transmission (S/N 9908 & Before)
7150393 1 Cover, Transmission (S/N 9909 & After)
4 NLA 1 Cover, Fuel/Hydraulic Tank (S/N 11020 & Before) For Service, Order P/N 7138614
7138614 1 Cover, Fuel/Hydraulic Tank (S/N 11021 & After)
5 7095452 2 Cover, Side Access
6 7097174 1 Cover, Radiator
7 8344010 3 Hinge
8 8307110 AR Washer, Flat 3/8"
9 8303034 8 TRHDCS, 1/4-20 x 3/4"
10 7111473 1 Cover
11 8307002 18 Washer, Lock 1/4"
12 8305004 18 Nut, Hex 1/4-20
13 8303656 6 HHCS, 5/16-18 x 7/8"
14 8307203 6 Washer, Flat 5/16"
15 8307004 6 Washer, Lock 5/16"
16 8305906 6 Nut, Retaining 5/16"
17 8342807 2 Lock w/Key
18 8342808 AR Key Set
19 8342416 3 Latch, w/Lock and Key
20 5746241 4 Tape, Foam - 38" (Cut to Fit)
21 8580213 2 Grommet
22 8582413 2 Plug, Bumper
23 8303729 6 HHCS, 1/4-20 x 5/8"
24 7084821 1 Shim
25 8310136 4 TRHDCS, 1/4-20 x 1-1/4"
26 7082311 2 Insert
27 8304660 2 SHCS, 3/8-16 x 3/4"
28 8307005 2 Washer, Lock 3/8"
29 5724742 2 Gasket
30 7094682 2 Hinge, Side Access Cover
31 8581007 AR Tape, Foam - 170" (Cut to Fit)
32 8307202 6 Washer, Flat 1/4"
33 8526035 AR Caulk, Clear RTV-08
8042/10042/10054 Rev. 2/00
6
SECTION 2
SECTION 2 OPERATOR S CAB AND CONTROLS
OPERATOR’S CAB - OPEN
PH0532
1
2
3
5
6
7
8
9
12
19
32
33
34
35 36
13
15
23
22
4
30
2
29
28
27
26
33
3
16
18
17
37
40
31
25
10
11
24
20
21
14
14
41
38
39
Torque to
13 - 16 lb/ft
(18 - 22 Nm)
Torque to
50 lb/ft
(68 Nm)
Torque to
210 lb/ft
(285 Nm)
2 Places
Torque to
515 lb/ft
(698 Nm)
2 Places
26
Frame
42
3
8042/10042/10054 Rev. 2/00
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$31.99
This comprehensive parts manual is specifically designed for the JLG SkyTrak Telehandlers 8042 10042 10054 ANSI. It provides easy access to essential information for both professional mechanics and DIY enthusiasts. The manual includes step-by-step instructions, detailed exploded diagrams, and pictures to facilitate correct and efficient completion of tasks.
The manual covers the following parts:
- Section 1: Main Frame & Guards
- Section 2: Operator's Cab & Controls
- Section 3: Drive Train
- Section 4: Power Plant
- Section 5: Hydraulic Circuits
- Section 6: Hydraulic Components
- Section 7: Electrical
- Section 8: Decals & Paint
- Section 9: Boom & Attachments
- Section 10: General Troubleshooting with Table of Contents
With instant access, there are no shipping costs or waiting for physical delivery. The manual is available for download immediately upon secure payment processing. It is compatible with all versions of Windows and Mac, and can be viewed using Adobe Reader and Win.
