Service 31200353 11-02-10 ANSI English

Service Manual
Models 6036, 6042, 8042, 10042 & 10054

6036 S/N0160039338 & After including 0160024571 & 0160037911 6042 S/N 0160039075 & After 8042, 10042 & 10054 S/N 0160029593 Thru TBD
31200353
Revised November 2, 2010
An Oshkosh Corporation Company
EFFECTIVITY PAGE
February 23, 2007 - A - Original Issue Of Manual November 2, 2010 - B - Revised pages 1-4, 2-3 thru 2-18, 3-4, 3-14, 3-49, 3-53, 7-3 thru 7-9, 8-13, 8-16 thru 8-20, 9-2 thru 9-13, 9-17, 9-21, 9-23, 9-24 & 9-25.
31200353
6036, 6042, 8042, 10042, 10054
EFFECTIVITY PAGE
ii
6036, 6042, 8042, 10042, 10054
31200353
SECTION CONTENTS
Section Subject Page
Section 1 Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 1.2 1.3 1.4 1.5 1.6 1.7 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-2 1-2 1-2 1-2 1-3 1-3 1-4
Section 2 General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 2.2 2.3 2.4 2.5 2.6 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid and Lubricant Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service and Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2-2 2-3 2-11 2-15 2-16 2-19
Section 3 Boom
3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12
...........................................................
Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom System - Three Section (6036, 6042, 8042 & 10042) . . . . . . . . . . . . . . . . . . . . . Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom System - Four Section (10054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quick Attach Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-3 3-4 3-4 3-4 3-15 3-15 3-28 3-48 3-49 3-50 3-53 3-54
Section 4 Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 4.2 4.3 4.4 4.5 Operators Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . Operators Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-2 4-3 4-3 4-8 4-9
6036, 6042, 8042, 10042, 10054
Section
Subject
Page
Section 5 Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 Axle, Drive Shaft and Wheel Component Terminology (6036 & 6042) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle, Drive Shaft and Wheel Component Terminology (8042, 10042 & 10054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5-2 5-3 5-4 5-4 5-11 5-14 5-15 5-16 5-18
Section 6 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 6.2 6.3 6.4 6.5 6.6 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6-2 6-3 6-3 6-3 6-3 6-8
Section 7 Engine - Cummins QSB3.3T/QSB4.5T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Isolation Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
7-2 7-4 7-4 7-4 7-5 7-5 7-7 7-8 7-9 7-10 7-12
Section 8 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valves and Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1
8-2 8-4 8-4 8-5 8-21 8-22 8-23 8-32
ii
6036, 6042, 8042, 10042, 10054
Section
Subject
Page
Section 9 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12 9.13 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Heater and Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoids, Sensors and Senders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Monitor and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1
9-2 9-3 9-3 9-3 9-5 9-12 9-13 9-14 9-16 9-17 9-23 9-24 9-26
Section 10 Stabil-TRAK System and Boom Interlock System . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 Stabil-TRAK System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Extend Interlock System Component Terminology (10054 Only) . . . . . . . . . . . . Stabil-TRAK Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stabil-TRAK Electrical Circuit Operation and Troubleshooting (6042, 8042 & 10042) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stabil-TRAK System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stabil-TRAK Boom Interlock Electrical Circuit Operation and Troubleshooting (10054). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom/Outrigger Interlock System Test (10054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stabil-TRAK Hydraulic Circuit Operation and Troubleshooting . . . . . . . . . . . . . . . . .
10-1
10-2 10-3 10-4 10-5 10-7 10-10 10-12 10-14
6036, 6042, 8042, 10042, 10054
iii
Section
Subject
Page
iv
6036, 6042, 8042, 10042, 10054
Section 1 Safety Practices
Contents
PARAGRAPH 1.1 1.2 1.3 1.4 1.5 1.6 TITLE PAGE 1-2 1-2 1-2 1-2 1-3 1-3 1-3 1-3 1-3 1-4 1-4 1-4
1.7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.1 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6036, 6042, 8042, 10042, 10054
1-1
Safety Practices
1.1
INTRODUCTION
1.2
DISCLAIMER
This service manual provides general directions for accomplishing service and repair procedures. 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. 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 consult your local authorized service distributor. Many factors contribute to unsafe conditions: carelessness, fatigue, overload, inattentiveness, unfamiliarity, even drugs and alcohol, among others. 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 machine. All references to the right side, left side, front and rear are given from the operators seat looking in a forward direction. Supplementary information is available from the manufacturer in the form of Service Bulletins, Service Campaigns, Service Training Schools, the manufacturer website, other literature, and through updates to the manual itself.
All information in this manual is based on the latest product information available at the time of publication. The manufacturer 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.
1.3
OPERATION & SAFETY MANUAL
The mechanic must not operate the machine until the Operation & Safety Manual has been read and understood, training has been accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator. An Operation & Safety Manual is supplied with each machine and must be kept in the manual holder located in the cab. In the event that the Operation & Safety Manual is missing, consult your local authorized service distributor before proceeding.
1.4
DO NOT OPERATE TAGS
Place Do Not Operate Tags on the ignition key switch and the steering wheel before attempting to perform any service or maintenance. Remove key and disconnect battery leads.
1-2
6036, 6042, 8042, 10042, 10054
Safety Practices
1.5
SAFETY INFORMATION
1.6
SAFETY INSTRUCTIONS
To avoid possible death or injury, carefully read, understand and comply with all safety messages. 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.
Following are general safety statements to consider before performing maintenance procedures on the telehandler. 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 1.5.1 Safety Alert System and Signal Words
Personal Hazards
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
PERSONAL SAFETY GEAR: Wear all the protective clothing and personal safety gear necessary to perform the job safely. This might include heavy gloves, safety glasses or goggles, filter mask or respirator, safety shoes or a hard hat. LIFTING: NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
1.6.2
Equipment Hazards
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. 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.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
6036, 6042, 8042, 10042, 10054
1-3
Safety Practices 1.6.3 General Hazards

appropriate container and dispose of in accordance with prevailing environmental regulations. RADIATOR CAP: The cooling system is under pressure, and escaping coolant can cause severe burns and eye injury. To prevent personal injury, NEVER remove the radiator cap while the cooling system is hot. Wear safety glasses. Turn the radiator cap to the first stop and allow pressure to escape before removing the cap completely. Failure to follow the safety practices could result in death or serious injury. FLUID FLAMABILTITY: DO NOT service the fuel or hydraulic systems near an open flame, sparks or smoking materials. NEVER drain or store fluids in an open container. Engine fuel and hydraulic fluid are flammable and can cause a fire and/or explosion. DO NOT mix gasoline or alcohol with diesel fuel. The mixture can cause an explosion. PRESSURE TESTING: When conducting any test, only use test equipment that is correctly calibrated and in good condition. Use the correct equipment in the proper manner, and make changes or repairs as indicated by the test procedure to achieve the desired result. LEAVING MACHINE: Lower the forks or attachment to the ground before leaving the machine. TIRES: Always keep tires inflated to the proper pressure to help prevent tipover. DO NOT over-inflate tires. NEVER use mismatched tire types, sizes or ply ratings. Always use matched sets according to machine specifications. MAJOR COMPONENTS: Never alter, remove, or substitute any items such as counterweights, tires, batteries or other items that may reduce or affect the overall weight or stability of the machine. BATTERY: DO NOT charge a frozen battery.Charging a frozen battery may cause it to explode. Allow the battery to thaw before jump-starting or connecting a battery charger.
SOLVENTS: Only use approved solvents that are known to be safe for use. HOUSEKEEPING: Keep the work area and operators cab clean, and remove all hazards (debris, oil, tools, etc.). FIRST AID: Immediately clean, dress and report all injuries (cuts, abrasions, burns, etc.), no matter how minor the injury may seem. Know the location of a First Aid Kit, and know how to use it. CLEANLINESS: Wear eye protection, and clean all components with a high-pressure or steam cleaner before attempting service. When removing hydraulic components, plug hose ends and connections to prevent excess leakage and contamination. Place a suitable catch basin beneath the machine to capture fluid run-off. Check and obey all Federal, State and/or Local regulations regarding waste storage, disposal and recycling.
1.6.4
Operational Hazards
ENGINE: Stop the engine before performing any service unless specifically instructed otherwise. VENTILATION: Avoid prolonged engine operation in enclosed areas without adequate ventilation. SOFT SURFACES AND SLOPES: NEVER work on a machine that is parked on a soft surface or slope. The machine must be on a hard level surface, with the wheels blocked before performing any service. FLUID TEMPERATURE: NEVER work on a machine when the engine, cooling or hydraulic systems are hot. Hot components and fluids can cause severe burns. Allow systems to cool before proceeding. FLUID PRESSURE: Before loosening any hydraulic or diesel fuel component, hose or tube, turn the engine OFF. Wear heavy, protective gloves and eye protection. NEVER check for leaks using any part of your body; use a piece of cardboard or wood instead. If injured, seek medical attention immediately. Diesel fluid leaking under pressure can explode. Hydraulic fluid and diesel fuel leaking under pressure can penetrate the skin, cause infection, gangrene and other serious personal injury. Relieve all pressure before disconnecting any component, part, line or hose. Slowly loosen parts and allow release of residual pressure before removing any part or component. Before starting the engine or applying pressure, use components, parts, hoses and pipes that are in good condition, connected properly and are tightened to the proper torque. Capture fluid in an 1-4
1.7
SAFETY DECALS
Check that all safety decals are present and readable on the machine. Refer to the Operation & Safety Manual supplied with machine for information.
6036, 6042, 8042, 10042, 10054
Section 2 General Information and Specifications
Contents
PARAGRAPH 2.1 2.2 TITLE PAGE 2-2 2-3 2-3 2-7 2-10 2-11 2-11 2-11 2-12 2-12 2-13 2-15 2-16 2-16 2-17 2-18 2-19
2.3
2.4 2.5
2.6
Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.2 Mertic Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.3 Hydraulic Hose Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.1 Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2 Hydraulic Cylinder Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.3 Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.4 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.5 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service and Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.1 10, 1st 50 & 50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.2 250, 1st 500 & 500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.3 1000 & 2000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6036, 6042, 8042, 10042, 10054
2-1
General Information and Specifications
2.1
REPLACEMENT PARTS AND WARRANTY INFORMATION
OH0281
Before ordering parts or initiating service inquiries, make note of the machine serial number. The machine serial number plate (1) is located as indicated in the figure. Note: The replacement of any part on this machine with any other than JLG authorized replacement parts can adversely affect the performance, durability, or safety of the machine, and will void the warranty. JLG disclaims liability for any claims or damages, whether regarding property damage, personal injury or death arising out of the use of unauthorized replacement parts. A warranty registration form must be filled out by the JLG distributor, signed by the purchaser and returned to JLG when the machine is sold and/or put into use. Registration activates the warranty period and helps to assure that warranty claims are promptly processed. To guarantee full warranty service, verify that the distributor has returned the business reply card of the warranty registration form to JLG.
2-2
6036, 6042, 8042, 10042, 10054
2.2
2.2.1
TORQUE CHARTS
SAE Fastener Torque Chart
Values for Zinc Yellow Chromate Fasteners

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Size TPI Bolt Dia Tensile Clamp Load Stress Area Sq In 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.0364 Sq In 0.0524 0.0580 0.0775 0.0878 0.1063 0.1187 0.1419 0.1599 0.1820 0.2030 0.2260 0.2560 0.3340 0.3730 0.4620 0.5090 0.6060 0.6630 0.7630 0.8560 0.9690 1.0730 1.1550 1.3150 1.4050 1.5800 LB Torque (Dry or Loctite 263) K= 0.20 IN-LB [N.m]
Torque Loctite 242 or 271 OR Vibra-TITE 111 or 140 K=.18

IN-LB [N.m]
Torque Loctite 262 OR Vibra-TITE 131 K=0.15

IN-LB [N.m]
In 4 6 8 10 1/4 40 48 32 40 32 36 24 32 20 28 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12 6 12 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 In 0.3125 0.3125 0.3750 0.3750 0.4375 0.4375 0.5000 0.5000 0.5625 0.5625 0.6250 0.6250 0.7500 0.7500 0.8750 0.8750 1.0000 1.0000 1.1250 1.1250 1.2500 1.2500 1.3750 1.3750 1.5000 1.5000
1320 1580 1800 2860 3280 LB 4720 5220 7000 7900 9550 10700 12750 14400 16400 18250 20350 23000 30100 33600 41600 45800 51500 59700 68700 77000 87200 96600 104000 118100 126500 142200
43 60 68 143 164 FT-LB 25 25 45 50 70 80 105 120 155 170 210 240 375 420 605 670 860 995 1290 1445 1815 2015 2385 2705 3165 3555
5 7 8 16 19 [N.m] 35 35 60 70 95 110 145 165 210 230 285 325 510 570 825 910 1170 1355 1755 1965 2470 2740 3245 3680 4305 4835
129 148 FT-LB 20 25 40 45 65 70 95 110 140 155 190 215 340 380 545 600 770 895 1160 1300 1635 1810 2145 2435 2845 3200
15 17 [N.m] 25 35 55 60 90 95 130 150 190 210 260 290 460 515 740 815 1045 1215 1580 1770 2225 2460 2915 3310 3870 4350 FT-LB 20 20 35 35 50 60 80 90 115 130 160 180 280 315 455 500 645 745 965 1085 1365 1510 1785 2030 2370 2665 [N.m 25 25 50 50 70 80 110 120 155 175 220 245 380 430 620 680 875 1015 1310 1475 1855 2055 2430 2760 3225 3625
5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2
NOTES:
1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = 10% 3. * ASSEMBLY USES HARDENED WASHER MY4660J
6036, 6042, 8042, 10042, 10054
2-3
General Information and Specifications 2.2.1 SAE Fastener Torque Chart (Continued)

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Size TPI Bolt Dia Tensile Clamp Load Stress Area Sq In 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.0364 Sq In 0.0524 0.0580 0.0775 0.0878 0.1063 0.1187 0.1419 0.1599 0.1820 0.2030 0.2260 0.2560 0.3340 0.3730 0.4620 0.5090 0.6060 0.6630 0.7630 0.8560 0.9690 1.0730 1.1550 1.3150 1.4050 1.5800 LB Torque (Dry or Loctite 263) K= 0.20 IN-LB [N.m]
Torque Loctite 242 or 271 OR Vibra-TITE 111 or 140 K=.18

IN-LB [N.m]

IN-LB [N.m]
In 4 6 8 10 1/4 40 48 32 40 32 36 24 32 20 28 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12 6 12 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 In 0.3125 0.3125 0.3750 0.3750 0.4375 0.4375 0.5000 0.5000 0.5625 0.5625 0.6250 0.6250 0.7500 0.7500 0.8750 0.8750 1.0000 1.0000 1.1250 1.1250 1.2500 1.2500 1.3750 1.3750 1.5000 1.5000
1320 1580 1800 2860 3280 LB 4720 5220 7000 7900 9550 10700 12750 14400 16400 18250 20350 23000 30100 33600 41600 45800 51500 59700 68700 77000 87200 96600 104000 118100 126500 142200
43 60 68 143 164 FT-LB 25 25 45 50 70 80 105 120 155 170 210 240 375 420 605 670 860 995 1290 1445 1815 2015 2385 2705 3165 3555
5 7 8 16 19 [N.m] 35 35 60 70 95 110 145 165 210 230 285 325 510 570 825 910 1170 1355 1755 1965 2470 2740 3245 3680 4305 4835
129 148 FT-LB 20 25 40 45 65 70 95 110 140 155 190 215 340 380 545 600 770 895 1160 1300 1635 1810 2145 2435 2845 3200
15 17 [N.m] 25 35 55 60 90 95 130 150 190 210 260 290 460 515 740 815 1045 1215 1580 1770 2225 2460 2915 3310 3870 4350 FT-LB 20 20 35 35 50 60 80 90 115 130 160 180 280 315 455 500 645 745 965 1085 1365 1510 1785 2030 2370 2665 [N.m 25 25 50 50 70 80 110 120 155 175 220 245 380 430 620 680 875 1015 1310 1475 1855 2055 2430 2760 3225 3625
5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2
NOTES:
1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = 10% 3. * ASSEMBLY USES HARDENED WASHER MY4660J
2-4
6036, 6042, 8042, 10042, 10054
SOCKET HEAD CAP SCREWS

Magni Coating*
Size TPI Bolt Dia Tensile Stress Area Clamp Load See Note 4 Torque (Dry) K = .17
Torque Loctite 242 or 271 OR Vibra-TITE 111 or 140 OR Precoat 85 K=0.16

IN-LB [N.m]

IN-LB [N.m]
In 4 6 8 10 1/4 40 48 32 40 32 36 24 32 20 28 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12 6 12 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 In 0.3125 0.3125 0.3750 0.3750 0.4375 0.4375 0.5000 0.5000 0.5625 0.5625 0.6250 0.6250 0.7500 0.7500 0.8750 0.8750 1.0000 1.0000 1.1250 1.1250 1.2500 1.2500 1.3750 1.3750 1.5000 1.5000
Sq In 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.0364 Sq In 0.0524 0.0580 0.0775 0.0878 0.1063 0.1187 0.1419 0.1599 0.1820 0.2030 0.2260 0.2560 0.3340 0.3730 0.4620 0.5090 0.6060 0.6630 0.7630 0.8560 0.9690 1.0730 1.1550 1.3150 1.4050 1.5800
LB
IN-LB
[N.m]
2860 3280 LB 4720 5220 7000 7900 9550 10700 12750 14400 16400 18250 20350 23000 30100 33600 41600 45800 51500 59700 68700 77000 87200 96600 104000 118100 126500 142200
122 139 FT-LB 20 25 35 40 60 65 90 100 130 145 180 205 320 355 515 570 730 845 1095 1225 1545 1710 2025 2300 2690 3020
14 16 [N.m] 25 35 50 55 80 90 120 135 175 195 245 280 435 485 700 775 995 1150 1490 1665 2100 2325 2755 3130 3660 4105
114 131 FT-LB 20 20 35 40 55 60 85 95 125 135 170 190 300 335 485 535 685 795 1030 1155 1455 1610 1905 2165 2530 2845
13 15 [N.m] 25 25 50 55 75 80 115 130 170 185 230 260 410 455 660 730 930 1080 1400 1570 1980 2190 2590 2945 3440 3870 FT-LB 20 20 35 35 50 60 80 90 115 130 160 180 280 315 455 500 645 745 965 1085 1365 1510 1785 2030 2370 2665 [N.m] 25 25 50 50 70 80 110 120 155 175 220 245 380 430 620 680 875 1015 1310 1475 1855 2055 2430 2760 3225 3625
5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = 10% *3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. MY4670J
6036, 6042, 8042, 10042, 10054
2-5
SOCKET HEAD CAP SCREWS

Zinc Yellow Chromate Fasteners*
Size TPI Bolt Dia Tensile Stress Area Clamp Load See Note 4 Torque (Dry) K = .20 IN-LB [N.m] Torque (Loctite 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85 K=0.18 IN-LB [N.m] Torque (Loctite 262TM TM or Vibra-TITE 131) K=0.15 IN-LB [N.m]
In 4 6 8 10 1/4 40 48 32 40 32 36 24 32 20 28 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 12 7 12 7 12 6 12 6 12 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 In 0.3125 0.3125 0.3750 0.3750 0.4375 0.4375 0.5000 0.5000 0.5625 0.5625 0.6250 0.6250 0.7500 0.7500 0.8750 0.8750 1.0000 1.0000 1.1250 1.1250 1.2500 1.2500 1.3750 1.3750 1.5000 1.5000
Sq In 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.0364 Sq In 0.0524 0.0580 0.0775 0.0878 0.1063 0.1187 0.1419 0.1599 0.1820 0.2030 0.2260 0.2560 0.3340 0.3730 0.4620 0.5090 0.6060 0.6630 0.7630 0.8560 0.9690 1.0730 1.1550 1.3150 1.4050 1.5800
LB
2860 3280 LB 4720 5220 7000 7900 9550 10700 12750 14400 16400 18250 20350 23000 30100 33600 41600 45800 51500 59700 68700 77000 87200 96600 104000 118100 126500 142200
143 164 FT-LB 25 25 45 50 70 80 105 120 155 170 210 240 375 420 605 670 860 995 1290 1445 1815 2015 2385 2705 3165 3555
16 19 [N.m] 35 35 60 70 95 110 145 165 210 230 285 325 510 570 825 910 1170 1355 1755 1965 2470 2740 3245 3680 4305 4835
129 148 FT-LB 20 25 40 45 65 70 95 110 140 155 190 215 340 380 545 600 775 895 1160 1300 1635 1810 2145 2435 2845 3200
15 17 [N.m] 25 35 55 60 90 95 130 150 190 210 260 290 460 515 740 815 1055 1215 1580 1770 2225 2460 2915 3310 3870 4350 FT-LB 20 20 35 35 50 60 80 90 115 130 160 180 280 315 455 500 645 745 965 1085 1365 1510 1785 2030 2370 2665 [N.m] 25 25 50 50 70 80 110 120 155 175 220 245 380 430 620 680 875 1015 1310 1475 1855 2055 2430 2760 3225 3625
5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2
2-6
6036, 6042, 8042, 10042, 10054
General Information and Specifications 2.2.2 Mertic Fastener Torque Chart

CLASS 8.8 METRIC BOLTS CLASS 8 METRIC NUTS
Torque Loctite Torque Loctite 262 242 or 271 OR OR Vibra-TITE 131 Vibra-TITE 111 or 140
[N.m] 1.2 1.9 2.8 5.6 9.4 16 23 45 79 126 197 271 383 523 663 970 1320 1790 2300 3680 [N.m] 1.4 2.3 3.4 6.8 12 19 28 55 97 154 241 331 469 639 811 1130 1530 2090 2690 4290
Size
PITCH
Tensile Stress Area
Clamp Load
Torque (Dry or Loctite 263TM)
Torque (Lub)
Sq mm 3 3.5 4 5 6 7 8 10 12 14 16 18 20 22 24 27 30 33 36 42 0.5 0.6 0.7 0.8 1 1 1.25 1.5 1.75 2 2 2.5 2.5 2.5 3 3 3.5 3.5 4 4.5 5.03 6.78 8.78 14.20 20.10 28.90 36.60 58.00 84.30 115 157 192 245 303 353 459 561 694 817 1120
KN 2.19 2.95 3.82 6.18 8.74 12.6 15.9 25.2 36.7 50.0 68.3 83.5 106.5 132.0 153.5 199.5 244.0 302.0 355.5 487.0
[N.m] 1.3 2.1 3.1 6.2 11 18 26 50 88 140 219 301 426 581 737 1080 1460 1990 2560 4090
[N.m] 1.0 1.6 2.3 4.6 7.9 13 19 38 66 105 164 226 320 436 553 810 1100 1490 1920 3070
6036, 6042, 8042, 10042, 10054
2-7
General Information and Specifications 2.2.2 Mertic Fastener Torque Chart (Continued)

CLASS 10.9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*
Torque Lube OR Loctite 242 or 271 OR Vibra-TITE 111 or 140 K= 0.18
[N.m]
Size
PITCH
Tensile Stress Area
Clamp Load
Torque Dry or Loctite 263

K = 0.20
Torque Loctite 262 OR Vibra-TITE 131

K=0.15 [N.m]
Sq mm 3 3.5 4 5 6 7 8 10 12 14 16 18 20 22 24 27 30 33 36 42 0.5 0.6 0.7 0.8 1 1 1.25 1.5 1.75 2 2 2.5 2.5 2.5 3 3 3.5 3.5 4 4.5 5.03 6.78 8.78 14.20 20.10 28.90 36.60 58.00 84.30 115 157 192 245 303 353 459 561 694 817 1120
KN 3.13 4.22 5.47 8.85 12.5 18.0 22.8 36.1 52.5 71.6 97.8 119.5 152.5 189.0 222.0 286.0 349.5 432.5 509.0 698.0
[N.m]
25.2 36.5 70 125 200 315 430 610 830 1065 1545 2095 2855 3665 5865
22.7 32.8 65 115 180 280 385 550 750 960 1390 1885 2570 3300 5275
18.9 27.4 55 95 150 235 325 460 625 800 1160 1575 2140 2750 4395
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = 10% *3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, MY4700J ADDITIONAL TESTING IS REQUIRED.
2-8
6036, 6042, 8042, 10042, 10054
General Information and Specifications 2.2.2 Mertic Fastener Torque Chart (Continued)
Magni Coating*
CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE*
Torque Lube OR Loctite Torque Torque Dry 242 or 271 Loctite 262 or OR OR Loctite 263 Vibra-TITE Vibra-TITE 131 111 or 140 K = .17 K = .16 K = .15
[N.m] [N.m] [N.m]
Size
PITCH
Tensile Stress Area
Clamp Load See Note 4
Sq mm 3 3.5 4 5 6 7 8 10 12 14 16 18 20 22 24 27 30 33 36 42 0.5 0.6 0.7 0.8 1 1 1.25 1.5 1.75 2 2 2.5 2.5 2.5 3 3 3.5 3.5 4 4.5 5.03 6.78 8.78 14.20 20.10 28.90 36.60 58.00 84.30 115 157 192 245 303 353 459 561 694 817 1120
kN
12.5 18.0 22.8 36.1 52.5 71.6 97.8 119.5 152.5 189.0 220.0 286.0 349.5 432.5 509.0 698.0
13 21 31 61 105 170 265 365 520 705 900 1315 1780 2425 3115 4985
12 20 29 58 100 160 250 345 490 665 845 1235 1680 2285 2930 4690
11 19 27 54 95 150 235 325 460 625 790 1160 1575 2140 2750 4395
6036, 6042, 8042, 10042, 10054
2-9
General Information and Specifications 2.2.3 Hydraulic Hose Torque Chart

O-Ring Face Seal & JIC Torque Chart Size 4 6 8 10 12 16 20 24 32 ORFS 13 lb-ft (18 Nm) 23 lb-ft (31 Nm) 40 lb-ft (54 Nm) 60 lb-ft (81 Nm) 74 lb-ft (100 Nm) 115 lb-ft (156 Nm) 170 lb-ft (230 Nm) 200 lb-ft (271 Nm) N/A JIC 13 lb-ft (18 Nm) 23 lb-ft (31 Nm) 40 lb-ft (54 Nm) 60 lb-ft (81 Nm) 85 lb-ft (115 Nm) 115 lb-ft (156 Nm) 170 lb-ft (230 Nm) 200 lb-ft (271 Nm) 270 lb-ft (366 Nm) Flats Method 1.5 to 1.75 1 to 1.5 1.5 to 1.75 1.5 to 1.75 1.0 to 1.5 0.75 to 1.0 0.75 to 1.0 0.75 to 1.0 0.75 to 1.0 Flats Method: 1. If equipped, lubricate o-ring with hydraulic oil. Hand tighten the swivel nut until no lateral movement of the swivel nut can be detected. Average hand torque is 3 lb-ft (4 Nm). 2. Mark a dot on one of the swivel nut flats and another dot in line on the hex of the adapter its connecting to. 3. Use the double wrench method while tightening to avoid hose twist. 4. After the connection has been properly tightened, mark a straight line across the connecting parts, not covering the dots indicating that the connection has been properly tightened.
Note: By definition the Flats Method will contain some variance. Use the Flats Method only when accessibility with a torque wrench is not possible. Torque Wrench: 1. Identify the appropriate application and refer to the above chart for the correct torque value. 2. If equipped, lubricate o-ring with hydraulic oil. Hand tighten the swivel nut until no lateral movement of the swivel nut can be detected. Average hand torque is 3 lb-ft (4 Nm). 3. Use the double wrench method while tightening to avoid hose twist. 4. Torque wrench must be held at the center of the grip. Apply constant force until it clicks. 5. After the connection has been properly tightened, mark a straight line across the connecting parts indicating that the connection has been properly tightened.
2-10
6036, 6042, 8042, 10042, 10054
2.3
2.3.1
SPECIFICATIONS
Travel Speeds
6036 & 6042 8042, 10042 & 10054 3.5 mph (5,6 km/hr) 6 mph (9,7 km/hr) 14 mph (23 km/hr) 20 mph (32 km/hr)
First Gear Second Gear Third Gear Fourth Gear
3.5 mph (5,6 km/hr) 5.5 mph (9,7 km/hr) 13.5 mph (22 km/hr) 20 mph (32 km/hr)
2.3.2
Hydraulic Cylinder Performance
Note: Machine with no attachment or load, engine at full throttle, hydraulic oil above 130 F (54 C) minimum, engine at operating temperature. APPROXIMATE TIMES (seconds) FUNCTION Boom Extend Boom Retract Boom Lift Retracted Boom Lower Retracted Attachment Tilt - Up Attachment Tilt - Down Frame Sway Left to Right with Boom Down Frame Sway Left to Right with Boom Above 40 and Emergency Brake Engaged Frame Sway Right to Left with Boom Down Frame Sway Right to Left with Boom Above 40 and Emergency Brake Engaged Outrigger - Left or Right, UP or DOWN Outrigger - Left and Right, UP or DOWN 6036 Less than 15.0 Less than 15.0 Less than 15.0 Less than 10.0 4.0-6.0 3.5-5.5 3.0-6.0 6042 Less than 19.0 Less than 19.0 Less than 17.0 Less than 13.0 6.5 6.0 12.0-15.0 8042 Less than 19.0 Less than 17.0 Less than 17.5 Less than 15.5 Less than 8.0 Less than 11.0 5.5-12.0 10042 Less than 19.0 Less than 17.0 Less than 17.5 Less than 15.5 Less than 8.0 Less than 11.0 5.5-12.0 10054 Less than 19.0 Less than 17.0 Less than 17.5 Less than 15.5 Less than 8.0 Less than 11.0 3-6
23.0-3.03
23.0-33.0
23.0-33.0
23.0-33.0
4.0-8.0
12.0-15.0
4.0-8.0
4.0-8.0
4.0-8.0
26.0-52.0
26.0-52.0
26.0-52.0
26.0-52.0
4.0-9.0 4.0-10.0
4.0-9.0 4.0-10.0
6036, 6042, 8042, 10042, 10054
2-11
General Information and Specifications 2.3.3 Electrical System

Battery Type, Rating Quantity Reserve Capacity Group/Series Alternator (6036 & 6042) Alternator (8042, 10042 & 10054) 12 BCI, Negative (-) Ground, Maintenance Free 3.3 Liter - 1, 4.5 Liter - 2 3.3 Liter - 700 Cold Cranking Amps @ 0 F (-18 C) 4.5 Liter - 900 Cold Cranking Amps @ 0 F (-18 C) Group 31 12V, 120 Amps 12V, 100 Amps
2.3.4
Engine Performance Specifications

Description 6036 & 6042 Cummins QSB3.3 201 in3 (3,3 liters) 1100 rpm 2600 rpm 99 hp (74 Kw) @ 2600 rpm 306 lb-ft (415 Nm) @ 1600 rpm Fuel Injection Dry Type, Replaceable Primary and Safety Elements
Engine Make/Model Displacement Low Idle High Idle Horsepower Peak Torque Fuel Delivery Air Cleaner
Description Engine Make/Model Displacement Low Idle High Idle Horsepower Peak Torque Fuel Delivery Air Cleaner
8042, 10042 & 10054

Cummins QSB4.5 274 in3 (4,5 liters) 1000 rpm 2500 rpm 110 hp (82 Kw) @ 2500 rpm 360 lb-ft (488 Nm) @ 1500 rpm Fuel Injection Dry Type, Replaceable Primary and Safety Elements
2-12
6036, 6042, 8042, 10042, 10054
General Information and Specifications 2.3.5 Tires
Note: Standard wheel lug nut torque is 450 20 lb-ft (610 27 Nm). Note: Pressure for foam filled tires are for initial fill ONLY. a. 6036 Size Tire Type Minimum Ply/ Star Rating 12 Ply Fill Type Pneumatic Foam - Approx 542 lb (246 kg) Pneumatic Foam - Approx 542 lb (246 kg) Pneumatic Foam - Approx 542 lb (246 kg) Pneumatic Foam - Approx 600 lb (272 kg) Pneumatic Foam - Approx 600 lb (272 kg) Pneumatic Foam - Approx 600 lb (272 kg) Pressure 55 psi (3,8 bar) 65 psi (4,5 bar) 55 psi (3,8 bar) 65 psi (4,5 bar) 55 psi (3,8 bar) 75 psi (5,2 bar) 55 psi (3,8 bar) 58 psi (3,9 bar) 55 psi (3,8 bar) 58 psi (3,9 bar) 58 psi (3,9 bar) 73 psi (5,0 bar)
13.0 x 24
G-2/L-2 Bias Ply Traction
13.0 x 24
G-3/L-3 Bias Ply Rock
12 Ply
13.0 R 24
G-2/L-2 Radial
1 Star
15.5 x 25
12 Ply
15.5 x 25
12 Ply
15.5 R 25
G-2/L-2 Radial
1 Star
b. 6042 Size Tire Type Minimum Ply/ Star Rating 12 Ply Fill Type Pneumatic Foam - Approx 542 lb (246 kg) Pneumatic Foam - Approx 542 lb (246 kg) Pneumatic Foam - Approx 542 lb (246 kg) Pneumatic Foam - Approx 600 lb (272 kg) Pneumatic Foam - Approx 600 lb (272 kg) Pneumatic Foam - Approx 600 lb (272 kg) Pressure 70 psi (4,8 bar) 65 psi (4,5 bar) 70 psi (4,8 bar) 65 psi (4,5 bar) 70 psi (4,8 bar) 65 psi (4,5 bar) 65 psi (4,5 bar) 58 psi (3,9 bar) 65 psi (4,5 bar) 58 psi (3,9 bar) 65 psi (4,5 bar) 58 psi (3,9 bar)
13.0 x 24
13.0 x 24
12 Ply
13.0 R 24
G-2/L-2 Radial
1 Star
15.5 x 25
12 Ply
15.5 x 25
12 Ply
15.5 R 25
G-2/L-2 Radial
1 Star
6036, 6042, 8042, 10042, 10054
2-13
c. 8042 Size Tire Type Minimum Ply/ Star Rating 12 Ply Fill Type Pneumatic Foam - Approx 600 lb (272 kg) Pneumatic Foam - Approx 600 lb (272 kg) Pneumatic Foam - Approx 600 lb (272 kg) Pressure 70 psi (4,8 bar) 58 psi (3,9 bar) 70 psi (4,8 bar) 58 psi (3,9 bar) 70 psi (4,8 bar) 73 psi (5,0 bar)
15.5 x 25
15.5 x 25
12 Ply
15.5 R 25
G2/L-2 Radial
1 Star
d. 10042 & 10054 Size Tire Type Minimum Ply/ Star Rating 12 Ply Fill Type Pneumatic Foam - Approx 785 lb (356 kg) Pneumatic Foam - Approx 785 lb (356 kg) Pneumatic Foam - Approx 785 lb (356 kg) Pressure 60 psi (4,1 bar) 51 psi (3,5 bar) 60 psi (4,1 bar) 51 psi (3,5 bar) 73 psi (5,0 bar) 73 psi (5,0 bar)
17.50 x 25
17.50 x 25
12 Ply
17.50 x 25
G-2/L-2 Radial
1 Star
2-14
6036, 6042, 8042, 10042, 10054
2.4
FLUID AND LUBRICANT CAPACITIES
Engine Crankcase Oil Capacity with Filter Change Oil Type Fuel Tank Capacity Type of Fuel Cooling System System Capacity Type of Fluid Hydraulic System System Capacity 6036 & 6042 - 57 gallons (216 liters) 8042 - 58 gallons (218 liters) 10042 & 10054 - 64 gallons (242 liters) 32 Gallon (122 liters) Mobilfluid 424 Tractor Hydraulic Fluid 4 gallons (15,1 liters) 50/50 ethylene glycol & water 37 gallons (140 liters) #2 Diesel Cummins QSB3.3 - 7.4 quarts (7,0 liters) Cummins QSB4.5 - 11.6 quarts (10,9 liters) 15W-40 CH
Reservoir Capacity to Full Mark Type of Fluid Transmission Capacity with Filter Change Filter Type of Fluid Axles Differential Housing Capacity Wheel End Capacity Type of Fluid
3 gallons (13,6 liters) 1.5 quarts (1,4 liters) Mobilfluid 424 Tractor Hydraulic Fluid
Front Axle - 11.2 quarts (10,6 liters) Rear Axle - 11.2 quarts (10,6 liters) Front Axle - 2.22 quarts (2,1 liters) Rear Axle - 1.85 quarts (1,75 liters) Mobilfluid 424 Tractor Hydraulic Fluid
6036, 6042, 8042, 10042, 10054
2-15
2.5
SERVICE AND MAINTENANCE SCHEDULES

10, 1st 50 & 50 Hour
2.5.1
EVERY
10
Check Fuel Level
Drain Fuel/ Water Seprator
Air Filter Restriction Indicator
Check Engine Oil Level
Check Hydraulic Oil Level
Check Tire Condition & Pressure
Check Transmission Oil Level
Check Engine Coolant Level
50
LB/F T (N m)
1st
Check Wheel Lug Nut Torque
Check Boom Chain Tension
Change Engine Oil & Filter
Change Transmission Filter
Change Hydraulic Filter
EVERY
50
Check Boom Wear Pads
Check Battery
Check Washer Fluid Level (if equipped)
Lubrication Schedule
MAQ0020
2-16
6036, 6042, 8042, 10042, 10054
General Information and Specifications 2.5.2 250, 1st 500 & 500 Hour
EVERY
250
Change Engine Oil and Filter*
Check Axle Oil Level
Check Wheel End Oil Levels
Change Air Filter Elements
Check Boom Chain
500
1st
Change Axle Oil
Change Wheel End
EVERY
500
LB/F T (N m)
Change Fuel Filter & Strainer
Check Wheel Lug Nut Torque

MAQ0030
Note: Engine oil and filter service interval can be extended. See Engine Manual for details.
6036, 6042, 8042, 10042, 10054
2-17
General Information and Specifications 2.5.3 1000 & 2000 Hour
EVERY
1000
Change Transmission Oil & Filter
Change Hydraulic Fluid & Filters
Change Axle Oil
Change Wheel End Oil
Check Axle Brake Discs
Check Boom Chain Tension
Check Boom Wear Pads
Check Fan Belt
Check Air Intake System
Lubricate Boom Chain
EVERY
2000
Change Engine Coolant

MAQ0040
2-18
6036, 6042, 8042, 10042, 10054
2.6
LUBRICATION SCHEDULES
a. 50 Hour (6036, 6042, 8042 & 10042)
EVERY
MYSTIK TETRIMOLY (NLGI 2 GC-LB)
50
OH4160
6036, 6042, 8042, 10042, 10054
2-19

b. 50 Hour (10054)
EVERY
50
OH4240
2-20
6036, 6042, 8042, 10042, 10054

c. 250 Hour
EVERY
250
OH4170
6036, 6042, 8042, 10042, 10054
2-21

d. 1000 Hour
1000
EVERY
OH4180
2-22
6036, 6042, 8042, 10042, 10054
Section 3 Boom
Contents
PARAGRAPH 3.1 3.2 3.3 3.4 TITLE PAGE 3-3 3-4 3-4 3-4 3-4 3-5 3-6 3-8 3-9 3-11 3-12 3-15 3-15 3-15 3-15 3-18 3-19 3-20 3-21 3-23 3-24 3-25 3-28 3-28 3-29 3-31 3-31 3-31 3-32 3-34 3-37 3-39 3-40 3-43
3.5 3.6
3.7
Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom System - Three Section (6036, 6042, 8042 & 10042) . . . . . . . . . . . . . . . . . 3.3.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.2 Third Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.3 Second Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.4 First Boom Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.5 First Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.6 Second Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.7 Third Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom System - Four Section (10054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.1 Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.2 Third Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.3 Second Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.4 First Boom Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.5 First Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.6 Second Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.7 Third Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.8 Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.1 Boom Chain Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.2 Inspection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.3 Expose Chains for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.4 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.5 Boom Chain Tension Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.6 Boom Chain Tension Adjustment (6036, 6042, 8042 & 10042) . . . . . . . . 3.7.7 Boom Chain Tension Adjustment (10054). . . . . . . . . . . . . . . . . . . . . . . . . 3.7.8 Extend Chains Removal and Replacement (6036, 6042, 8042 & 10042). 3.7.9 Retract Chain Removal and Replacement (6036, 6042, 8042 & 10042) . 3.7.10 Extend Chains Removal and Replacement (10054) . . . . . . . . . . . . . . . . . 3.7.11 Retract Chain Removal and Replacement (10054) . . . . . . . . . . . . . . . . .
6036, 6042, 8042, 10042, 10054
3-1
Boom
3.8 Quick Attach Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.1 Disconnecting from an Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.2 Connecting to an Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.3 Quick Attach Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.4 Quick Attach Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.1 Wear Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.2 Wear Pad Installation and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.1 Boom Chain Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.2 Inspection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.3 Expose Chains for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.4 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48 3-48 3-48 3-48 3-48 3-49 3-49 3-49 3-50 3-50 3-50 3-52 3-53 3-53 3-54
3.9
3.10
3.11 3.12
3-2
6036, 6042, 8042, 10042, 10054
Boom
3.1
BOOM SYSTEM COMPONENT TERMINOLOGY
The following illustrations identify the components that are referred to throughout this section.
THREE SECTION BOOM (6036, 6042, 8042 & 10042)
THIRD BOOM SECTION
BOOM EXTEND CHAINS
BOOM RETRACT CHAIN
SECOND BOOM SECTION
FIRST BOOM SECTION
EXTEND/RETRACT CYLINDER ATTACHMENT TILT CYLINDER
BOOM PROXIMITY SENSOR SLAVE CYLINDER LIFT/LOWER CYLINDER
QUICK ATTACH
FOUR SECTION BOOM (10054) SECOND & THIRD BOOM SECTION EXTEND CHAINS THIRD BOOM SECTION FOURTH BOOM SECTION RETRACT CHAIN SECOND BOOM SECTION SECOND & THIRD BOOM SECTION RETRACT CHAIN
FOURTH BOOM SECTION EXTEND CHAIN FOURTH BOOM SECTION
FIRST BOOM SECTION
BOOM PROXIMITY SENSOR EXTEND/RETRACT CYLINDER ATTACHMENT TILT CYLINDER
BOOM PROXIMITY SENSOR
SLAVE CYLINDER LIFT/LOWER CYLINDER

MH4351
QUICK ATTACH
6036, 6042, 8042, 10042, 10054
3-3
Boom
3.2
SAFETY INFORMATION
WARNING
DO NOT service the machine without following all safety precautions as outlined in the Safety Practices section of this manual.
WARNING
NEVER weld or drill the boom unless approved in writing by the manufacturer. The structural integrity of the boom will be impaired if subjected to any repair involving welding or drilling.
3.3
BOOM SYSTEM - THREE SECTION (6036, 6042, 8042 & 10042)

Boom System Operation
3.4.1
Boom Removal
3.3.1
1. Remove any attachment from the quick attach assembly. Refer to Section 3.8.1, Disconnecting from an Attachment. Note: If replacing the third section boom, remove the quick attach from the third section. Refer to Section 3.8.3, Quick Attach Removal. 2. Park the machine on a hard, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 3. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 4. Open the rear door. Allow the system fluids to cool. 5. Move the Attachment Tilt joystick in both directions to relieve any trapped pressure in the Attachment Tilt system. If the machine is equipped with Auxiliary controls, move the Auxiliary hydraulic joystick in both directions to relieve any trapped pressure in the Auxiliary hydraulic system. 6. Properly disconnect the battery. 7. Label, disconnect and cap the hydraulic hoses at the rear of the boom. Cap all fittings to keep dirt and debris from entering the hydraulic system. 8. Label and disconnect the boom proximity sensor at the rear of the boom. 9. Remove the pin from the rod end of the slave cylinder being careful not to drop the cylinder. Lower the cylinder onto the frame rails. 10. Remove the pin from the rod end of the lift/lower cylinders. Lower the cylinders onto the frame rails. 11. Confirm that the boom assembly is balanced with the sling and remove the boom assembly pivot pin. 12. Lift the boom assembly from the machine and lower onto suitable supports
The three section boom assembly consists of first, second and third boom section assemblies with double top boom extend chains and a single retract chain. Boom extension and retraction is accomplished via hydraulic power and chain movement. As the Extend/Retract hydraulic cylinder, which is anchored at the rear of the second boom section and the rear of the first boom section, begins to extend, it forces the second boom section out of the first boom section. The second and third boom sections are connected by extend and retract chains. These chains are routed around sheaves on the second boom section. As the second boom section is forced out, the extend chain pulls the third boom section out of the second boom section. As hydraulic pressure is applied to the retract port on the Extend/Retract cylinder, the second boom section is pulled back into the first boom section, and retract chain pulls the third boom section back into the second section. This mechanical linkage formed by the chains and supporting hardware extends and retracts the second and third boom sections at the same rate. The first boom section does not extend or retract, but lifts and lowers via action of the lift/lower cylinder.
3.4
BOOM ASSEMBLY MAINTENANCE
These instructions must be completed in sequence. The third boom section must be removed before removing the second boom section. The third and second boom section must be removed at one time before removing the first boom section. Before beginning, conduct a visual inspection of the machine and work area, and review the task about to be undertaken. Read, understand and follow these instructions.
3-4
6036, 6042, 8042, 10042, 10054
Boom 3.4.2 Third Boom Section Removal

1 2
1. Remove any attachment from the quick attach assembly. Refer to Section 3.8.1, Disconnecting from an Attachment. Note: If replacing the third section boom, remove the quick attach from the third section. Refer to Section 3.8.3, Quick Attach Removal. 2. Park the machine on a hard, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 3. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 4. Open the rear door. Allow the system fluids to cool. 5. Move the Attachment Tilt joystick in both directions to relieve any trapped pressure in the Attachment Tilt system. If the machine is equipped with Auxiliary controls, move the Auxiliary hydraulic joystick in both directions to relieve any trapped pressure in the Auxiliary hydraulic system. 6. Label, disconnect and cap the hoses attached to the Attachment Tilt cylinder. Cap all fittings to keep dirt and debris from entering the hydraulic system. 7. If the machine is equipped with Auxiliary hydraulics, label, cap and remove the hoses from the bulkhead fittings. 8. If replacing the third boom section with a new boom section: Remove the female coupler, male nipple and bulkhead fittings from the bulkhead plate inside the boom head. 9. Remove the rear cover from the boom. 10. If equipped with Auxiliary hydraulics, inside the third boom section, loosen, but DO NOT remove the capscrews securing the left side wear pad and hose clamp support bracket to the top of the third boom section.
MH2841
11. Remove the stack clamps (1) and hose clamp support bracket (2) to the left side of the third boom section.
MH0871
12. Pull the free ends of the hydraulic hoses (3) from the inside the third boom section and out of the rear of the boom. Allow the hoses to hang from the rear of the boom. 13. Remove the top and side wear pads and spacers to the inside of the second boom section. Label and tag each set of wear pads being removed.
6036, 6042, 8042, 10042, 10054
3-5
Boom
7
MH0912
14. At the rear of the boom, measure the amount of threads protruding beyond each locknut (4) and record the measurement for reassembly. Remove the two locknuts and flat washers holding both extend chain clevis to the anchor plate on the first boom section.
MH2551
Note: Record the location of the shoulder bolt (6) to ensure correct installation. 16. At the rear of the boom, locate the retract chain (7) on the right side of the boom. In front of the retract chain sheave, locate the shoulder bolt which holds the retract chain to the anchor plates on the third boom section. Remove the locknut from the shoulder bolt. Allow the retract chain to hang out the rear of the boom. Note: If replacing the third boom section with a new boom section, the quick attach assembly and the Attachment Tilt cylinder should be removed at this time. Refer to Section 3.8.3, Quick Attach Removal.. If the third boom section is not to be replaced, the quick attach assembly and Attachment Tilt cylinder can remain in place.
MH0921
15. At the front of the second boom section, pull both extend chains (5) out from between the second and third boom sections. The extend chains can remain anchored between the yoke plates on the first boom section. Loop both chains over the top of the chain sheave and lay the chains on top of the boom.
17. Using a sling or suitable support, pull the third boom section straight out of the second boom section. Reposition the slings as needed so the third boom section balances when removed from the second boom section. Set the boom section down on a hard, level surface. Support the boom as needed to prevent it from tipping over. 18. At the rear of the third boom section, remove the remaining wear pads, shims and hardware. Label and tag each set of wear pads being removed. 19. Inspect all wear pads for wear. Refer to Section 3.9, Boom Wear Pads.
3.4.3
Second Boom Section Removal
1. At the front of the first boom section, remove the top, bottom and side wear pads to the inside of the boom. Label and tag each set of wear pads being removed.
3-6
6036, 6042, 8042, 10042, 10054
Boom
2. Remove the capscrews and lockwashers holding the center wear pad spacer mount to the front of the first boom section. Label and tag each set of wear pads being removed. 8. Pull the hose reel, with hoses, out the back of the second boom section. Allow the hose reel assembly to slide down the hoses and rest it on the floor. 9. Label and remove the hoses from the hose reel. The center bolt can remain in place to hold the hose reel and side plates together.
10
MH1021
MH1451
3. At the rear of the second boom section, remove the capscrew and lockwasher holding the retract chain sheave pin (8) to the mounting plate inside the boom. 4. Remove the retract chain sheave pin from the mount and the retract chain sheave. Remove the retract chain sheave from the second boom section. 5. Inspect the bushings inside the sheave. Replace the bushings if there are any signs of wear. Inspect the pin for wear or damage. Replace the pin if showing signs of wear.
10. Label, disconnect and cap the hydraulic hoses from the bottom tube assemblies at the mounting plate (10). 11. Pull the hose ends out from between the second and first boom sections and out the rear of the boom. 12. Using a suitable sling or support, secure the front of the Extend/Retract cylinder.
11 9
MH1051
MH1501
13. Remove the retaining ring from one side of the Extend/Retract cylinder rod end mounting pin (11). 14. Using a sling or suitable support, pull the second boom section straight out of the first boom section. Reposition the slings as needed so the second boom section balances when removed from the first boom section. Set the second boom section down on blocks on a hard, level surface. 15. Remove the remaining wear pads. Label and tag each set of wear pads being removed. 3-7
6. At the rear of the second boom section, remove the hose reel assembly (9), lower wear pad and spacer. Reassemble the capscrews, lockwashers and flat washers to hold the lower wear pad in place for second boom section removal. 7. Remove hose reel side plate, lower left side wear pad and shims. Label and tag each set of wear pads being removed.
6036, 6042, 8042, 10042, 10054
Boom
16. Inspect all wear pads for wear. Refer to Section 3.9, Boom Wear Pads.
14
12
MH1131
4. Label, disconnect and cap the hydraulic hoses from the bulkhead fittings on the mounting plate (14). Remove the tubes from the bulkhead fittings. 5. At the rear right side of the boom, label, disconnect and cap the boom Extend/Retract hoses from the bulkhead fittings on the mounting plate. Cap the fittings to keep dirt and debris from entering the hydraulic system.
MH1091
17. Remove the extend chain sheave (12).
3.4.4
First Boom Section Removal

16
1. Use a suitable overhead lifting device and sling attached to the Lift/Lower cylinder; remove slack from the sling.
15
MH1151
6. Remove the tube clamps (15) and clamp covers to the Extend and Retract tubes under the boom.
13
MH1111
2. At the underside of the boom, locate the retract chain locknut (13). Measure the amount of threads protruding beyond the locknut and record that measurement for reassembly of the chain. Remove the locknut and flat washer. 3. Remove the retract chain by pulling it out through the rear of the boom. Place the retract chain on a clean surface.
7. At the rear right side of the boom, label, disconnect and cap the Extend and Retract tubes (16) from the bulkhead fittings. Cap the fittings to keep dirt and debris from entering the hydraulic system.
17
MH1201
3-8
6036, 6042, 8042, 10042, 10054
Boom
8. Label, disconnect and cap the hydraulic hoses attached to both slave cylinders (17). Cap all fittings to keep dirt and debris from entering the hydraulic system. 9. Support the slave cylinder on the right side of the machine. Remove the rod end pins securing the cylinder in position. Move the cylinder to a clean, flat surface. Repeat this procedure for the left side slave cylinder. 15. Lower the base end of the Extend/Retract cylinder and remove the rod end of the cylinder from the retainer at the front of the boom. Place the Extend/ Retract cylinder on a clean, flat surface. 16. At the front of the first boom section, remove rubber bumper to the Extend/Retract cylinder retainer. Inspect the rubber bumper. If it is in good condition, the rubber bumper can be reused. If the bumper is showing signs of cracking or deterioration, it should be replaced. 17. Remove the two yoke plates to the mount at the front of the boom. Inspect the yoke plates for wear or distortion. If any wear or distortion is detected, both plates must be replaced. If no wear is detected, the plates can remain assembled to the extend chain clevis. 18. Inspect all wear pads for wear. Refer to Section 3.9, Boom Wear Pads.
18
3.4.5
MH1221
First Boom Section Installation
10. Remove the boom proximity sensor (18) from the right side boom pivot mounting plate. 11. Securely block up or support the right Lift/Lower cylinder. Remove the rod end pin. Repeat this procedure for the left Lift/Lower cylinder.
1. On the rear of the boom, assemble the Extend and Retract bulkhead fittings to the mounting plate on the right side. Insert the fittings from the bottom up and secure in place with the bulkhead fitting nuts on the top side. Tighten securely. Repeat this procedure for the Attachment Tilt fittings on the left side. Note: Keep the caps on the threaded ends of the fittings to protect the threads from damage and to keep dirt and debris from entering the hydraulic system. 2. If equipped with Auxiliary hydraulics, assemble the Auxiliary hydraulic bulkhead fittings to the mounting plate on the left side. Insert the fittings from the bottom up into the outer set of holes and secure in place with the bulkhead fitting nuts on the top side. Tighten securely.
19
MH1241
12. Remove the boom pivot pins (19) to the frame. While removing the pins, note the location and quantity of shims between the outer boom and frame. 13. Using a sling or suitable support, carefully lift the first boom section away from the machine. Set the boom section down on a hard, level surface. Support the boom as required to allow removal of the Extend/ Retract cylinder from the underside of the boom. 14. Use a hoist and slings to support the Extend/Retract cylinder. At the base end of the cylinder, remove a retaining ring from one side of the cylinder base end pin.
3. Using a sling, position the Extend/Retract cylinder to its original orientation under the boom. 4. Coat the base end of the cylinder with anti-seize compound. Insert the base end cylinder pin through both mounting ears and the base end of the Extend/ Retract cylinder. Secure the pin in place with a retaining ring on each side of the pin. 5. Lift the rod end of the Extend/Retract cylinder enough to insert the threaded stud on the rubber bumper into the hole in the Extend/Retract cylinder retainer. Secure the rubber bumper in place with a locknut. Tighten securely. Lower the rod end of the Extend/Retract cylinder, and allow it to rest on the rubber bumper.
6036, 6042, 8042, 10042, 10054
3-9
Boom
6. Using a suitable hoist and slings, lift the boom assembly and position the boom on the frame. Align the mounting plates on the frame between the mounting hubs on each side of the boom assembly. Lower the boom assembly until the holes in the boom assembly and the mounting plates align. 7. On the end of the boom pivot pin, closest to the capscrew hole, mark the capscrew mounting hole location. Coat the entire pin with anti-seize compound. 8. Insert the pivot pin from the outside of the boom assembly, making sure the marks for the capscrew mounting hole stay in line with the capscrew mounting holes in the boom mounting hub.
1
11. Use a hoist or suitable support to position the right side Slave cylinder to its original orientation onto the lower cylinder mount. Coat the entire Slave cylinder pin with anti-seize compound. Insert the pin through the rod end of the cylinder and the self-aligning bearing. Secure with lockbolt. Repeat procedure for left side Slave cylinder. 12. Install the boom proximity sensor on the right side mounting plate. With the boom properly shimmed, position the boom assembly all the way to the right side.
2
MH1391
20
13. Insert the boom proximity sensor through the hole in the right side mounting plate. Install the jam nut onto the boom proximity sensor on the inside of the plate. Adjust the inner and outer jam nuts on the sensor until the gap (2) between the sensor and the boom is 0.12 in (3 mm). Torque the inside jam nut to 36 lb-in (4,1 Nm), to hold the sensor in position.
MH1381
9. Shim the boom as required using the shims (20) to maintain a 0.10 (2,5 mm) maximum gap (1) between the boom mounting hub and the self aligning bearing in the frame. If an additional shim is required to maintain the maximum gap, the extra shim MUST be inserted on the right side of the boom. 10. Align the rod end of the right Lift/Lower cylinder with the self-aligning bearing on the boom assembly. Coat the entire Lift/Lower cylinder pin with anti-seize compound. Insert the pin through the rod end of the cylinder and the self-aligning bearing. Secure with lock bolt. Repeat procedure with left Lift/Lower cylinder.
3 4
MH1151
14. Install the Extend and Retract tubes (3) to the inside bulkhead fitting and the Extend/Retract cylinder. 15. Install the Extend and Retract tube clamp halves (4). 16. Uncap and connect the hydraulic hoses and attach to their appropriate cylinder locations.
3-10
6036, 6042, 8042, 10042, 10054
Boom
17. Install the Extend and Retract and Auxiliary (if equipped) tube assemblies to their appropriate bulkhead fittings. Secure with tube clamps. 18. Uncap and connect the previously labeled Attachment Tilt and Auxiliary (if equipped) hydraulic hoses to their appropriate bulkhead fittings.
3.4.6
Second Boom Section Installation
MH1481
1. At the rear of the second boom section, assemble the retract chain sheave (6) to the mounting ears on the right side of the boom. Place the sheave between the ears and insert the sheave pin from the left side. Align the hole in the pin retainer plate with the threaded hole in the left ear. Secure the pin.
MH1461
2. Apply grease to the grease fitting in the pin. Spin the sheave by hand to ensure the sheave spins freely on the pin and to distribute grease evenly.
19. Inside the rear of the boom, slide the threaded clevis end (5) of the retract chain down the right side of the boom. Guide the threaded part of the clevis out through the hole in the tab on the bottom of the boom. Pull threaded part of clevis all the way through tab. 20. Coat the entire threaded portion of the clevis with multi-purpose grease. Install a flat washer and locknut onto the clevis. Thread the nut onto the clevis until the threads are flush with the top of the nut. 21. Install the bottom wear pads to the first boom section with the previously used hardware.
MH1501
3. Install the hose reel assembly (7), left side and bottom wear pads to the rear of the second boom section. 4. Install the boom side and top wear pads. 5. Grease the sections of the boom in areas where the wear pads will slide.
6036, 6042, 8042, 10042, 10054
3-11
Boom
6. Before installing the second boom section into the first boom section, place a string (heavy enough to pull the Attachment Tilt and Auxiliary hydraulic hoses) down the inside of the boom. Allow the string to hang out the rear of the boom. Pull the other end out the opening on the left side of the boom where the hoses will exit the boom. Position the strings all the way to the left side of the first boom section. 7. Using a suitable sling, carefully slide the second boom section into the first boom section. Leave enough room at the front of the boom to install the center wear pad. 8. Install the center wear pad mount and wear pad to the bottom front of the first boom section. 9. Install the side and top wear pads to the front of the first boom section.
3.4.7
Third Boom Section Installation

.00 96 cm) 1 8 (49
MH1401
1. Stretch the Attachment Tilt and Auxiliary (if equipped) hoses out straight on a flat surface. Measure from the male end of each hose back 196 in (498 cm) and apply tape around each hose at that point. The tape is for proper tensioning of the hoses during reassembly of the hose clamps. 2. Slide the elbow ends of the hoses down the third boom section and out the boom head. Be careful not to cross the hoses as you pull them out. Secure the hoses in place with hose clamps. DO NOT tighten the hose clamps at this time.
8
MH1091
10. Install the double extend chain sheave (8) to the front of the second boom section. 11. With the sling still in place, install the rod end of the Extend/Retract cylinder, pin and retaining ring. 12. Install the front, bottom wear pads in the second boom section.
10
MH1631
3. Install the hose clamp support bracket (9) and top left side wear pad to the third boom section (Auxiliary hydraulics only). 4. Position the Attachment Tilt and Auxiliary hydraulic hoses with the edge of the tape at the hose clamps (10). Hold the hoses in this position, and tighten the hose clamps.
3-12
6036, 6042, 8042, 10042, 10054
Boom
5. Install the top, bottom and side wear pads to the rear of the third boom section. If the machine is equipped with Auxiliary hydraulics, the top left wear pad is already installed.
11 12
MH1651
6. Lay the two extend chains (11) on the top of the third boom section with the threaded clevis ends toward the rear of the boom. Coat the threads on each clevis with multi-purpose grease and insert the clevis through the holes in the anchor plate. Install a washer and locknut onto each clevis. Tighten the locknut enough so the threads are even with the top of the locknut. 7. At the rear of the third boom section, place the male ends of the hydraulic hoses in the third boom section to prevent damage while installing the third boom section into the second boom section. 8. Grease the sections of the boom in areas where the wear pads will slide. 9. Using a suitable sling, carefully slide the third boom section into the second boom section. Leave enough room at the front of the boom to install the remaining wear pads. 10. Install the top and side wear pads to the inside of the second boom section. 11. Pull the male ends of the hydraulic hoses out the rear of the third boom section. Stretch the hoses out straight behind the machine.
MH1691
12. Assemble the hoses to the hose reel (12) at the rear of the boom. Note: Keep the hoses in the same order as they come from the hose clamps. DO NOT allow the hoses to cross. 13. Tie the strings (positioned inside the first boom section) to the male end of the hydraulic hoses coming off the bottom of the hose reel assembly. 14. Working from the front of the boom, pull each hose through the boom assembly through the opening at the bottom of the first boom section. 15. Remove the strings from the hoses.
13
MH1451
16. At the front of the first boom section, assemble the hose assemblies and tube assemblies to the mounting plate (13). Note: Where the hose assemblies come out of the outer boom, lubricate the radius in the first boom section with soap and water to allow proper tensioning of hoses. 17. Place the retract chain up around the retract chain sheave on the right side of the boom. Stretch the chain forward and place the clevis between the two anchor plates. Align the hole in the clevis with the second hole from the rear of the anchor plates.
6036, 6042, 8042, 10042, 10054
3-13
Boom
18. Insert the shoulder bolt from the top down and secure in place with a locknut.
15
3.4.8
Boom Installation
1. Park the machine on a hard, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Using suitable slings, balance the boom assembly, lift and guide the boom assembly into place. Align the frame pivot bores with the boom assembly pivot bores. Install the boom pivot pin.
14
SH1871
19. Assemble the two extend chains to the mount if the yoke plates (14) were removed from the extend chains. Secure in place with a locknut. Tighten the locknut securely; but the yoke plates must pivot freely. 20. Align the holes in the yoke plates with the hole in the mount on the first boom section. Coat the shoulder bolt (15) with anti-seize compound and insert the shoulder bolt through the yoke plates and the mount on the boom. Secure in place with a locknut. Tighten the locknut securely; but the yoke plates must pivot freely. 21. Install the quick attach and Attachment Tilt cylinder to the front of the boom. Refer to Section 3.8.4, Quick Attach Installation. 22. If necessary, install the Auxiliary hydraulic fittings to the front of the boom. 23. Uncap and connect the previously labeled hoses to the Attachment Tilt cylinder. 24. Properly connect the battery. 25. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 26. Start the engine and operate all boom functions several times. Check the chain tension again and adjust as necessary. Check for leaks, and check the hydraulic fluid level in the tank; add fluid if required. 27. Clean up all debris, hydraulic fluid, etc., in, on, near and around the machine. 28. Install the rear cover to the boom. 29. Close and secure the rear door.
3. Move the Attachment Tilt joystick in both directions to relieve any trapped pressure in the Attachment Tilt system. If the machine is equipped with Auxiliary controls, move the Auxiliary hydraulic joystick in both directions to relieve any trapped pressure in the Auxiliary hydraulic system. 4. With the sling still in place, install the rod end of the slave cylinder, pin and bolt. Apply Loctite 242 torque lock bolt to 100-110 lb-ft (135-149 Nm). 5. With the sling still in place, install the rod end of each lift/lower cylinder, pin and bolt. Apply Loctite 242 torque lock bolt to 200-215 lb-ft (271-291 Nm). 6. Uncap and connect the hydraulic hoses at the rear of the boom. 7. Connect the boom proximity sensor at the rear of the boom. 8. Recheck wear pad gaps to ensure they meet the minimum gap requirement. Shim as necessary. 9. Ensure that the boom chains are properly adjusted. Refer to Section 3.7.6, Boom Chain Tension Adjustment (6036, 6042, 8042 & 10042). 10. Properly connect the battery. 11. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 12. Start the engine and operate all boom functions several times. Check for leaks, and check the hydraulic fluid at the reservoir; add fluid if required.
3-14
6036, 6042, 8042, 10042, 10054
Boom
3.5
BOOM SYSTEM - FOUR SECTION (10054)

Boom System Operation
3.6.1
Fourth Boom Section Removal
3.5.1
The four section boom consists of the fourth, third, second and first boom assemblies with double intermediate boom extend chains, a single inner boom extend chain, a single inner boom retract chain and a single intermediate boom retract chain. As the Extend/Retract hydraulic cylinder, which is anchored at the front of the second boom section, and the rear of the first boom section begins to extend, it forces the second boom section out of the first boom section. The fourth, third, second and first boom sections are connected by extend and retract chains. These chains are routed around sheaves on the third and second boom sections. As the second and third boom sections are forced out, the extend chain pulls the fourth boom section out of the third. As hydraulic pressure is applied to the retract port on the Extend/Retract cylinder, the third boom section is pulled back into the fourth boom section, and the retract chain pulls the third and fourth boom sections back into the second boom section. This mechanical linkage formed by the chains and supporting hardware, extends and retracts the second, third and fourth boom sections at the same rate. The first boom section does not extend or retract, but lifts and lowers via action of the Lift/Lower cylinders.
1. Remove any attachment from the quick attach assembly. Refer to Section 3.8.1, Disconnecting from an Attachment. Note: If replacing the fourth section boom, remove the quick attach from the fourth section. Refer to Section 3.8.3, Quick Attach Removal. 2. Park the machine on a hard, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 3. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 4. Open the rear door. Allow the system fluids to cool. 5. Move the Attachment Tilt joystick in both directions to relieve any trapped pressure in the Attachment Tilt system. If the machine is equipped with Auxiliary controls, move the Auxiliary hydraulic joystick in both directions to relieve any trapped pressure in the Auxiliary hydraulic system. 6. Label, disconnect and cap the hoses attached to the Attachment Tilt cylinder. Cap all fittings to keep dirt and debris from entering the hydraulic system. 7. If the machine is equipped with Auxiliary hydraulics, label, cap and remove the hoses from the bulkhead fittings. If replacing the fourth boom section with a new boom section: Remove the female coupler, male nipple and bulkhead fittings from the bulkhead plate inside the boom head. 8. Remove the rear cover from the boom.
3.6
BOOM ASSEMBLY MAINTENANCE
These instructions must be completed in sequence. The fourth boom section must be removed before removing the third boom section. The third boom section must be removed before removing the second boom section.The fourth, third and second boom section must be removed at one time before removing the first boom section. Before beginning, conduct a visual inspection of the machine and work area, and review the task about to be undertaken. Read, understand and follow these instructions.
WARNING
NEVER weld or drill the boom unless approved in writing by the manufacturer. The structural integrity of the boom will be impaired if subjected to any repair involving welding or drilling.
16
MH1451
9. At the front of the first boom section, label and remove the hydraulic hoses from the bottom tube assemblies at the mounting plate (16). Cap the hose ends. 3-15
6036, 6042, 8042, 10042, 10054
Boom
17
MH1691
MH1791
10. Label and remove the hydraulic hoses from the hose reel (17).
18
16. At the front of the boom, disconnect the fourth boom section extend chain clevis (1) from the anchor plates on the third boom section. Pull the extend chain clevis from between the plates and lay over the front of the fourth boom section (2). 17. Remove the extend chain sheave. 18. Remove the top and side wear pads on the inside of the third boom section. Label and tag each set of wear pads being removed.
19
MH1781
11. At the rear of the boom, locate the fourth boom section extend chain locknut (18). Measure the amount of threads protruding beyond the locknut and record the measurement for reassembly. 12. Loosen, but DO NOT remove the locknut. 13. At the rear of the boom, locate the two third boom section extend chain locknuts (19). Measure the amount of threads protruding beyond each locknut and record the measurements for reassembly. 14. Loosen, but DO NOT remove the locknuts. 15. Return to the cab, start the engine and extend the boom approximately 2 (51 mm). Retract the boom slightly until there is slack in the fourth boom section extend chain. Shut the engine OFF.
MH1501
19. At the rear of the boom, remove the hose reel assembly (3). This requires removal of the bottom and side wear pads. Reinstall the wear pads for second boom section removal.
3-16
6036, 6042, 8042, 10042, 10054
Boom
23. Remove the two capscrews and lockwashers holding the hose carrier support (7) and the lower wear pad to the third boom section. 24. Pull the hose carrier support with hose carrier attached toward the rear of the boom. Reinstall the capscrews and lockwashers to hold the wear pad in place. DO NOT fully tighten the capscrews.
4
25. Remove the hose carrier support from the hose carrier. Note: If replacing the third boom section with a new boom section, the quick attach assembly and the Attachment Tilt cylinder should be removed at this time. Refer to Section 3.8.3, Quick Attach Removal..
MH2841
20. Inside the third boom section, remove the hose clamps and hose clamp support bracket (4). 21. Return to the cab, start the engine and fully retract the boom slowly. Shut the engine OFF. Note: Record the location of the shoulder bolt to ensure correct installation.
5
26. Using a sling or suitable support, pull the fourth boom section straight out of the third boom section. Reposition the slings as needed so the fourth boom section balances when removed from the third boom section. Set the boom section down on a hard, level surface. Support the boom as needed to prevent it from tipping over.
8
MH1871
27. At the rear of the boom section, remove the extend chain clevis (8) from the extend chain clevis anchor. 28. At the rear of the fourth boom section, remove the remaining wear pads, shims and hardware. Label and tag each set of wear pads being removed. 29. Inspect all wear pads for wear. Refer to Section 3.9, Boom Wear Pads.
MH4071
22. At the rear of the boom, remove the shoulder bolt (5) to the fourth boom section retract chain (6). Let the chain hang out the rear of the boom.
MH1861
6036, 6042, 8042, 10042, 10054
3-17
Boom
11
MH1901
30. Inside the boom section, remove the hardware securing the hose carrier (9) to the bottom of the boom. 31. On each side of the boom, remove the hardware securing the rear of the hose carrier guide in place.
MH1961
35. Remove the hose carrier assembly (11) from the boom by carefully pulling both the upper and lowers portions through the rear of the boom at the same time. 36. Carefully slide the hose channel assembly out of the rear of the boom.
3.6.2
Third Boom Section Removal
10
1. At the front of the second boom section, remove the top and side wear pads. Label and tag each set of wear pads being removed.
12
MH1911
32. Loosen, but DO NOT remove the hardware holding the front of the hose carrier guide and the top wear pad (10) to each side of the boom. 33. Tilt the back of the hose carrier guide up. Label all hoses and their orientations. Pull the hoses from the channels inside the boom. Lay the hoses out behind the boom. 34. After the hoses are removed, remove the hose carrier guide by pulling the guide out the rear of the boom.
MH1991
2. Remove the shoulder bolt (12) holding the yoke plates to the mount at the front of the first boom section. 3. Remove the extend chain sheave pin and sheave on the third boom section.
3-18
6036, 6042, 8042, 10042, 10054
Boom 3.6.3
13
Second Boom Section Removal
1. At the front of the first boom section, remove the top, side and bottom wear pads. Label and tag each set of wear pads being removed.
14
4. Remove the locknuts (13) holding the threaded clevis of the extend chains to the anchor bracket on the rear of the third boom section. 5. Pull both extend chains out from the front of the boom. 6. At the rear of the third boom section, remove the retract chain sheave. 7. Remove the shoulder bolt. Let the retract chain hang out the rear of the boom. 8. Using a sling or suitable support, pull the third boom section straight out of the second boom section. Reposition the slings as needed so the third boom section balances when removed from the second boom section. Set the boom section down on a hard, level surface. Support the boom as needed to prevent it from tipping over. 9. Remove the remaining wear pads, shims and hardware. Label and tag each set of wear pads being removed. 10. Inspect all wear pads for wear. Refer to Section 3.9, Boom Wear Pads.
15
MH2171
MH2121
2. Remove the retract chain sheave (14) from the inside of the second boom section. 3. Using a suitable sling or support, secure the front of the Extend/Retract cylinder. 4. Remove the retaining ring from one side of the Extend/Retract cylinder rod end mounting pin.
5. On the left side of the first boom section, remove the boom extend interlock proximity sensor (15) and mounting bracket. 6. Using a sling or suitable support, pull the second boom section straight out of the first boom section. Reposition the slings as needed so the second boom section balances when removed from the first boom section. While pulling the second boom section out of the first boom section, guide the retract chain into the rear of the boom. Set the boom section down on a hard, level surface. Support the boom as needed to prevent it from tipping over.
6036, 6042, 8042, 10042, 10054
3-19
Boom
7. Remove the remaining wear pads, shims and hardware. Label and tag each set of wear pads being removed. 8. Inspect all wear pads for wear. Refer to Section 3.9, Boom Wear Pads. 5. Remove the retract chain by pulling it out the rear of the boom.
18
MH1131
6. Label, disconnect and cap the Attachment Tilt and Auxiliary (if equipped) hydraulic hoses on the mounting plate (18). 7. Label, disconnect and cap the Attachment Tilt and Auxiliary (if equipped) hydraulic tubes from the bulkhead fittings.
16
MH2141
8. Label, disconnect and cap the Extend/Retract hydraulic hoses from the bulkhead fittings.
9. At the underside of the second boom section, remove the locknut (16) from the retract chain clevis. Pull the retract chain out of the boom through the rear of the boom.
19 1
3.6.4
First Boom Section Removal
1. Attach a suitable overhead lifting device and sling to the Lift/Lower cylinder, and remove slack in the sling. 2. Securely support the first boom section. 3. Remove all wear pads, shims and hardware. Label and tag each set of wear pads being removed.
MH1151
9. Label, disconnect and cap the Extend/Retract hydraulic tubes (19) from the bulkhead fittings. Remove the tube clamps (1).
17
MH1111
4. At the underside of the boom, remove the retract chain locknut (17). Measure the amount of threads protruding beyond the locknut and record the measurement for reassembly of the chain. 3-20
MH1201
10. Label, disconnect and cap the hydraulic hoses attached to the Slave cylinders (2).
6036, 6042, 8042, 10042, 10054
Boom
11. Use a hoist and a sling to hold the left Slave cylinder in position. Remove the lockbolt from the Slave cylinder rod end mounting pin. Remove the locknut from the base end of Slave cylinder. Lift the Slave cylinder away from the machine. Repeat procedure for the right Slave cylinder. 19. Remove the rubber bumper from the Extend/Retract cylinder retainer. Inspect the rubber bumper. If it is in good condition, the rubber bumper can be reused. If the bumper is showing signs of cracking or deterioration, it should be replaced. 20. Remove the Extend/Retract cylinder from the boom.
3.6.5
3
First Boom Section Installation
1. Using a suitable hoist and sling, position the Extend/ Retract cylinder with the port elbows facing down. Place the rod end of the cylinder through the cylinder retainer at the front of the boom. 2. Coat the base end of the cylinder with anti-seize compound. Insert the base end cylinder pin through both mounting ears and the base end of the Extend/ Retract cylinder. Secure the pin in place with a retaining ring on each side of the pin. 3. Lift the rod end of the Extend/Retract cylinder enough to insert the threaded stud on the rubber bumper into the hole in the Extend/Retract cylinder retainer. Secure the rubber bumper in place with a new locknut. Tighten securely. Lower the rod end of the Extend/Retract cylinder, and allow it to rest on the rubber bumper. 4. Using a suitable hoist and slings, lift the boom assembly and position the boom on the frame. Align the mounting plates on the frame between the mounting hubs on each side of the boom assembly. Lower the boom assembly until the holes in the boom assembly and the mounting plates align. 5. On the end of the boom pivot pin, closest to the capscrew hole, mark the capscrew mounting hole location. Coat the entire pin with anti-seize compound.
MH1241
MH1221
12. On the right side boom pivot mounting plate, remove the boom proximity sensor (3). 13. With the boom securely supported, block the Lift/ Lower cylinders. Remove the lockbolts from the rod end of the cylinders and lower the cylinders onto the machine.
4
14. Remove the boom pivot pins (4) and lockbolts. 15. Using a sling or suitable support, carefully lift the first boom section away from the machine. Set the boom section down on a hard, level surface. Support the boom as required to allow removal of the Extend/ Retract cylinder from the underside of the boom. 16. Inspect all wear pads for wear. Refer to Section 3.9, Boom Wear Pads. 17. Use a hoist and slings to support the Extend/Retract cylinder. 18. Remove the retaining rings from the ends of the Extend/Retract cylinder.
6. Insert the pivot pin from the outside of the boom assembly, making sure the marks for the capscrew mounting hole stay in line with the capscrew mounting holes in the boom mounting hub.
6036, 6042, 8042, 10042, 10054
3-21
Boom
MH1391
MH1381
7. Shim the boom as required using the shims (5) to maintain a 0.10 in (2,5 mm) maximum gap (6) between the boom mounting hub and the self aligning bearing in the frame. If an additional shim is required to maintain the maximum gap, the extra shim MUST be inserted on the right side of the boom. 8. Align the rod end of the right Lift/Lower cylinder with the self-aligning bearing on the boom assembly. Coat the entire Lift/Lower cylinder pin with anti-seize compound. Insert the pin through the rod end of the cylinder and the self-aligning bearing. Secure with lock bolt. Repeat procedure with left Lift/Lower cylinder. 9. Use a hoist or suitable support to position the right side Slave cylinder to its original orientation onto the lower cylinder mount. Coat the entire Slave cylinder pin with anti-seize compound. Insert the pin through the rod end of the cylinder and the self-aligning bearing. Secure with lockbolt. Repeat procedure for left side Slave cylinder. 10. Install the boom proximity sensor on the right side mounting plate. With the boom properly shimmed, position the boom assembly all the way to the right side.
11. Insert the boom proximity sensor through the hole in the right side mounting plate. Install the jam nut onto the boom proximity sensor on the inside of the plate. Adjust the inner and outer jam nuts on the sensor until the gap (7) between the sensor and the boom is 0.12 in (3 mm). Torque the inside jam nut to 36 lb-in (4,1 Nm), to hold the sensor in position.
MH1151
12. Install the Extend and Retract tubes (8) to the inside bulkhead fitting and the Extend/Retract cylinder. 13. Install the Extend and Retract tube clamp halves (9). 14. Uncap and connect the previously labeled hydraulic hoses and attach to their appropriate cylinder locations. 15. Install the Extend and Retract and Auxiliary (if equipped) tube assemblies to their appropriate bulkhead fittings. Secure with tube clamps. 16. Uncap and connect the previously labeled Attachment Tilt and Auxiliary (if equipped) hydraulic hoses to their appropriate bulkhead fittings.
3-22
6036, 6042, 8042, 10042, 10054
Boom
side. Align the hole in the pin retainer plate with the threaded hole in the left ear. Secure the pin. 2. Apply grease to the grease fitting in the pin. Spin the sheave by hand to ensure the sheave spins freely on the pin and to distribute grease evenly.
12 10
MH1461
17. Inside the rear of the boom, slide the threaded clevis end (10) of the retract chain down the right side of the boom. Guide the threaded part of the clevis out through the hole in the tab on the bottom of the boom. Pull threaded part of clevis all the way through tab. 18. Coat the entire threaded portion of the clevis with multi-purpose grease. Install a flat washer and locknut onto the clevis. Thread the nut onto the clevis until the threads are flush with the top of the nut. 19. Install the bottom wear pads to the first boom section with the previously used hardware.
MH1501
3. Install the hose reel assembly (12), left side and bottom wear pads to the rear of the second boom section. 4. Install the boom side and top wear pads of the second boom section. 5. Grease the sections of the boom in areas where the wear pads will slide. 6. Before installing the second boom section into the first boom section, place a string (heavy enough to pull the Attachment Tilt and Auxiliary hydraulic hoses) down the inside of the boom. Allow the string to hang out the rear of the boom. Pull the other end out the opening on the left side of the boom where the hoses will exit the boom. Position the strings all the way to the left side of the first boom section. 7. Using a suitable sling, carefully slide the second boom section into the first boom section. Leave enough room at the front of the boom to install the center wear pad.
3.6.6
Second Boom Section Installation
11
MH2261
1. At the rear of the second boom section, assemble the retract chain sheave to the mounting ears on the right side of the boom. Place the sheave between the ears and insert the sheave pin (11) from the left
6036, 6042, 8042, 10042, 10054
3-23
Boom 3.6.7 Third Boom Installation
1. Install the bottom, side and top wear pads to the rear of the third boom section.
15
13
MH2211
8. Install the center wear pad mount (13) and wear pad to the bottom front of the first boom section. 9. Install the side and top wear pads to the front of the first boom section. 10. Install the double extend chain sheave to the front of the second boom section. 11. With the sling still in place, install the rod end of the Extend/Retract cylinder, pin and retaining ring. 12. Install the front, bottom wear pads in the second boom section.
MH2021
2. At the rear of the third boom section, assemble the retract chain sheave (15) to the mounting ears on the left side of the boom. Place the sheave between the ears and insert the sheave pin from the right side. Line up the hole in the pin retainer plate with the threaded hole in the right ear. Secure the pin. 3. Apply grease to the grease fitting in the pin. Spin the sheave by hand to ensure the sheave spins freely on the pin and to distribute grease evenly. 4. Install the bottom front wear pads.
16
14
MH2171
MH2301
13. On the left side of the first boom section, reassemble the boom extend interlock sensor (14) with mounting bracket. Secure in place with the previously used hardware. Tighten securely. 14. Secure the boom extend interlock sensor wire to the Attachment Tilt tubes under the boom with new tie wraps.
5. Lay the two extend chains (16) on the top of the third boom section with the threaded clevis ends toward the rear of the boom. Coat the threads on each clevis with multi-purpose grease and insert the clevis through the holes in the anchor plate. Install a washer and locknut onto each clevis. Tighten the locknut enough so the threads are even with the top of the locknut. 6. Grease the sections of the boom in areas where the wear pads will slide.
3-24
6036, 6042, 8042, 10042, 10054
Boom
7. Using a suitable sling, carefully slide the third boom section into the second boom section. Leave enough room at the front of the boom to install the remaining wear pads. 8. Install the top and side wear pads to the inside of the second boom section. 9. Place the two extend chains up through the double sheave mounting bracket on the front of the second boom section. 10. Assemble the two extend chains to the mount if the yoke plates were removed from the extend chains. Secure in place with a locknut. Tighten the locknut securely; but the yoke plates must pivot freely. 11. Install the double extend chain sheave. Apply grease to the sheave. Turn the sheave by hand to distribute the grease evenly.
17
MH2381
3.6.8
Fourth Boom Section Installation

0 6.0 ) 19 8 cm (49
1. Lay the hose carrier assembly out flat on a level surface. Stretch the four male ends of the hoses out straight from the hose carrier assembly. Measure from the male end of each hose back toward the hose carrier assembly 196 (498 cm) and apply tape around each hose at that point. The tape is for proper tensioning of the hoses during reassembly of the hose clamps. 2. Insert the hose channel assembly into the rear of the fourth boom section. Slide the hose channel assembly into the boom and line up the holes for the side wear pads. 3. Install the side, bottom and top wear pads.
18
MH1991
12. Align the holes in the yoke plates with the hole in the mount on the first boom section. Coat the shoulder bolt with anti-seize compound and insert the shoulder bolt (17) through the yoke plates and the mount on the boom. Secure in place with a locknut. Tighten the locknut securely; but the yoke plates must pivot freely. 13. Place the retract chain around the retract chain sheave on the right side of the boom. Stretch the chain forward and place the clevis between the two anchor plates. Align the hole in the clevis with the hole location recorded in the removal procedure. Insert the shoulder bolt and locknut, tighten securely.
MH2441
4. Lay the fourth boom section extend chain (18) on the top of the fourth boom section with the threaded clevis end toward the rear of the boom. Coat the threads on the clevis with multi-purpose grease and insert the clevis through the hole in the anchor plate. Install a washer and locknut onto the clevis. Tighten the locknut enough so the threads are even with the top of the locknut. Note: The hose carrier only folds one way; DO NOT force it. DO NOT twist the hose carrier while folding.
6036, 6042, 8042, 10042, 10054
3-25
Boom
19 1
MH2411
5. Fold the hose carrier assembly in half, ensure the female ends (19) of the hoses are on the bottom, and carefully slide the folded hose carrier into the fourth boom section. 6. Line up the lower mounting holes in the hose carrier assembly with the holes in the bottom of the fourth boom section. Secure with the previously used hardware. 7. Lift the upper part of the hose carrier assembly and place the hose carrier guide under the hose carrier with the angled guides toward the front. Slide the hose guide into the fourth boom section, and place the front notches onto the rear wear pad mounting capscrew. Be sure the notch in the side of the hose guide is under the flat washer on each side of the boom. 8. Rotate the back of the hose guide up toward the top of the fourth boom section as far as it will go. Tighten the rear wear pad mounting capscrews enough to hold the hose guide.
MH2471
9. With the hose guide tilted up in the back, insert the female ends of the two left side hoses (from the hose carrier) one at a time over the top of the angled guide (1) on the front side of the hose guide. Push the hoses into the hose channel on the left side of the fourth boom section and down to the front of the boom section. Repeat this procedure for the two right side hoses into the hose channel on the right side of the boom. 10. Insert a capscrew through the hole in the fourth boom section. Secure the hose guide in place with a flat washer and locknut. Torque to 31 3 lb-ft (42 4 Nm). 11. Run the hose carrier out and in by hand to check for interference. Note: DO NOT allow the hydraulic hoses to cross inside the boom. 12. At the front of the boom, pull the previously labeled hydraulic hoses out the opening in the back of the boom head. Let the hoses hang out of the boom head. 13. Grease the sections of the boom in areas where the wear pads will slide. 14. Using a suitable sling, lift the fourth boom section. While guiding the hoses into the third boom section, carefully slide the fourth boom section into the front of the third boom section.
3-26
6036, 6042, 8042, 10042, 10054
Boom
22. Place the extend chain clevis between the mounting plates at the front of the second boom section. Coat the shoulder bolt (4) with anti-seize compound and insert through the plates and clevis. Secure the shoulder bolt in place with a locknut. Tighten securely, but the chain clevis should pivot freely. Note: Keep the four hoses in line as they come out of the hose carrier assembly at the rear of the boom. DO NOT allow the hoses to cross. 23. Install the hose clamp support bracket and top left side wear pad. 24. Position the hydraulic hoses with the edge of the tape at the hose clamps. Hold the hoses in this position, and tighten the hose clamps.
MH1861
15. Reassemble the hose carrier support to the hose carrier on the right side. Install the hose carrier support (2) and lower wear pad with the previously used hardware. 16. Place the retract chain up around the retract chain sheave on the left side of the boom. Stretch the chain forward and place the clevis between the two anchor plates. Line up the hole in the clevis with the anchor plate hole location recorded during removal. 17. Insert the shoulder bolt and secure in place with a locknut. Tighten the locknut. 18. Install the side and top wear pads. 19. Place the fourth boom section extend chain sheave (3) between the mounts at the front of the third boom section. Insert the sheave pin through the mounts and the sheave. Secure in place with the previously used hardware. 20. After the sheave is assembled, apply a good grade of multi-purpose grease to the grease fitting at the end of the pin. Turn the sheave by hand to distribute grease evenly. 21. Place the fourth boom section extend chain up and around the sheave at the front of the third boom section.
4
MH1691
25. Assemble the hoses to the hose reel (5) at the rear of the boom. 26. Tie the strings (positioned inside the first boom section during installation) to the male end of the hydraulic hoses coming off the bottom of the hose reel assembly. 27. Working from the front of the boom, pull each hose through the boom assembly through the opening at the bottom of the first boom section.
28. Remove the strings from the hoses.
MH2521
6036, 6042, 8042, 10042, 10054
3-27
Boom
3.7
BOOM EXTEND AND RETRACT CHAINS

Boom Chain Inspection
3.7.1
WARNING
6
MH1451
Worn pins, stretched or cracked links or corrosive environments can cause chain failure. A chain failure could result in uncontrolled boom movement, loss of load or machine instability. Under normal operating conditions the boom chains will need to be inspected every 250 hours of operation. The retract chains need to be exposed and inspected every 1000 hours of operation. Environmental conditions and dynamic impulse/shock loads can drastically affect normal operating conditions and require more frequent inspection intervals. Environments in which material handling machines operate can vary widely from outdoor moisture to temperature to mildly corrosive or highly corrosive industrial atmospheres, in addition to abrasive exposures such as sand and grit. Some effects can be as follows: Moisture - Corrosive rusting reduces chain strength by pitting and cracking. Temperature - Low temperature reduces chain strength by embrittlement. Going in and out of cold storage results in moisture from condensation. Chemical Solutions or Vapors - Corrosive attack on the chain components and/or the mechanical connections between the chain components. Cracking can be (and often is) microscopic. Going from microscopic cracking to complete failure can be either abrupt or may require an extended period of time. Abrasives - Accelerated wearing and scoring of the articulating members of the chain (pins an d plates), with a corresponding reduction in chain strength. Due to the inaccessibility of the bearing surfaces (pin surfaces and plate apertures), wear and scoring are not readily noticeable to the naked eye.
29. At the front of the first boom section, assemble the hose assemblies and tube assemblies to the mounting plate (6). Note: Where the hose assemblies come out of the outer boom, lubricate the radius in the first boom section with soap and water to allow proper tensioning of hoses. 30. Install the quick attach and Attachment Tilt cylinder to the front of the boom. Refer to Section 3.8.4, Quick Attach Installation. 31. Uncap and connect the previously labeled hoses to the Attachment Tilt cylinder. 32. Properly connect the battery. 33. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 34. Start the engine and operate all boom functions several times. Check the chain tension again and adjust as necessary. Check for leaks, and check the hydraulic fluid level in the tank; add fluid if required. 35. Clean up all debris, hydraulic fluid, etc., in, on, near and around the machine. 36. Install the rear cover to the boom. 37. Close and secure the rear door.
3-28
6036, 6042, 8042, 10042, 10054
Boom
Following are some examples of dynamic shock loading which can impose abnormal loads above the endurance limit of a leaf chain. High velocity movement of load, followed by sudden, abrupt stops. Carrying loads in suspension over irregular surfaces such as railroad tracks, potholes, and rough terrain. Attempting to inch loads which are beyond the rated capacity of the machine. The above load cycles and environmental conditions make it impossible to predict chain life. It is therefore necessary to conduct frequent inspections until replacement life can be predicted. The boom chains normal life expectancy can be expressed as a maximum percent of elongation. This is generally 3%. As the chain flexes back and forth over the sheave, the bearing joints (pins and inside link plates) gradually incur wear due to articulation. Edge Wear
MZ1463
Check the chain for wear on the link plate edges caused by running back and forth over the sheave. The maximum reduction of material should not exceed 5%. Measure and compare to a normal link plate height by measuring a portion of chain that does not run over the sheave. If the measured plate height (1) is 5% less than the normal plate height (2), discard and replace the chain. Elongation It is important to measure the chain in the section that moves over the sheaves because it receives the most frequent articulation. Measuring the chain near its clevis terminals could give an inaccurate reading. The ends of the chains, near the clevis terminal, will not have flexed as frequently, if at all, as the middle of the chains. It is best to measure in 12 pin increments from pin center to pin center. For example, if the links are one inch from pin center to pin center, the distance should be 12 in (305 mm). If the links are 3/4 in apart, the distance after 12 pins should be 9 in. 4 3
3.7.2
Inspection Guidelines
1. Park the machine on a firm, level surface, raise the boom to a horizontal (level) position, place the transmission control lever in (N) NEUTRAL, engage the park brake switch. 2. Fully extend the boom until the extend chain is taut. Shut the engine off. 3. The extend chains will be visible for inspection with the machine in this state. 4. While doing the chain inspection, check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain. 5. Inspect the retract chains every 1000 hours of operation. 6. Inspect the chains for the following conditions:
MY1360
If the distance measured (3) is 3% greater than the normal length (4), discard and replace the chain.
6036, 6042, 8042, 10042, 10054
3-29
Boom
Distorted or Battered Link Plates 8 5 Cracked Plates Inspect the chains very carefully, front and back as well as side to side, for any evidence of cracked plates. If any one crack is discovered, the chain should be replaced in its entirety. It is important, however to determine the cause of the crack before installing a new chain so the condition does not repeat itself.
MZ1466
The types of cracks are: Fatigue Cracking Fatigue cracks (9) are a result of repeated cyclic loading beyond the chains endurance limit. Stress Corrosion Cracking - The 10 outside link plates are particularly susceptible to stress corrosion cracking (10). 9
MZ1467
Distorted or battered link plates (5) on a leaf chain can cause tight joints and prevent flexing. Turning or Protruding Pins Highly loaded chain, operating with inadequate lubrication can generate abnormal frictional forces between pin and link plates. When chain is allowed to operate in this condition, a pin or series of pins, can begin to twist out of a chain, resulting in failure.
MZ1468
6
MZ1465
7 8
Corrosion Fatigue Cracking - Corrosion fatigue cracks are very similar to fatigue cracks in appearance. Corrosion fatigue is the combined action of an aggressive environment and cyclic stress. Other Modes of Failure Ultimate Strength Failure These types of failures are 1 caused by overloads far in excess of the design load. Either fractured plates (1) or 2 enlarged holes (2) can occur. If either of these failures occurs, the chain should be replaced immediately.
Examine the pin head rivets to determine if the VEE flats are still in correct alignment (6). Chain with rotated/displaced heads (7) or abnormal pin protrusion (8) should be replaced immediately. DO NOT attempt to repair the chain by welding or driving the pin(s) back into the chain. Once the press fit integrity between outside plates and pins has been altered, it cannot be restored. Any wear pattern on the pin heads or the sides of the link plates indicates misalignment in the system. This condition damages the chain as well as increases frictional loading and should be corrected.
MZ1469
MZ1470
Tight Joints - All joints in the chain should flex freely. Tight 3 MZ1471 joints (3) resist flexing. If the problem is caused by dirt or foreign substance packed in the joints, clean and lubricate thoroughly before re-installing the chain. If the problem is caused by corrosion and rust or bent pins, replace the chain.
3-30
6036, 6042, 8042, 10042, 10054
Boom 3.7.3 Expose Chains for Inspection 3.7.4 Chain Lubrication
e. Extend Chains 1. Park the machine on a firm, level surface. Place the transmission control lever in (N) NEUTRAL, engage the park brake switch and raise the boom to a horizontal (level) position. 2. Fully extend the boom and shut the engine OFF. The extend chains will be visible for inspection with the machine in this state. While doing the chain inspection, check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain. If during the inspection, any chain is found to be damaged or stretched, the chain must be replaced. It is recommended that when any chain is replaced, that all the chains and clevises be replaced at the same time. f. Retract Chains
After inspection and before being returned to service, chains must be lubricated with a quality chain lubricant (LUBRIPLATE Chain & Cable Fluid, LPS3 or equivalent). The lubricant must penetrate the chain joint to prevent wear. Applying lubricant to the external surfaces will prevent rust, but the chains should be articulated to make sure the lubricant penetrates to the working surfaces between the pins and links. To prepare the chain for lubrication, the chain plates should be brushed with a stiff brush or wire brush to clear the space between the plates so that lubricant can penetrate to the working surfaces. Lubricant may be applied with a narrow paint brush or directly poured on, but the chain should be well flooded with lubricant and the boom should be extended and retracted to be sure that the lubricant penetrates to the working surfaces. All surplus lubricant should be wiped away from the external surfaces. DO NOT use a solvent for this wiping operation. Regular application of lubricant is necessary to make sure that all working surfaces are adequately lubricated. In extremely dusty conditions, it may be necessary to lubricate the chains more often. Lubrication of chains on machines working consistently in extreme hot or cold conditions requires special consideration. It is important that a reputable lubrication specialist or a JLG distributor be consulted for guidance.
The retract chains are only partially visible through the rear of the boom with all the sections retracted. It is possible to see a section of the retract chain as the boom is slowly extended. If there is ANY question that one or all the retract chains are damaged, the boom should be removed and disassembled with the retract chains being inspected and replaced if necessary. Note: DO NOT attempt to repair a chain. Replace a stretched or damaged chain with a new part. Always replace both the chain and the clevis. It is recommended that when any chain is replaced, that all chains and clevis be replaced at the same time.
3.7.5
Boom Chain Tension Check
1. Make sure the attachment is attached to the boom head before doing the tension check. 2. Park the machine on level ground. Place the transmission control lever in (N) NEUTRAL, engage the parking brake switch and level the boom. 3. Slowly, fully extend the boom and retract it about halfway. Fully extend the boom, then retract it 2 in (51 mm) (one inch per section). Turn the engine OFF.
6036, 6042, 8042, 10042, 10054
3-31
Boom 3.7.6
1
Boom Chain Tension Adjustment (6036, 6042, 8042 & 10042)
Note: Always perform Section 3.7.5, Boom Chain Tension Check before adjusting the boom chain tension.
OA0493
4. Measure the sag (1) in each of the boom extend chains between the bottom of the extend chains and the top of the boom at their closest point. Acceptable boom chain sag is between 1.5 in (38 mm) and 2.5 in (64 mm) for the 8042 & 10042 and between 2.85 in (72 mm) and 3.85 in (98 mm). If the measurement is either less than, or greater than the range given, the boom chains need to be adjusted. Continue with Section 3.7.6, Boom Chain Tension Adjustment (6036, 6042, 8042 & 10042) or Section 3.7.7, Boom Chain Tension Adjustment (10054), to adjust the chain system. 5. Start the engine, retract the boom completely and turn the engine OFF.
OH0241
1. Adjust the two boom extend chains (2).

3
MH1752
If the chain sag measurement (1) is less than 1.5 in (38 mm), tighten the two extend chain adjustment locknuts (3). If the chain sag measurement is more than 2.5 in (64 mm), loosen the two extend chain adjustment locknuts. 2. Tighten or loosen the two extend chain adjustment locknuts located at the rear of the boom. Be sure each of the locknuts are adjusted equally so that each extend chain maintains the same tension. Equal chain tension can be checked by the position of the yoke (4) on the outer boom. The front of the yoke should be parallel with the front edge of the outer boom.
3-32
6036, 6042, 8042, 10042, 10054
Boom
a. Component/Assembly Verification
9
5 8 7
OH1091
OA0513
3. If there is no adjustment left on the extend chains, tighten the retract chain locknut (5) at the front on the underside of the outer boom. 4. Recheck chain tension. Refer to Section 3.7.5, Boom Chain Tension Check.
The third (7) to second (8) boom section separation should be checked when assembling new boom sections or chains, or when the rear retract chain clevis has been moved forward on the anchor plate. Measure the separation (9) between the third and second boom section top plates. The distance should be at least 8.5 in (216 mm) and not greater than 11 in (279 mm) with the boom fully retracted and the chains properly tensioned. A distance of less than 8.5 in (216 mm) could result in interference and cause damage to boom components. If the distance is less than 8.5 in (216 mm) or greater than 11 in (279 mm): 1. Verify that the retract chain clevis (6) is not mounted in the last hole in the anchor plate. 2. Make sure that the chain system is properly tensioned. Refer to Section 3.7.5, Boom Chain Tension Check.
MA9451
5. Further chain adjustment can be achieved by loosening all three chain locknuts and moving the rear retract chain clevis (6) from the original mounting hole in the anchor plate to the next hole. This is only acceptable when boom chain sag cannot be acquired and the chain elongation measurement is still less than 12.36 in (313 mm). Follow the instructions in Section 3.7.6, a. Component/ Assembly Verification. 6. Recheck chain tension. Refer to Section 3.7.5, Boom Chain Tension Check.
3. To increase the separation distance: Loosen the retract chain locknut (5) on the bottom of the boom one or two turns and tighten the two extend chain locknuts equally the same number of turns. A minimum of one full thread on the clevis must protrude beyond the collar of the locknut. 4. To decrease the separation distance: Loosen the extend chain locknuts at the rear of boom equally one or two turns and tighten the retract chain locknut (5) the same number of turns. A minimum of one full thread on the clevis must protrude beyond the collar of the locknut. 5. Install the rear boom cover. 6. If the third to second boom separation distance cannot be achieved, contact your local JLG service distributor.
6036, 6042, 8042, 10042, 10054
3-33
Boom 3.7.7 Boom Chain Tension Adjustment (10054)
a. Outer Boom Chains Tension Adjustment Note: Always perform Section 3.7.5, Boom Chain Tension Check. before adjusting the boom extend chain tension.
10
12
OH0552
OA0493
2. Tighten or loosen the two extend chain adjustment locknuts (11) located at the rear of the boom. Be sure each of the locknuts are adjusted equally so that each extend chain maintains the same tension. Equal chain tension can be checked by the position of the yoke (12) on the first boom section. The front of the yoke should be parallel with the front edge of the outer boom.
11
13
MH1781
1. Adjust the two second and third boom section extend chains. If the chain sag measurement (10) is less than 2.85 in (72 mm), tighten the two extend chain adjustment locknuts (11). If the chain sag measurement (10) is more than 3.85 in (98 mm), loosen the two extend chain adjustment locknuts (11).
OA0513
3. If there is no adjustment left on the extend chains, tighten the retract chain locknut (13) at the front on the underside of the boom. 4. Recheck chain tension. Refer to Section 3.7.5, Boom Chain Tension Check.
3-34
6036, 6042, 8042, 10042, 10054
Boom
If the distance is less than 8.5 in (216 mm) or greater than 11 in (279 mm):
14
1. Verify that the retract chain clevis is not mounted in the last hole in the anchor plate. 2. Make sure that the chain system is properly tensioned. Refer to Section 3.7.5, Boom Chain Tension Check..
18
MA9451
5. Further chain adjustment can be achieved by loosening all three chain locknuts and moving the rear retract chain clevis (14) from the original mounting hole in the anchor plate to the next hole. This is only acceptable when boom chain sag cannot be acquired and the chain elongation measurement is still less than 12.36 in (313 mm). Follow the instructions in Section 3.7.7, b. Component/ Assembly Verification. 6. Recheck chain tension. Refer to Section 3.7.5, Boom Chain Tension Check. b. Component/Assembly Verification The third to second boom section separation should be checked when assembling new boom sections or chains, or when the rear retract chain clevis has been moved forward on the anchor plate.
17
MH1781
3. To increase the separation distance: Loosen the retract chain locknut (13) on the bottom of the boom one or two turns and tighten the two extend chain locknuts (18) equally the same number of turns. A minimum of one full thread on the clevis must protrude beyond the collar of the locknut. 4. To decrease the separation distance: Loosen the extend chain locknuts (18) at the rear of boom equally one or two turns and tighten the retract chain locknut (13) the same number of turns. A minimum of one full thread on the clevis must protrude beyond the collar of the locknut. Note: If the third to second boom section separation distance cannot be achieved, contact your local authorized service distributor.
16 15
OH2862
Measure the separation between the third (15) and second (16) section boom top plates. The distance (17) should be at least 8.5 in (216 mm) and not greater than 11 in (279 mm) with the boom fully retracted and the chains properly tensioned. A distance of less than 8.5 in (216 mm) could result in interference and cause damage to boom components.
6036, 6042, 8042, 10042, 10054
3-35
Boom
c. Inner Boom Chain Tension Adjustment Note: Always perform the Section 3.7.5, Boom Chain Tension Check, before adjusting the fourth boom section extend chain tension.
19 2
OH0661
2. If there is no adjustment left on the extend chains, tighten the retract chain locknut (2) on the bottom of the second boom section several turns.
OA0493
3. Recheck chain tension. Refer to Section 3.7.5, Boom Chain Tension Check.
1 3
MH1781
1. Adjust the fourth boom section extend chain: If the chain sag measurement (19) is less than 2.85 in (72 mm), tighten the extend chain adjustment locknut (1). If the chain sag measurement (19) is more than 3.85 in (98 mm), loosen the extend chain adjustment locknut (1).
MH4071
4. Further chain adjustment can be achieved by loosening both chain locknuts and moving the rear retract chain clevis (3) from the original mounting hole in the anchor plate to the next hole. This is only acceptable when boom chain sag cannot be acquired and the chain elongation measurement is still less than 12.36 in (313 mm). Follow the instructions in Section 3.7.7, d. Component/ Assembly Verification. 5. Recheck chain tension. (Refer to Section 3.7.5, Boom Chain Tension Check.)
3-36
6036, 6042, 8042, 10042, 10054
Boom
d. Component/Assembly Verification The fourth to third boom section separation should be checked when assembling new boom sections or chains, or when the rear retract chain clevis has been moved forward on the anchor plate.
6
3.7.8
Extend Chains Removal and Replacement (6036, 6042, 8042 & 10042)
1. Park the machine on level ground. Place the transmission control lever in (N) NEUTRAL, engage the parking brake switch, level the boom and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Properly disconnect the battery. 4. Remove the boom rear cover.
7
5
OH2871
Measure the separation between the third (4) and fourth (5) boom section top plates. The distance (6) should be at least 13.75 in (349 mm) and not greater than 14.25 in (362 mm) with the boom fully retracted and the chains properly tensioned. A distance of less than 13.75 in (349 mm) could result in interference and cause damage to boom components. If the distance is less than 13.75 in (349 mm) or greater than 14.25 in (362 mm): 1. Verify that the retract chain clevis is not mounted in the last hole in the anchor plate. 2. Make sure that the chain system is properly tensioned. Refer to Section 3.7.5, Boom Chain Tension Check 3. To increase the separation distance: Loosen the retract chain locknut on the bottom of the second boom section one or two turns and tighten the extend chain locknut the same number of turns. A minimum of one full thread on the clevis must protrude beyond the collar of the locknut. 4. To decrease the separation distance: Loosen the extend chain locknut at the rear of boom one or two turns and tighten the retract chain locknut on the bottom of the second boom section the same number of turns. A minimum of one full thread on the clevis must protrude beyond the collar of the locknut. Note: If the fourth to third boom section separation distance cannot be achieved, contact your local authorized service distributor.
MH1752
5. At the rear of the boom, locate the extend chain locknuts (7). Record the amount of threads extending beyond both the locknuts. These measurements will be the starting point for adjustment of the extend chains after installation. 6. Remove and replace the extend chains one at a time. Remove the right side locknut and flat washer, holding the clevis to the anchor plate.
8
SH1811
7. At the front of the boom, remove the capscrew (8) and locknut holding the right side extend chain clevis to the yoke plates. Replace the capscrew if damaged or worn.
6036, 6042, 8042, 10042, 10054
3-37
Boom
9 10
11
MH6510
8. At the rear of the boom, attach one end of a wire to the threaded clevis (9) on the right side extend chain using a threaded eye or a flat washer tack welded to a capscrew. The outside diameter of the eye or flat washer must be smaller than the diameter of the threads on the clevis. 9. Have an assistant pull the chain from the front of the boom while guiding the wires into the boom from the rear. Remove the wire from the clevis, but not from inside the boom. 10. Inspect wear and condition of the booms, chains, clevis, chain sheaves, Extend/Retract cylinder, chain rods, clevis anchors and all mounting hardware. Replace any worn or damaged parts. DO NOT attempt to make any repairs to the chain. Note: Chains and clevis are wear items and experience the same stress. DO NOT attempt to repair a chain. Replace a stretched or damaged chain with a new part. Always replace both the chain and the clevis. 11. Coat the threads of the threaded clevis with multipurpose grease. 12. Lay the new extend chain on top of the first boom section with the threaded clevis toward the front of the boom. 13. Attach the wire to the threaded clevis of the new extend chain using a threaded eye or a flat washer tack welded to a capscrew. The outside diameter of the eye or flat washer must be smaller than the diameter of the threads on the clevis.
12
SH1852
14. Pull the extend chain forward and place over the right side of the chain sheave (10). Guide the wire and the threaded clevis under the chain sheave, and between the top of the third boom section (11) and the second boom section (12). 15. Have an assistant guide the extend chain into the front of the boom, while pulling on the wire from the rear of the boom. Guide the threaded clevis into the hole in the anchor plate. 16. Assemble the flat washer and locknut to the threaded clevis. Thread the locknut until the threads are flush with the top of the nut. 17. Pull the anchor clevis up around the double chain sheave and position the clevis between the yoke plates. 18. Coat the capscrew with anti-seize compound. Insert the capscrew through the yoke plates and clevis and secure in place with a locknut. Tighten securely; but the chain must pivot freely. 19. Remove the wire from the clevis. 20. Repeat this procedure for the left side extend chain. 21. At the rear of the boom, tighten the two locknuts on the extend chain clevis until the amount of threads protruding beyond each locknut is the same as the measurement recorded during removal of the chains. 22. Check and adjust boom chain tension. Refer to Section 3.7.5, Boom Chain Tension Check. 23. Install the boom rear cover. 24. Properly connect the battery. 25. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
3-38
6036, 6042, 8042, 10042, 10054
Boom 3.7.9 Retract Chain Removal and Replacement (6036, 6042, 8042 & 10042)
washer must be smaller than the diameter of the threads on the clevis. The wire or string will be used to pull the chain back through the boom during reassembly. 8. Remove the locknut and flat washer holding the retract chain threaded clevis to the mounting tab. Note: Record the location of the shoulder bolt to ensure correct installation.
15
1. Park the machine on level ground. Place the transmission control lever in (N) NEUTRAL, engage the parking brake switch, level the boom and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Properly disconnect the battery. 4. Remove the boom rear cover.
13
MH2551
OA0513
5. At the front underside of the boom, record the amount of threads extending beyond the locknut (13). This measurement will be the starting point for adjustment of the boom retract chain. 6. At the front underside of the boom, loosen the locknut far enough that it can be removed by hand.
9. At the rear of the boom, locate the two retract chain anchor plates holding the retract chain to the third boom section just in front of the retract chain sheave. Remove the locknut and shoulder bolt (15) holding the retract chain clevis to the anchor plates. The two anchor plates can remain in place on the third boom section. 10. From the rear of the boom, pull the retract chain out of the rear of the boom. 11. Inspect wear and condition of the booms, chains, clevis, chain sheaves, Extend/Retract cylinder, chain rods, clevis anchors and all mounting hardware. Replace a worn or damaged chain. DO NOT attempt to make any repairs to the chain. Note: Chains and clevis are wear items and experience the same stress. DO NOT attempt to repair a chain. Replace a stretched or damaged chain with a new part. Always replace both the chain and the clevis. 12. Remove the string from the old chain and attach it to the new clevis. 13. Coat the threads of the threaded clevis with multipurpose grease.
14
MA9441
7. Attach a wire or string (14) to the threaded clevis with a threaded eye or a flat washer tack welded to a capscrew. The outside diameter of the eye or flat
6036, 6042, 8042, 10042, 10054
3-39
Boom
14. From the rear of the boom, have an assistant push the threaded clevis end of the chain under the chain sheave and down between the second and first boom sections. Pull the front clevis using the string or wire. Keep the chain to the right side of the boom, push the threaded clevis down to the tab at the front underside of the first boom section. 15. Have an assistant guide the threaded end of the clevis through the hole in the tab. 16. Remove the string or wire from the end of the clevis. 17. Reassemble the flat washer and locknut onto the threaded clevis. Tighten the locknut until the threaded end of the clevis is flush with the top of the locknut. 18. At the rear of the boom, place the retract chain up and over the chain sheave. Place the clevis between the two anchor plates. 19. If re-installing a used chain, insert the saved shoulder bolt, in the same position in the plates and clevis recorded during removal. 20. If installing a new chain, line up the hole in the clevis with the second hole from the rear of the anchor plates. Insert the shoulder bolt, saved during removal of the old chain. 21. Secure the shoulder bolt in place with a locknut. Tighten the locknut securely. 22. Tighten the locknut on the retract chain clevis until the amount of threads protruding beyond the locknut is the same as the measurement recorded during removal of the retract chain. 23. Check and adjust retract chain tension. Refer to Section 3.7.5, Boom Chain Tension Check. 24. Install the boom rear cover. 25. Properly connect the battery. 26. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
MH1781
3.7.10
Extend Chains Removal and Replacement (10054)
a. Second and Third Boom Section Extend Chains Removal and Replacement 1. Park the machine on level ground. Place the transmission control lever in (N) NEUTRAL, engage the parking brake switch, level the boom and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Properly disconnect the battery. 4. Remove the boom rear cover.
16
5. At the rear of the boom, locate the extend chain locknuts (16). Record the amount of threads extending beyond the locknuts. This measurement will be the starting point for adjustment of the extend chains after installation. 6. Remove and replace the boom extend chains one at a time. Remove the right side locknut and flat washer holding the right side chain clevis to the anchor plate.
17
SH1811
7. At the front of the first boom section, remove the capscrews (17) and locknuts holding the extend chain clevis to the yoke plates.
3-40
6036, 6042, 8042, 10042, 10054
Boom
8. Inspect the capscrews for signs of wear or damage. Replace with new capscrews if damaged or worn. 9. At the front of the second boom section, remove the capscrew and lockwasher holding the extend chain sheave pin to the sheave mount bracket. Remove the pin from the mount bracket and the extend chain sheave. Remove the extend chain sheave from the mount.
19
18
MH2601
MH6510
10. At the rear of the boom, attach one end of a wire to the threaded clevis (18) on the right side extend chain with a threaded eye or a flat washer tack welded to a capscrew. The outside diameter of the eye or flat washer must be smaller than the diameter of the threads on the clevis. 11. Have an assistant pull the chain from the front of the boom while guiding the wire into the boom from the rear. Remove the wire from the clevis, but not from inside the boom. 12. Coat the threads of the threaded clevis with multipurpose grease. 13. Lay the new extend chain on top of the first boom section with the threaded clevis toward the front of the boom. 14. Attach the wire to the threaded clevis of the new extend chain using a threaded eye or a flat washer tack welded to a capscrew. The outside diameter of the eye or flat washer must be smaller than the diameter of the threads on the clevis.
15. Pull the extend chain forward and place in between the chain sheave mounts. Guide the wire (19) and the threaded clevis into the boom by placing the threaded clevis between the top of the third boom section and the second boom section. 16. Have an assistant guide extend chain into the front of the boom while pulling the wire and threaded clevis toward the rear of the boom. Guide the threaded clevis into the hole in the anchor plate. 17. Place the flat washer onto the threaded end of the threaded clevis and assemble the locknut. Thread locknut onto the threaded clevis until the threads are flush with the top of the nut. 18. Remove the wire from the clevis. 19. Repeat this procedure for the left side extend chain. 20. After both of the chains are replaced inside the boom, assemble the double sheave to the mount at the front of the second boom section. 21. Place the double extend chain sheave between the mounts and under the extend chains at the front of the second boom section. Insert the sheave pin through the mounts and the double sheave. Line up the mounting hole in the sheave pin with the threaded hole in the sheave mount and secure in place with the capscrew and the lockwasher. Tighten securely. 22. Pull the anchor clevis up around the double chain sheave and position the clevis one at a time between the yoke plates. 23. Coat the capscrews with anti-seize compound. Insert the capscrews through the yoke plates and clevis and secure in place with locknuts. Tighten each locknut securely, but the chain clevis must pivot freely.
6036, 6042, 8042, 10042, 10054
3-41
Boom
24. At the rear of the boom, tighten the two locknuts on the chain clevis until the amount of threads protruding beyond each locknut is the same as the measurement recorded during removal of the extend chains. 25. Check and adjust the retract chain tension. Refer to Section 3.7.5, Boom Chain Tension Check. 26. Install the boom rear cover. 27. Properly connect the battery. 28. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. b. Fourth Boom Section Extend Chains Removal and Replacement 1. Park the machine on level ground. Place the transmission control lever in (N) NEUTRAL, engage the parking brake switch, level the boom and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Properly disconnect the battery. 4. Remove the boom rear cover.
1
3
MH1791
7. At the front of the boom, disconnect the extend chain clevis from the anchor plates on the second boom section. Remove the locknut holding the shoulder bolt (2) to the anchor plates. Pull the extend chain clevis from between the plates and lay over the front of the fourth boom section (3). 8. Remove the locknut and capscrew holding the extend chain sheave to the front of the third boom section. 9. Inspect the sheave pin for corrosion or damage. If the pin is damaged, it should be replaced. Minor corrosion can be repaired with fine emery cloth. Save the chain sheave, pin and capscrew.
MH1781
5. At the rear of the boom, locate the extend chain locknut (1). Record the amount of threads extending beyond the locknut. This measurement will be the starting point for adjustment of the extend chain after installation. 6. Remove the locknut and flat washer holding the extend chain clevis to the anchor plate on the boom.
MH6510
10. At the rear of the boom, attach one end of a wire to the threaded clevis (4) on the extend chain with a threaded eye or a flat washer tack welded to a capscrew. The outside diameter of the eye or flat washer must be smaller than the diameter of the threads on the clevis. 11. Have an assistant pull the chain from the front of the boom while guiding the wire into the boom from the rear. Remove the wire from the clevis, but not from inside the boom.
3-42
6036, 6042, 8042, 10042, 10054
Boom
12. Coat the threads of the threaded clevis with multipurpose grease. 13. Lay the new extend chain on top of the fourth boom section with the threaded clevis toward the front of the boom. 14. Attach the wire to the threaded clevis of the new extend chain with a threaded eye or a flat washer tack welded to a capscrew. The outside diameter of the eye or flat washer must be smaller than the diameter of the threads on the clevis. 21. After the sheave is assembled, apply a good grade of multi-purpose grease to the grease fitting at the end of the pin. Turn the sheave by hand to distribute the grease evenly. 22. Pull the extend chain up and around the sheave at the front of the third boom section. 23. Place the extend chain clevis between the mounting plates at the front of the third boom section. Coat the saved shoulder bolt with anti-seize compound and insert through the plates and clevis. Secure the shoulder bolt in place with a locknut. Tighten securely, but the chain clevis should pivot freely. 24. At the rear of the boom, tighten the locknut on the extend chain clevis until the amount of threads protruding beyond the locknut is the same as the measurement recorded during removal of the extend chain.
5
25. Check and adjust the extend chain tension. Refer to Section 3.7.5, Boom Chain Tension Check.. 26. Install the boom rear cover. 27. Properly connect the battery. 28. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
6
3.7.11
MH5731
Retract Chain Removal and Replacement (10054)
15. Pull the extend chain forward and place in between the chain sheave mounts. Guide the wire and the threaded clevis into the boom by placing the threaded clevis between the third boom section (5) and the top of the fourth boom section (6). 16. Have an assistant guide the extend chain into the front of the boom while pulling the wire and threaded clevis into the hole in the anchor plate. 17. Place the flat washer onto the threaded end of the threaded clevis and assemble the locknut. Thread the locknut onto the threaded clevis until the threads are flush with the top of the nut. 18. Remove the wire from the clevis. 19. After the chain is replaced inside the boom, assemble the sheave to the mount at the front of the third boom section. 20. Place the extend chain sheave between the mounts at the front of the third boom section. Insert the sheave pin through the mounts and the sheave. Secure in place with the capscrew, saved, and a locknut. Tighten securely.
c. Third Boom Section Retract Chain Removal and Replacement 1. Park the machine on level ground. Place the transmission control lever in (N) NEUTRAL, engage the parking brake switch, level the boom and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Properly disconnect the battery. 4. Remove the boom rear cover.
6036, 6042, 8042, 10042, 10054
3-43
Boom
9. From the rear of the boom, pull the boom retract chain out of the rear of the boom. 10. Disconnect the string or wire from the retract chain clevis, and allow it to hang out the rear of the boom.
7
11. Coat the threads of the threaded clevis with multipurpose grease. 12. At the rear of the boom, attach the string or wire to the new retract chain threaded clevis end with a threaded eye or a flat washer tack welded to a capscrew. The outside diameter of the eye or flat washer must be smaller than the diameter of the threads on the clevis. 13. From the rear of the boom, have an assistant push the threaded clevis end of the new retract chain under the chain sheave and down between the second and first boom sections, while pulling the retract chain through the boom using the previously attached string or wire. Keep the retract chain to the right side of the boom, push and pull the threaded clevis down to the tab at the front underside of the boom.
OA0513
5. At the front underside of the boom, locate the retract chain locknut (7). Record the amount of threads extending beyond the locknut. This measurement will be the starting point for adjustment of the retract chain after installation. 6. At the front underside of the fourth boom section, remove the locknut and flat washer holding the retract chain threaded clevis to the mounting tab. 7. Attach a wire or string to the threaded clevis with a threaded eye or a flat washer tack welded to a capscrew. The outside diameter of the eye or flat washer must be smaller than the diameter of the threads on the clevis. The wire or string will be used to pull the chain back through the boom during reassembly. Note: Record the location of the shoulder bolt to ensure correct installation.
9 8
MH2561
14. Reassemble the flat washer and a locknut (9) onto the threaded clevis. Tighten the locknut until the threaded end of the clevis is flush with the top of the locknut. 15. At the rear of the boom, place the retract chain up and over the chain sheave. Place the clevis between the two anchor plates. Line up the hole in the clevis with the anchor plate hole position recorded during removal. 16. Insert the shoulder bolt through the plates and clevis and secure in place with a locknut. Tighten the locknut securely. 17. Check and adjust the retract chain tension. Refer to Section 3.7.5, Boom Chain Tension Check.
6036, 6042, 8042, 10042, 10054
MH2551
8. At the rear of the boom, locate the two retract chain anchor plates. Remove the locknut and shoulder bolt (8) holding the retract chain clevis to the anchor plates. The two anchor plates can remain in place on the third boom section. 3-44
Boom
18. Install the boom rear cover. 19. Properly connect the battery. 20. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. d. Fourth Boom Section Retract Chain Removal and Replacement 1. Park the machine on level ground. Place the transmission control lever in (N) NEUTRAL, engage the parking brake switch, level the boom and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Properly disconnect the battery. 4. Remove the boom rear cover. 5. Start the engine and extend the boom until the retract chain adjustment nut on the bottom of the second boom section is visible. Shut the engine OFF. 6. At the front underside of the boom, locate the retract chain locknut. Record the amount of threads extending beyond the locknut. This measurement will be the starting point for adjustment of the retract chain after installation.
MH2671
until all the tension on the retract chain is relieved. Shut the engine OFF. Note: Record the location of the shoulder bolt to ensure correct installation.
11
9. At the rear of the boom, locate the two retract chain anchor plates (11). The two anchor plates can remain in place on the fourth boom section. 10. Pull the retract chain clevis toward the rear of the boom, through the middle of the two center hoses on the chain reel and over the top of the chain reel. Let the clevis end of the retract chain hang out the rear of the boom. Use a piece of wire that is approximately 6 feet (1,8 m) long and tie it to the clevis end of the retract chain. This wire will be used to guide the chain back into the boom when the boom is extended to expose the other end for removal. 11. Have an assistant start the engine and slowly extend the boom. Guide the retract chain with the wire attached into the back of the boom. Extend the boom until the retract chain adjustment nut on the lower left side of the second boom section can be accessed and removed. Turn the engine OFF. 12. Remove the locknut and flat washer holding the threaded clevis on the retract chain to the tab in the second boom section.
10
OH0661
7. Loosen the locknut (10) on the retract chain clevis. DO NOT remove the locknut at this time, but loosen the nut as far as possible to gain as much slack as possible in the retract chain. 8. Return to the operators cab, start the engine and slowly retract the boom all the way back, and then extend the boom approximately 1 in (25 mm) or just
12
MH6510
6036, 6042, 8042, 10042, 10054
3-45
Boom
13. Attach a wire to the end of the retract chain clevis (12) with a threaded eye or a flat washer tack welded to a capscrew. The outside diameter of the eye or flat washer must be smaller than the diameter of the threads on the clevis. The wire must be long enough to pull the clevis and chain through the boom. The wire must be heavy enough to pull the weight of the entire chain back through the boom during the reassembly. 14. From the rear of the boom, using the wire attached to the rear anchor clevis, pull the retract chain through the middle of the two center hoses on the chain reel and over the top of the chain reel and out of the rear of the boom. 15. Remove the wire still attached from the clevis on the old chain. 16. Install the wire still attached, to the new chain clevis. 17. Coat the threads of the threaded clevis on the new chain with multi-purpose grease.
13 14
19. Guide the threaded end of the clevis through the hole in the tab (16) on the second boom section. 20. Remove the wire from the end of the clevis. 21. Place the flat washer onto the threaded clevis. Assemble a locknut onto the threaded clevis. Turn the locknut only 2 or 3 turns onto the clevis to allow assembly of the other end of the retract chain. 22. At the front of the boom, disconnect the extend chain clevis from the anchor plates on the second boom section. Remove the locknut holding the shoulder bolt to the anchor plates. Pull the extend chain clevis from between the plates and lay over the front of the fourth boom section. 23. Return to the operators compartment and start the engine and slowly retract the boom. To avoid having the retract chain becoming entangled, keep tension on the chain coming out the back of the boom. Retract the boom as far as possible with the Extend/ Retract cylinder. Turn the engine OFF. 24. The fourth boom section will not retract completely and must be manually pushed in. To avoid having the retract chain becoming entangled, keep tension on the chain coming out the back of the boom while the fourth boom section is pushed in. Note: Care should be taken not to push the fourth boom section in too far. If the fourth boom section is pushed in too far it could damage the hose reel at the back of the boom. 25. Remove the wire from the anchor clevis at the rear of the boom. Place the retract chain up and over the chain sheave in front of the hose reel assembly. Place the clevis between the two anchor plates. Line up the hole in the clevis with the anchor plate hole position recorded during removal.
17
15
MH6021
18. From the front of the boom, have an assistant pull on the tow wire while guiding the chain clevis between the two center hoses of the hose reel and under the chain sheave (13), on the left side of the boom and down the boom between the third (14) and second (15) boom sections. Keep the retract chain lined up squarely with the chain sheave and help feed the retract chain in while pulling on the wire from the front of the boom.
16
MH2671 MH5991
3-46
6036, 6042, 8042, 10042, 10054
Boom
26. Insert the shoulder bolt (17) through the plates and clevis and secure in place with a locknut. Tighten the locknut securely. 27. Pull the extend chain up and around the sheave at the front of the third boom section. 28. Place the extend chain clevis between the mounting plates at the front of the third boom section. Coat the shoulder bolt with anti-seize compound and insert through the plates and clevis. Secure the shoulder bolt in place with a locknut. Tighten securely, but the chain clevis should pivot freely. 29. Return to the operators compartment and start the engine. Slowly extend the boom to gain access to the retract chain adjustment nut on the lower left side of the second boom section. Shut the engine OFF. 30. Tighten the adjustment nut until the threads of the threaded clevis are flush with the top edge of the nut. This will be a starting point for adjustment of the fourth boom section retract chain. 31. Check and adjust the retract chain tension. Refer to Section 3.7.5, Boom Chain Tension Check. 32. Install the boom rear cover. 33. Properly connect the battery. 34. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
6036, 6042, 8042, 10042, 10054
3-47
Boom
3.8
QUICK ATTACH ASSEMBLY
4. Raise the boom until the attachment pivot pins have seated fully in the hooks on the attachment. 5. Tilt the attachment up slightly. The quick attach link should be tight up against the rear of the attachment, and the holes in the link and the attachment should be aligned. 6. Place the travel select lever in the (N) NEUTRAL position, engage the parking brake switch, unbuckle the seat belt and exit the machine using both hand holds. 7. Lift the quick attach lever. Insert the quick attach pin completely through the attachment and the quick attach link. Be sure that the quick attach lock lever has lowered and seated itself into the groove in the quick attach pin. 8. If equipped, connect Auxiliary hydraulic hoses. 9. If equipped, connect Auxiliary electric harness. 10. Return to the cab, fasten the seat belt and resume operation.
This machine is equipped with a quick attach assembly system for easy attachment changes.
3.8.1
Disconnecting from an Attachment
1. Park the machine on a hard, level surface. 2. Place the transmission control lever in the (N) NEUTRAL position and engage the parking brake switch 3. Ground the attachment and extend it out approximately 10 ft (3,05 m) and tilt the carriage backward. Shut the engine OFF. 4. Exit the machine using both hand holds. Note: If removing a standard carriage with forks, spread the forks apart on the carriage shaft. This will help give the carriage better support to stand alone. 5. If equipped, disconnect Auxiliary electric harness. 6. If equipped, disconnect Auxiliary hydraulic hoses.
3.8.3
2 3
Quick Attach Removal
1. Remove the lock bolt holding the Attachment Tilt cylinder rod end pin to the quick attach assembly. Remove the Attachment Tilt Cylinder pin. 2. Support the quick attach assembly. Remove the capscrew and locknut securing the quick attach pivot pin to the quick attach assembly. Remove the quick attach assembly. Record the location and quantity of the shim washers as the pin is being removed. 3. Inspect the above pins for nicks or surface corrosion. Use fine emery cloth to fix minor nicks or corrosion. If damaged or if it cannot be repaired the pin must be replaced.
OS0332
7. Raise the quick attach pin lock lever (2) and pull out the lock pin (3) at the bottom of the quick attach. 8. Return to the operators cab, fasten the seat belt and lower the attachment to the ground in a level position. Tilt the attachment forward. This will rotate the quick attach link back away from the attachment. 9. Lower and then retract the boom until the attachment pivot pins have disconnected from the attachment.
3.8.4
Quick Attach Installation
3.8.2
Connecting to an Attachment
1. Assemble the quick attach to the boom head. Line up the quick attach between the mounts on the boom head. The quick attach should be centered in the boom head. Reassemble the shims between the quick attach and the boom head. 2. Coat the quick attach head pin with an anti-seize compound. Insert the quick attach head pin through the quick attach and boom head. Secure with the previous capscrew and locknut. 3. Align the quick attach with the Attachment Tilt cylinder rod end and insert the Attachment Tilt cylinder pin. Align the Attachment Tilt cylinder pin and screw in the locking bolt. Torque as required.
1. Perform this procedure on a hard, level surface only. Position the machine directly behind the attachment to be mounted. 2. Tilt the quick attach backward. 3. Extend the boom approximately 10 ft (3,05 m) and drive the machine forward until the attachment pivot pins are below and between the two hooks on the attachment. 3-48
6036, 6042, 8042, 10042, 10054
Boom
3.9
BOOM WEAR PADS

5
The wear pads on this machine are flat rectangular wear pads with metal inserts. A total of 32 wear pads are installed on the boom sections of the 6036, 6024, 8042 & 10042 machines and 47 wear pads on the 10054 machines.
3.9.1
1
Wear Pad Inspection

1
Ma2070
Inspect all wear pads for wear. If the angle indicators (1) on the ends of the wear pads are visible, the wear pads can be reused. If the pads show uneven wear (front to back), they should be replaced. Replace pads as a set if worn or damaged.
Maintain a total boom section clearance (5) of 0.070 - 0.130 in (1,78 - 3,30 mm) both the horizontal and vertical directions.
A
3.9.2
Wear Pad Installation and Lubrication
MY3620
Note: Inspect all wear pads. Replace as necessary. The following wear pad procedure must be followed to insure the proper wear pad installation: The wear pad inserts and mounting bolts MUST be clean from any grease, oil or other contaminates before applying Loctite 242 and installing mounting bolts. Apply Loctite 242 to all wear pad mounting bolts.
4
3 2
The length of the wear pad bolt depends on the number of shims, spacers and washers being used. The thickness of each threaded wear pad insert is 0.562 in (14,27 mm)(A). The bolt length should be determined by measuring the distance from the face of the insert to the face of the boom (B) including any spacer, shim(s) and washer(s). Bolt thread engagement in the wear pad insert should be 0.275 0.040 in (6,98 1,0 mm). One or two hardened washers are to be used on each wear pad bolt except where noted otherwise. DO NOT use more than two hardened washers. Use only one hardened washer if mounting bolts are recessed. Wear Pad Bolt Torque: 3/8-16 Bolt, 31 lb-ft (42 Nm) Torque wear pad bolts after shimming is completed. Lubricate the face and pockets of each wear pad after being installed. Boom Section Wear Pad Pathway Lubrication: Clean and lightly grease all wear pad pathways with Mystik Tetrimoly grease. Clean and lightly grease the hose carrier guide bar pathways with Mystik Tetrimoly grease.
MAQ0010
A spacer (2) must be used before any shim (3) is used. A shim (3) must be inserted between the spacer (2) and wear pad support plate, block or boom section (4). The number of shims can vary at each shim point. The bottom wear pads must be shimmed equally on each side.
6036, 6042, 8042, 10042, 10054
3-49
Boom
3.10
BOOM EXTEND AND RETRACT CHAINS

Boom Chain Inspection
Following are some examples of dynamic shock loading which can impose abnormal loads above the endurance limit of a leaf chain. High velocity movement of load, followed by sudden, abrupt stops. Carrying loads in suspension over irregular surfaces such as railroad tracks, potholes, and rough terrain. Attempting to inch loads which are beyond the rated capacity of the vehicle. The above load cycles and environmental conditions make it impossible to predict chain life. It is therefore necessary to conduct frequent inspections until replacement life can be predicted. The boom chains normal life expectancy can be expressed as a maximum percent of elongation. This is generally 3%. As the chain flexes back and forth over the sheave, the bearing joints (pins and inside link plates) gradually incur wear due to articulation.
3.10.1
WARNING
Worn pins, stretched or cracked links or corrosive environments can cause chain failure. A chain failure could result in uncontrolled boom movement, loss of load or machine instability. Under normal operating conditions the boom chains will need to be inspected every 250 hours of operation. The retract chains need to be exposed and inspected every 1000 hours of operation. Environmental conditions and dynamic impulse/shock loads can drastically affect normal operating conditions and require more frequent inspection intervals. Environments in which material handling vehicles operate can vary widely from outdoor moisture to temperature to mildly corrosive or highly corrosive industrial atmospheres, in addition to abrasive exposures such as sand and grit. Some effects can be as follows: Moisture - Corrosive rusting reduces chain strength by pitting and cracking. Temperature - Low temperature reduces chain strength by embrittlement. Going in and out of cold storage results in moisture from condensation. Chemical Solutions or Vapors - Corrosive attack on the chain components and/or the mechanical connections between the chain components. Cracking can be (and often is) microscopic. Going from microscopic cracking to complete failure can be either abrupt or may require an extended period of time. Abrasives - Accelerated wearing and scoring of the articulating members of the chain (pins an d plates), with a corresponding reduction in chain strength. Due to the inaccessibility of the bearing surfaces (pin surfaces and plate apertures), wear and scoring are not readily noticeable to the naked eye.
3.10.2
Inspection Guidelines
1. Park the machine on a firm, level surface, raise the boom to a horizontal (level) position, place the transmission control lever in (N) NEUTRAL, engage the park brake switch. 2. Fully extend the boom until the extend chain is taut. Shut the engine off. 3. The extend chains will be visible for inspection with the vehicle in this state. 4. While doing the chain inspection, check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain. 5. Inspect the retract chains every 1000 hours of operation. 6. Inspect the chains for the following conditions:
3-50
6036, 6042, 8042, 10042, 10054
Boom
Edge Wear Distorted or Battered Link Plates 8 5 1 2
MZ1463
Check the chain for wear on the link plate edges caused by running back and forth over the sheave. The maximum reduction of material should not exceed 5%. Measure and compare to a normal link plate height by measuring a portion of chain that does not run over the sheave. If the measured plate height (1) is 5% less than the normal plate height (2), discard and replace the chain. Elongation It is important to measure the chain in the section that moves over the sheaves because it receives the most frequent articulation. Measuring the chain near its clevis terminals could give an inaccurate reading. The ends of the chains, near the clevis terminal, will not have flexed as frequently, if at all, as the middle of the chains. It is best to measure in 12 pin increments from pin center to pin center. For example, if the links are one inch from pin center to pin center, the distance should be 12 in (305 mm). If the links are 3/4 in (19,0 mm) apart, the distance after 12 pins should be 9 in (228,6 mm). 4 3
MZ1466
Distorted or battered link plates (5) on a leaf chain can cause tight joints and prevent flexing. Turning or Protruding Pins Highly loaded chain, operating with inadequate lubrication can generate abnormal frictional forces between pin and link plates. When chain is allowed to operate in this condition, a pin or series of pins, can begin to twist out of a chain, resulting in failure.
6
MZ1465
7 8
Examine the pin head rivets to determine if the VEE flats are still in correct alignment (6). Chain with rotated/displaced heads (7) or abnormal pin protrusion (8) should be replaced immediately. DO NOT attempt to repair the chain by welding or driving the pin(s) back into the chain. Once the press fit integrity between outside plates and pins has been altered, it cannot be restored. Any wear pattern on the pin heads or the sides of the link plates indicates misalignment in the system. This condition damages the chain as well as increases frictional loading and should be corrected.
MY1360
If the distance measured (3) is 3% greater than the normal length (4), discard and replace the chain.
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Boom
Cracked Plates Inspect the chains very carefully, front and back as well as side to side, for any evidence of cracked plates. If any one crack is discovered, the chain should be replaced in its entirety. It is important, however to determine the cause of the crack before installing a new chain so the condition does not repeat itself. The types of cracks are: Fatigue Cracking Fatigue cracks (9) are a result of repeated cyclic loading beyond the chains endurance limit. Stress Corrosion Cracking - The 10 outside link plates are particularly susceptible to stress corrosion cracking (10). 9
MZ1467
3.10.3
Expose Chains for Inspection
e. Extend Chains 1. Park the machine on a firm, level surface. Place the transmission control lever in (N) NEUTRAL, engage the park brake switch and raise the boom to a horizontal (level) position. 2. Fully extend the boom until both extend chains are taut. Shut the engine OFF. The extend chains will be visible for inspection with the machine in this state. While doing the chain inspection, check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain. If during the inspection, any chain is found to be damaged or stretched, the chain must be replaced. It is recommended that when any chain is replaced, that all the chains and clevises be replaced at the same time. f. Retract Chains
MZ1468
Corrosion Fatigue Cracking - Corrosion fatigue cracks are very similar to fatigue cracks in appearance. Corrosion fatigue is the combined action of an aggressive environment and cyclic stress. Other Modes of Failure Ultimate Strength Failure These types of failures are 11 caused by overloads far in excess of the design load. Either fractured plates (11) 12 or enlarged holes (12) can occur. If either of these failures occurs, the chain should be replaced immediately.
The three retract chains are only partially visible through the rear of the boom with all the sections retracted. It is possible to see a section of the retract chain as the boom is slowly extended. If there is ANY question that one or all the retract chains are damaged, the boom should be removed and disassembled with the retract chains being inspected and replaced if necessary. Note: DO NOT attempt to repair a chain. Replace a stretched or damaged chain with a new part. Always replace both the chain and the clevis. It is recommended that when any chain is replaced, that all chains and clevis be replaced at the same time.
MZ1469
MZ1470
Tight Joints - All joints in the chain should flex freely. Tight MZ1471 13 joints (13) resist flexing. If the problem is caused by dirt or foreign substance packed in the joints, clean and lubricate thoroughly before re-installing the chain. If the problem is caused by corrosion and rust or bent pins, replace the chain.
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Boom 3.10.4 Chain Lubrication
3.11
FORKS
After inspection and before being returned to service, chains must be lubricated with Mystik Tetrimoly Grease. The lubricant must penetrate the chain joint to prevent wear. Applying lubricant to the external surfaces will prevent rust, but the chains should be articulated to make sure the lubricant penetrates to the working surfaces between the pins and links. To prepare the chain for lubrication, the chain plates should be brushed with a stiff brush or wire brush to clear the space between the plates so that lubricant can penetrate to the working surfaces. Lubricant may be applied with a narrow paint brush or directly poured on, but the chain should be well flooded with lubricant and the boom should be extended and retracted to be sure that the lubricant penetrates to the working surfaces. All surplus lubricant should be wiped away from the external surfaces. DO NOT use a solvent for this wiping operation. Regular application of lubricant is necessary to make sure that all working surfaces are adequately lubricated. In extremely dusty conditions, it may be necessary to lubricate the chains more often. Refer to Section 2.5, Service and Maintenance Schedules, and Section 2.6, Lubrication Schedules, for detailed information. Lubrication of chains on vehicles working consistently in extreme hot or cold conditions requires special consideration. Contact the local distributor for guidance.
Forks should be cleaned and inspected prior to being attached to carriage. If the following criteria is not met, forks must be removed from service immediately. Daily Inspection
6 9 10 5 4 14 8 7
13 12
11
MH6460
1. Inspect forks (4) for cracks, paying special attention to heel (5) and mounting tubes (6). 2. Inspect forks for broken or bent tips (7) and twisted blades (8) and shanks (9). Yearly Inspection 1. Straightness of the upper face of blade (8) and the front face of shank (9) should not exceed 0.5 percent of the length of blade or height of shank. 2. Angle (10) between upper face of blade and front face of shank should not exceed 93 degrees. 3. Thickness of blade (13) and shank (14) should not be reduced to 90 percent of original thickness. 4. Ensure fork length (12) is adequate for intended loads. 5. Fork markings should be legible, re-stamp if required. 6. Compare fork tips (11) when mounted on a carriage. Maximum difference in height of fork tips is 3 percent of the length of the blade (13).
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Boom
3.12
TROUBLESHOOTING
This section provides an easy reference guide covering the most common problems that occur during operation of the boom.
Problem
1. Boom will not extend or retract
Cause
1. Broken hydraulic hose(s) or tube(s) and/or connections leaking. 2. Extend/retract hydraulic system not operating properly. 3. Faulty extend/retract cylinder.
Remedy
1. Locate break, replace hose(s) or tube(s), tighten connections. 2. Refer to Section 8.4, Hydraulic Circuits. 3. Repair cylinder. Refer to Section 8.8.1, General Cylinder Instructions. 4. Replace chains as needed 1. Shim wear pads to correct gap. Replace wear pads as needed. Refer to Section 3.9, Boom Wear Pads. 1. Lubricate at regular intervals. Refer to Section 2.6, Lubrication Schedules. Replace worn pins as needed. 2. Replace bearing(s) and lubricate at regular intervals Refer to Section 2.6, Lubrication Schedules. 1. Lubricate at regular intervals. Refer to Section 2.6, Lubrication Schedules. Replace worn pins as needed. 2. Replace bushing(s) and lubricate at regular intervals. 1. Locate break, replace hose(s) or tube(s), tighten connections. 2. Refer to Section 8, Hydraulic System. 3. Repair cylinder. Refer to Section 8.10.4, Cylinder Inspection. 4. Replace bearing.
4. Broken chains or anchors 2. Boom shifts to right or left when extending. 1. Boom side wear pads improperly shimmed or worn.
3. Excessive pivot pin noise and/or wear.
1. Insufficient lubrication.
2. Worn bearing(s).
4. Excessive Compensation cylinder pivot pin noise and/ or wear.
1. Insufficient lubrication.
2. Worn bushing(s). 5. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes and/or connection leaks. 2. Lift/lower hydraulic system not operating properly. 3. Faulty lift/lower cylinder. 4. Seized boom pivot pin bearing.
3-54
6036, 6042, 8042, 10042, 10054
Boom
Problem
6. Drooping chain, or jerky boom extend or retract functions.
Cause
1. Chain(s) tension not properly adjusted. 2. Chain(s) stretched or binding.
Remedy
1. Adjust chain(s). 2. Replace chains as needed. Refer to Section 3.7, Boom Extend and Retract Chains. 3. Replace wear pad. Refer to Section 3.9, Boom Wear Pads. 4. Remove contamination and/or corrosion from wear pad sliding surfaces and lubricate. If the surfaces cannot be reconditioned, replace the boom section(s). 5. Refer to Section 8.4, Hydraulic Circuits. 6. Replace the damaged boom section. Refer to Section 3.4, Boom Assembly Maintenance. 1. Locate break, replace hose(s) or tube(s), tighten connections. 2. Refer to Section 8.4, Hydraulic Circuits. 3. Repair cylinder. Refer toSection 8.8.1, General Cylinder Instructions. 4. Replace bushing. 1. Lubricate at regular intervals. Refer to Section 2.5, Service and Maintenance Schedules. Replace worn pins as needed. Refer to Section 8.8.1, General Cylinder Instructions. 2. Replace bushing(s) and lubricate at regular intervals. Refer to Section 2.6, Lubrication Schedules.
3. Wear pads loose, contaminated, excessively worn or damaged. 4. Contaminated, corroded or rusted wear pad sliding surfaces.
5. Extend/Retract hydraulic system not operating properly. 6. Damaged boom section.
7. Boom will not raise or lower.
1. Broken hydraulic hoses or tubes and/or connection leaks. 2. Lift/Lower hydraulic system not operating properly. 3. Faulty Lift cylinder.
4. Seized boom pivot pin bushing. 8. Excessive Lift/Lower cylinder pivot pin noise and/or wear. 1. Insufficient lubrication.
2. Worn self-aligning bushing(s).
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3-55
Boom
Problem
9. Rapid boom pad wear.
Cause
1. Incorrect wear pad gap.
Remedy
1. Check wear pad gaps and correct as needed. Refer to Section 3.9, Boom Wear Pads. 2. Reduce cycle times. 3. Remove contamination and/or corrosion from wear pad sliding surfaces and lubricate. If the surfaces cannot be reconditioned, replace the boom section(s). 4. Clean equipment frequently. 1. Refer to Section 8, Hydraulic System. 1. Adjust to correct tension. Refer to Section 3.7.1, Boom Chain Inspection.- Replace chains as needed. 2. Lubricate chain sheave. (Refer to Section 2.5, Service and Maintenance Schedules. 3. Lubricate chain sheave. Refer to Section 2.5, Service and Maintenance Schedules. Repair or replace chain sheave(s) as needed. 4. Lubricate at regular intervals. Refer to Section 2.5, Service and Maintenance Schedules. Replace chains as needed.
2. Rapid cycle times with heavy loads. 3. Contaminated, corroded or rusted wear pad sliding surfaces.
4. Operating in extremely dusty/ abrasive conditions. 10. Auxiliary hydraulics will not operate. 11. Excessive chain wear. 1. Auxiliary hydraulic system not operating properly. 1. Improper chain adjustment.
2. Chain sheave(s) not properly lubricated. 3. Chain sheave(s) not rotating freely.
4. Improper chain lubrication.
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Section 4 Cab and Covers
Contents
PARAGRAPH 4.1 4.2 TITLE PAGE 4-2 4-3 4-3 4-3 4-3 4-3 4-4 4-5 4-6 4-7 4-7 4-8 4-9
4.3
4.4 4.5
Operators Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . Operators Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.1 Steering Column and Steering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.2 Service Brake Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.3 Throttle Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.4 Joystick Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.5 Windshield Wiper Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.6 Heater/Defroster System (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4-1
Cab and Covers
4.1
OPERATORS CAB AND COVERS COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the machine cab and covers. The following illustration identifies the components that are referred to throughout this section.
HEATER AND A/C CONTROLS (OPTIONAL) STEERING WHEEL INSTRUMENT PANEL
TRANSMISSION CONTROL LEVER
BOOM CONTROL JOYSTICK PARK BRAKE SWITCH ATTACHMENT TILT/ SWAY CONTROL JOYSTICK
IGNITION SWITCH
AUXILIARY HYDRAULIC CONTROL JOYSTICK (IF EQUIPPED)
SERVICE BRAKE PEDAL
MH6230
ACCELERATOR PEDAL
4-2
6036, 6042, 8042, 10042, 10054
Cab and Covers

3. Open the rear door. Allow the system fluids to cool.
WARNING
DO NOT service the machine without following all safety precautions as outlined in the Safety Practices section of this manual.
4. Properly disconnect the battery. 5. Remove the left, right and lower dash panels.
1
4.2
4.2.1
OPERATORS CAB
Cab Safety
2
WARNING
The protection offered by this ROPS/FOPS will be impaired if subjected to any modification or structural damage, at which time replacement is necessary. ROPS/FOPS must be properly installed using fasteners of correct size and grade, and torqued to their specified value. DO NOT weld, grind, drill, repair or modify the cab in any way. Any modification or damage to cab structural components requires cab replacement. The lives of the operator and others are potentially at stake. To help ensure optimum safety, protection and performance, replace the cab if it is damaged. Refer to the appropriate parts manual for ordering information.
MY0120
4.2.2
Serial Number Decal
The cab serial number decal is located on the left side of the cab, behind the seat. Information specified on the serial number plate includes the cab model number, the cab serial number and other data. Write this information down in a convenient location to use in cab correspondence.
6. Remove the steering wheel (1), disconnect and remove the travel select lever (2), disconnect the instrument panel harness connector (3). 7. Label, disconnect and cap the four hoses from the side of the steering valve (4). Cap the fittings on the steering valve. Label, disconnect and plug the load sense hose at the front of the steering valve. Cap the fitting on the steering valve. 8. Disconnect the horn button wire from the cab wiring harness. 9. Support the bottom of the steering valve, and remove the four capscrews and lockwashers. Remove the steering valve through the lower dash panel opening.
4.3
4.3.1
CAB COMPONENTS
Steering Column and Steering Valve
a. Steering Valve Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake and turn the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.
6036, 6042, 8042, 10042, 10054
4-3
Cab and Covers

7. Install the travel select lever, connect the instrument panel harness connector, install the steering wheel assembly. Torque the steering wheel nut to 50 lb-ft (68 Nm). 8. Properly connect the battery. 9. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 10. Start the engine and check the operation of steering system. Check for hydraulic fluid leaks. Check the hydraulic fluid level in the tank and add fluid as required. 11. Install the left, right and lower dash panels. 12. Close and secure the rear door. c. Steering Test Conduct a pressure check of the steering hydraulic circuits at the main control valve. Refer to Section 8.3.1, Pressure Checks and Adjustments.
MA8861
4.3.2
Service Brake Pedal
10. Remove the steering column (5), by pushing it down, and removing it through the lower dash panel opening. Note: DO NOT disassemble the steering valve. The steering valve is not serviceable and must be replaced in its entirety, if defective. b. Steering Valve Installation 1. Install the steering column and steering valve, by inserting them through the lower dash panel opening. Position steering valve in the cab to its original orientation. Secure the steering valve and column with the previously used hardware. Torque to 13 lb-ft (18 Nm). Note: ALWAYS use new o-rings when servicing the machine. 2. Install new o-rings into the fittings. Lubricate the orings with clean hydraulic oil. 3. Uncap and connect the previously labeled load sense hose to the steering valve. 4. Install new o-rings into the steering valve fittings. Lubricate the o-rings with clean hydraulic oil. 5. Uncap and connect the remaining previously labeled four hoses to the steering valve. 6. Connect the horn button wire to the cab wiring harness.
a. Brake Valve Removal Refer to Section 8.7.3, Service Brake Valve, for removal information. b. Brake Valve Installation Refer to Section 8.7.3, Service Brake Valve, for installation information. c. Service Brake Pedal Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake and turn the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 4. Properly disconnect the battery.
4-4
6036, 6042, 8042, 10042, 10054
Cab and Covers 4.3.3 Throttle Pedal
a. Throttle Pedal Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake and turn the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Properly disconnect the battery.
MH6210
5. Remove the lower dash panel. 6. Remove the two capscrews, four flat washers, two pivots and two nuts securing the service brake pedal to the cab. 7. Remove the service brake pedal from the cab. d. Service Brake Pedal Installation 1. Position the service brake pedal in its mounting location within the cab. 2. Insert the two brake pedal pivots into mounting locations on the service brake pedal. 3. Install the service brake pedal with the previously used hardware. 4. Be sure the brake pedal has the correct range of motion. Secure pivot pin with bolt and lockwasher. 5. Adjust the service brake as needed. Refer to Section 9.10.5, c. Service Brake Switch Adjustment. 6. Install the lower dash panel. 7. Properly connect the battery. 8. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 9. Close and secure the rear door.
MH6240
4. Disconnect the electrical harness connector (4). 5. Remove the bolts (5) securing the throttle pedal to the throttle pedal bracket (6). 6. Remove the throttle pedal assembly from the cab. b. Throttle Pedal Installation 1. Position the throttle pedal in its mounting location within the cab. 2. Secure the throttle pedal in place with previously used hardware. 3. Reconnect the wire harness plug to the front of the throttle pedal. 4. Properly connect the battery. 5. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
6036, 6042, 8042, 10042, 10054
4-5
Cab and Covers 4.3.4 Joystick Assemblies

4
These removal and installation instructions apply to the boom control, attachment tilt/sway and auxiliary hydraulic joysticks. a. Joystick Assembly Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake and turn the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Properly disconnect the battery. 4. Remove the console panel in the cab.
MAQ0050
6. Remove the four capscrews (4) and remove the joystick assembly from the machine. b. Joystick Assembly Installation 1. Secure the joystick to the cab with the previously used hardware. 2. Connect the control cables at the joystick: a. Install the end of the control cable into the slider head (5) as recorded during removal. Tighten the upper jam nut (3). b. Loosely install the cable nut (2) into the slider head. c. Engage the control lever to expose the flats (1) on the slider head. Place a wrench on the flats to hold the slider head, and tighten the cable nut to a maximum of 55 lb-ft (75 Nm). d. Repeat steps for remaining cables. 3. Properly connect the battery.
4. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 5. Test the joystick function: Boom Control Joystick: Move the joystick handle rearward, activating the boom lift function. The boom should RISE. Move the joystick handle forward, activating the boom lower function. The boom should LOWER. Move the joystick handle to the right, activating the boom extend function. The boom should EXTEND.
MA8521
Move the joystick handle to the left, activating the boom retract function. The boom should RETRACT. Attachment Tilt/Sway Control Joystick Move the joystick handle rearward, activating the attachment tilt function. The boom should TILT UP. Move the joystick handle forward, activating the attachment tilt function. The boom should TILT DOWN. Move the joystick handle to the right, activating the frame sway function. The boom should SWAY RIGHT.
6036, 6042, 8042, 10042, 10054
Note: Record the location, and label all cables to ensure correct installation. 5. Disconnect control cables at the joystick: a. Push the control lever to expose the flats (1) on the slider head. Place a wrench on the flats to hold the slider head, and loosen the cable nut (2). b. Loosen the upper jam nut (3), and remove the cable from the bracket. c. Repeat steps for remaining control cables. 4-6
Cab and Covers

Move the joystick handle to the left, activating the frame sway function. The boom should SWAY LEFT. Auxiliary Control Joystick Move the joystick handle to the right, the auxiliary attachment should LOWER/OPEN. Move the joystick handle to the left, the auxiliary attachment should RAISE/CLOSE. 6. Install console panel in the cab. 7. Install the transmission covers.
6 8 7
4.3.5
Windshield Wiper Assembly
Refer to Section 9.8, Window Wiper/Washer Windshield Wiper Motor, for removal and installation information.
4.3.6
Heater/Defroster System (If Equipped)
MA8371
a. Heater Assembly Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Place a suitable container beneath the radiator drain plug or petcock. Slowly turn the radiator cap to the first stop, and allow any pressure to escape. Remove the radiator cap. 6. Place a funnel at the base of the radiator to channel the drained coolant into the container. Loosen the drain plug or petcock and allow the coolant to drain. 7. Transfer the coolant to a container with a cover, and label as Used Antifreeze. Dispose of the used coolant at an approved recycling facility. 8. Close the radiator drain plug or petcock. 9. Remove the heater access panel. 10. Label, disconnect and cap the heater hoses. Pull the hoses through the grommets.
Note: The capscrew (6) at the lower rear position on each side of the heater will be secured with an insert nut (7). 11. Remove the eight capscrews, six nuts and six lockwashers. 12. Carefully pull the heater assembly forward. Label and disconnect the wiring harness connections at the blower. 13. Remove the heater assembly (8). 14. If the heater assembly is to be replaced: Remove the four hex-slotted capscrews, and remove the mounting bracket from the heater assembly. b. Heater Assembly Installation 1. Connect the wiring harness connections to the blower. Note: The capscrew (6) at the lower rear position on each side of the heater will be secured with an insert nut (7). 2. Slide the heater/mounting bracket assembly (8) into the seat riser, and secure with the eight capscrews, six lockwashers and six nuts. 3. Pull the hoses through the grommets. Uncap and connect the previously labeled hoses to the heater. 4. Install the heater access panel and secure with the previously used hardware. 5. Fill the cooling system completely with coolant, allowing time for the coolant to fill the engine block. The cooling system capacity is listed in Section 2.4, Fluid and Lubricant Capacities. 6. Properly connect the battery.
6036, 6042, 8042, 10042, 10054
4-7
Cab and Covers

7. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. Note: When the engine is initially started, run it briefly at low idle and check the machine for any visual sign of fluid leakage. STOP the engine immediately if any leakage is noted, and make any necessary repairs before continuing. 8. Wait for the engine to cool and check the coolant level. Add coolant as required to bring the coolant to the proper level. 5. Place a suitable container beneath the radiator drain plug or petcock. Slowly turn the radiator cap to the first stop and allow any pressure to escape. Remove the radiator cap. 6. Place a funnel at the base of the radiator to channel the drained coolant into the container. Loosen the drain plug or petcock and allow the coolant to drain. 7. Transfer the coolant to a container with a cover, and label as Used Antifreeze. Dispose of the used coolant at an approved recycling facility. 8. Close the radiator drain plug or petcock.
4.4
CAB REMOVAL
WARNING
The protection offered by this ROPS/FOPS will be impaired if subjected to any modification or structural damage, at which time replacement is necessary. ROPS/FOPS must be properly installed using fasteners of correct size and grade, and torqued to their specified value. Note: To help ensure safety and optimum performance, replace the cab if it is damaged. Refer to the appropriate parts manual for ordering information. Inspect the cab, its welds and mounts. If modification, damage, a cracked weld and/or fatigued metal is discovered, replace the cab. Contact an authorized service distributor with any questions about the suitability or condition of a cab. Note: Remove and label cab components as needed before removing the cab from the machine. Label, disconnect and cap hydraulic hoses. Transfer cab parts to the replacement cab after the replacement cab is securely mounted on the machine. 1. Park the machine on a firm, level surface. Allow sufficient overhead and side clearance for cab removal. Level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the park brake and shut the engine OFF. 2. Block all four wheels to help prevent the machine from moving. Assure that there is sufficient overhead and side clearance for cab removal. 3. Open the rear door. Allow the system fluids to cool. 4. Properly disconnect the battery. Note: Steps 5 thru 10 apply to machines equipped with cab heater.
MA8781
9. Working under the cab, loosen the clamp screw (1) and disconnect the heater control cable (2) from the heater control valve. Label, disconnect and cap the heater hoses. 10. Remove the heater access panel. Label, disconnect and cap the heater hoses and route them through the opening in the bottom of the cab. 11. Remove the console panel in the cab.
MA8471
4-8
6036, 6042, 8042, 10042, 10054
Cab and Covers

12. Label and disconnect the two cab-to-wiring harness connectors (3). Push the connectors through the opening at the bottom of the cab. 13. Remove the joystick assemblies from the cab. Refer to Section 4.3.4, a. Joystick Assembly Removal. Route the joystick cables through the opening at the bottom of the cab. 19. Carefully begin to lift the cab. Stop and check that all wiring, hydraulic hoses and fasteners are disconnected and removed. 20. When all wiring, hydraulic hoses and fasteners are disconnected or removed, carefully and slowly lift the cab and remove it from the frame. Readjust the position of the sling as needed to help balance the cab during removal. 21. When the cab is completely clear of the machine, carefully lower it to the ground. Block up or support the cab so that it does not move or fall. Assure that no personnel enter the cab while it is being removed from the machine. 22. Inspect the condition of the fittings, clamps, hydraulic hoses, etc. Replace parts as indicated by their condition.
4
MA8501
23. Inspect and replace other machine parts that are exposed with the cab removed. Repair or replace as required.
14. Working under the cab, label, disconnect and cap the hydraulic hoses at the cab fittings (4). Cap all fittings to keep dirt and debris from entering the hydraulic system. 15. If necessary, remove mirrors and other cab components that may become damaged during cab removal.
6
4.5
CAB INSTALLATION
1. Block all four wheels to help prevent the machine from moving. Assure that there is sufficient overhead and side clearance for cab installation. 2. Attach a clevis (5) to each of the cab lifting brackets. Route a sling (6) with a suitable lifting capacity to carry the weight of the cab through the clevis to a hoist or over head crane. Make sure the sling is centered between the clevis to ensure even lifting. 3. Carefully begin to align the cab with the mounting holes in the frame. Stop and check that wiring, hydraulic hoses, cables, etc. will not be pinched or damaged as the cab is positioned. Readjust the position of the sling as needed to help balance the cab during installation. 4. Install the two upper cab-to-frame capscrews and washers. Torque to 480 lb-ft (651 Nm). 5. Install the two lower cab-to-frame capscrews and washers. Torque to 480 lb-ft (651 Nm).
MA3331
6. Under the cab, install new o-rings into the fittings. Lubricate the o-rings with clean hydraulic oil.
16. Attach a clevis (5) to each of the cab lifting brackets. Route a sling (16) with a suitable lifting capacity to a hoist or overhead crane. Center the sling to ensure even lifting. 17. Remove the two upper cab-to-frame capscrews and two flat washers. 18. Remove the two lower cab-to-frame capscrews and two flat washers.
6036, 6042, 8042, 10042, 10054
4-9
Cab and Covers
4
MA8501
7. Uncap and connect the previously labeled hydraulic hoses at the cab fittings (4). 8. Route the joystick control cables through the opening at the bottom of the cab. Install the joystick assemblies. Refer to Section 4.3.4, b. Joystick Assembly Installation.
MA8781
13. Connect the heater control cable (2) to the heater control valve (1). 14. Fill the cooling system completely with coolant, allowing time for the coolant to fill the engine block. The cooling system capacity is listed in Section 2.4, Fluid and Lubricant Capacities. 15. Properly connect the battery. 16. Carefully examine all cab components, fasteners, etc., one last time before engine start-up. Rectify any faulty conditions. 17. Start the engine and check the operation of all controls. Check for hydraulic fluid leaks. Check the hydraulic fluid level in the tank and add fluid as required. Note: When the engine is initially started, run it briefly at low idle and check the machine for any visual sign of fluid leakage. STOP the engine immediately if any leakage is noted, and make any necessary repairs before continuing.
MA8471
9. Route the wiring harness connectors through the opening at the bottom of the cab. Connect the previously labeled connectors (2). 10. Install the console panel. 11. Install the transmission covers. 12. Working under the cab, connect the coolant hoses to the heater hoses.
18. Wait for the engine to cool and check the coolant level. Add coolant to the overflow bottle as required to bring the coolant to the proper level. 19. Install the mirrors and all other cab components as needed, if removed. 20. Unblock the wheels. 21. Close and secure the rear door.
4-10
6036, 6042, 8042, 10042, 10054
Section 5 Axles, Drive Shafts, Wheels and Tires
Contents
PARAGRAPH 5.1 5.2 5.3 5.4 TITLE PAGE 5-2 5-3 5-4 5-4 5-4 5-4 5-4 5-4 5-5 5-7 5-11 5-14 5-14 5-14 5-14 5-14 5-14 5-14 5-15 5-16 5-16 5-16 5-18
5.5 5.6
5.
5.8 5.9
Axle, Drive Shaft and Wheel Component Terminology (6036 & 6042) . . . . . . . . Axle, Drive Shaft and Wheel Component Terminology (8042, 10042 & 10054) . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.1 Axle Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.2 Axle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.3 Axle Internal Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.4 Axle Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.5 Axle Replacement (6036 & 6042). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.6 Axle Replacement (8042, 10042 & 10054). . . . . . . . . . . . . . . . . . . . . . . . Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6.1 Drive Shaft Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6.2 Drive Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6.3 Drive Shaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6.4 Drive Shaft Cleaning and Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6.5 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repeat the above procedure on the rear drive shaft. . . . . . . . . . . . . . . . . . . . . . 5.7.1 Removing Wheel and Tire Assembly from Machine. . . . . . . . . . . . . . . . . 5.7.2 Installing Wheel and Tire Assembly onto Machine . . . . . . . . . . . . . . . . . . Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8.1 Brake Disc Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6036, 6042, 8042, 10042, 10054
5-1
Axles, Drive Shafts, Wheels and Tires
5.1
AXLE, DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGY (6036 & 6042)
To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the axles, drive shafts, wheels and tires. The following illustration identifies the components that are referred to throughout this section.
ENGINE-TO-TRANSMISSION DRIVE SHAFT
STABILIZER CYLINDER (6042 ONLY)
FRAME SWAY CYLINDER
REAR STEERING CYLINDER
FRONT STEERING CYLINDER
REAR AXLE ASSEMBLY REAR DRIVE SHAFT
FRONT DRIVE SHAFT
FRONT AXLE ASSEMBLY

MA9181
5-2
6036, 6042, 8042, 10042, 10054
5.2
AXLE, DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGY (8042, 10042 & 10054)
To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the axles, drive shafts, wheels and tires. The following illustration identifies the components that are referred to throughout this section.
ENGINE-TOTRANSMISSION DRIVE SHAFT
STABILIZER CYLINDER
FRAME SWAY CYLINDER
REAR STEERING CYLINDER FRONT STEERING CYLINDER REAR AXLE ASSEMBLY REAR DRIVE SHAFT
FRONT DRIVE SHAFT FRONT AXLE ASSEMBLY

MH3241
6036, 6042, 8042, 10042, 10054
5-3
5.3
GENERAL INFORMATION
5.4.3
Axle Internal Service
WARNING
DO NOT service the machine without following all safety precautions as outlined in Section 1, Safety Practices, of this manual. Note: To help ensure optimum performance, the drive shaft assemblies are specially balanced as a unit at the factory. When servicing any flange yoke, slip yoke or drive shaft tube, order a complete assembly if components are bent or damaged. Refer to the appropriate parts manual for ordering information. Before performing any inspection, maintenance or service operation, thoroughly clean the unit. The axles and drive shafts should be checked and repaired only by experienced service technicians who are aware of all safety instructions and particular component features. Use suitable products to thoroughly clean all disassembled mechanical parts to help prevent personal injury to the worker and prevent damage to the parts. Carefully inspect the integrity of all moving parts (bearings, yokes, tubes, gears, shafts, etc.) and fasteners (nuts, bolts, washers, etc.) as they are subject to major stress and wear. Always replace any damaged, worn, cracked, seized or otherwise improper parts that could affect the safe and proper functioning of the machine, axles and drive shafts.
Detailed axle service instructions (covering the axle, differential, brakes and wheel-end safety, repair, disassembly, reassembly, adjustment and troubleshooting information) are provided in the appropriate ZF Axle Repair Manual. Machine 6036, 6042 8042, 10042, 10054 8042 10042, 10054 ZF Model MS-T 3045 MS-T 3060 MS-T 3045 MS-T 3055 Axle Both Front Rear Rear P/N 8990419 8990430 8990419 8990419
5.4.4
Axle Maintenance
CLEANING: Clean parts with machined or ground surfaces (such as gears, bearings and shafts) with emulsion cleaners or petroleum-based cleaners. DO NOT steam clean internal components and the interior of the planetary hub and axle housing. Water can cause corrosion of critical parts. Rust contamination in the lubricant can cause gear and bearing failure. Remove old gasket material from all surfaces. DRYING: Use clean, lintless towels to dry components after cleaning. DO NOT dry bearings by spinning them with compressed air; this can damage mating surfaces due to lack of lubrication. After drying, lightly coat components with oil or a rust-preventive chemical to help protect them from corrosion. If storing components for a prolonged period, wrap them in wax paper. PERIODIC OPERATION REQUIREMENT: Every two weeks, drive the machine far enough to cause the drivetrain components to make several complete revolutions. This will help ensure that internal components receive lubrication to minimize deterioration caused by environmental factors such as high humidity. SUBMERSION: If the machine has been exposed to water deep enough to cover the hubs, disassemble the wheel ends and inspect for water damage and contamination. If the carrier housing was submerged in water, especially if the water level was above the vent tube (breather), drain the axle and inspect internal parts for water damage and contamination. Before assembling and refilling the unit with the specified lubricant(s), clean, examine and replace damaged parts as necessary. Note: Use a suitable puller for bearing removal. Clean, inspect and lubricate all bearings just prior to reassembly. If replacement of a damaged bearing cup or cone is necessary, replace the cup and cone as a set.
5.4
5.4.1
AXLE ASSEMBLIES
Axle Serial Number Plate
The front axle serial number plate is located on a mounting pad on the inboard portion of the right beam trumpet. The rear axle serial number plate is located on a mounting pad on the inboard portion of the left trumpet. Information on the serial number plate is required in correspondence regarding the axle. Supply information from the axle serial number plate when communicating about an axle assembly or axle components.
5.4.2
Axle Specifications
General axle specifications are found in Section 2.4, Fluid and Lubricant Capacities.
5-4
6036, 6042, 8042, 10042, 10054
Axles, Drive Shafts, Wheels and Tires 5.4.5 Axle Replacement (6036 & 6042)
a. Axle Removal The front and rear axle assemblies differ in that the front axle assembly is equipped with a parking brake mechanism and a limited-slip feature; the rear axle has neither. The following steps outline a typical axle removal procedure, suitable for either the front or the rear axle assembly. Cleanliness is extremely important. Before attempting to remove the axle, thoroughly clean the machine. Avoid spraying water or cleaning solution on the stabilizer solenoids and other electrical components. If using a steam cleaner, seal all openings before steam cleaning. Note: Clear the work area of all debris, unnecessary personnel, etc. Allow sufficient space to raise the machine and to remove the axle. 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake, straighten all wheels and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 4. Properly disconnect the battery.
2
MA9091
6. Front Axle: Remove the front access panel (2) to gain access to the front axle hose connections and mounting bolts. Rear Axle: Open the right and left side engine compartment doors to gain access to the rear hose connections and mounting bolts. 7. Label, disconnect and cap the steering and brake lines at the axle. Cap all fittings to prevent dirt and debris from entering the hydraulic system. Wipe up any spilled oil. 8. Block the front and rear of both tires on the axle that is not being removed. Ensure that the machine will remain in place during axle removal before proceeding. 9. Raise the machine using a suitable jack or hoist. Place suitable supports under both sides of the frame and lower the machine onto the supports. Ensure that the machine will remain in place during axle removal. 10. Support the axle that is being removed with a suitable jack, hoist or overhead crane and sling. DO NOT raise the axle or the machine. 11. Remove both wheel and tire assemblies from the axle that is being removed. (Refer to Section 5.7.1, Removing Wheel and Tire Assembly from Machine.) Note: The wheel and tire assemblies must be re-installed later with the directional tread pattern arrows facing in the direction of forward travel. 12. Remove the drive shaft assembly. Refer to Section 5.6.3, Drive Shaft Removal. 13. Remove the capscrew and locknut securing the lower position cylinder-mount pin to the cylinder. Tap the cylinder mount pin out, and move the cylinder to prevent it from interfering with axle removal.
OA1321
5. If the axle will be disassembled after removal, place a suitable receptacle under the axle drain plug (1). Remove the drain plug and allow the axle oil to drain into the receptacle. Transfer the used axle oil into a suitable covered container, and label the container as Used Oil. Dispose of used oil at an approved recycling facility.
6036, 6042, 8042, 10042, 10054
5-5

14. Remove the capscrews securing the axle supports to the machine frame. 15. Remove the axles from the machine using the jack, hoist or overhead crane and sling supporting the axle. DO NOT raise or otherwise disturb the machine while removing the axle. Balance the axle and prevent it from tipping, turning or falling while removing it from beneath the machine. Place the axle on a suitable support or holding stand. b. Axle Installation 1. Before proceeding, ensure that the machine will remain in place during axle installation. Block the front and rear of both tires on the axle that is already installed on the machine. 2. If applicable, raise the machine using a suitable jack or hoist. Place suitable supports beneath the frame and lower the machine onto the supports, allowing enough room for axle installation. Ensure that the machine will remain in place during axle installation. 3. Using a suitable jack, hoist or overhead crane and sling, remove the axle from its support or holding stand. Balance the axle and prevent it from tipping, turning or falling while positioning it beneath the machine. DO NOT raise or otherwise disturb the machine while installing the axle. Keep the axle supported and balanced on the jack, hoist or overhead crane and sling throughout the installation procedure. 4. Install the capscrews securing the axle to the frame. Torque to 600-680 lb-ft (813-922 Nm).
11 12 1 2 3 8 7 6 5 4
MT0822
7. Install the drive shaft assemblies. Refer to Section 5.6.5, Drive Shaft Installation. 8. If reinstalling an axle previously removed from the machine, position the driveshaft yoke on the axle according to the alignment marks made earlier. If installing a new axle, note the position of the driveshaft yoke at the transmission. Align the driveshaft yoke on the axle in the same plane as the yoke on the transmission. 9. Install the wheel and tire assemblies. Refer to Section 5.7.2, Installing Wheel and Tire Assembly onto Machine. 10. Carefully remove the jack, hoist or overhead crane and sling supporting the axle. 11. Carefully raise the machine using a suitable jack or hoist. Remove the supports from beneath the frame and lower the machine to the ground. 12. Remove the blocks from the front and rear of both tires on the other axle. Note: ALWAYS use new o-rings when servicing the machine. 13. Install new o-rings into the fittings. Lubricate the o-rings with clean hydraulic oil. 14. Uncap and connect the steering and brake lines at their axle fittings. 15. Check the hydraulic reservoir oil level. 16. Properly connect the battery. 17. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 18. Start the engine. Turn the steering wheel several times lock to lock, operate the frame tilt function several times in both directions and check the function of the brakes. Check for hydraulic leaks, and tighten or repair as necessary. 19. Front Axle: Install the front access panel. 20. Close and secure the rear door. Note: The service brake circuit will need to be bled after axle installation. Refer to Section 8.7.4, Brake Test.
10 9
Note: If new frame sway (front) or stabilizer (rear) cylinder bearings (3) have been installed in the axles or machine frame, the fracture in the bearing race must be positioned at the 9 oclock position as shown below. 5. Move the cylinder into position on the axle cylinder anchor. Insert a cylinder-mount pin through the cylinder and cylinder anchor. Secure the cylindermount pin with one capscrew and new locknut. 6. Apply multi-purpose grease through the self-tapping lube fitting to lubricate the self-align bearing and the cylinder-mount pin. 5-6
6036, 6042, 8042, 10042, 10054
Axles, Drive Shafts, Wheels and Tires 5.4.6 Axle Replacement (8042, 10042 & 10054)
a. Outrigger Removal (10042 & 10054 only) On Models 10042 and 10054 equipped with outriggers, it is necessary to remove the outrigger assembly before removing the front axle. 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake, straighten all wheels and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 4. Properly disconnect the battery.
8 9 6
MH6260
8. Label, disconnect and cap the outrigger hydraulic hoses (6). Cap all fittings to keep dirt and debris from entering the hydraulic system.
4 5
9. Support the outrigger assembly using a suitable jack, hoist or overhead crane. 10. Remove the capscrews, hex nuts, flat washers and mount plates (7). Note: Record the number and thickness of shims to ensure correct installation.
MH3281
5. Label and disconnect the wiring harness connectors at both outrigger cylinder pressure switches (4). Remove the wire ties securing the wiring harness to the outrigger cylinders. 6. Tie a length of string to each pressure switch wiring connector, and pull the harness out through the openings (5) at the rear of the outrigger housing. 7. Untie the strings from the wiring connectors and tape, or otherwise secure the ends of the strings to the outrigger housing. These strings will be used to pull the harness through the housing during installation.
11. Remove the outrigger assembly using a suitable jack, hoist or overhead crane. Remove the shims (8) from the pivot pin. 12. Move the outrigger assembly away from the machine and carefully lower it to the ground. Block up or support the assembly so that it does not move or fall. 13. Inspect the pivot bearing (9). Replace the bearing if worn or damaged. b. Outrigger Installation 1. Using a suitable jack, hoist or overhead crane and sling, remove the outrigger assembly from its supports. Balance the assembly and prevent it from tipping, turning or falling while positioning it on the machine. DO NOT raise or otherwise disturb the machine while installing the outrigger assembly. 5-7
6036, 6042, 8042, 10042, 10054

Keep the assembly supported and balanced during the installation procedure. 2. Place the same number and thickness of shims (8) on the pivot pin, as recorded during removal. 3. Position the outrigger assembly onto the machine, aligning the hole in the assembly on the axle pivot pin and the mounting plate under the axle flanges. 4. Install the two mount plates (7) onto the top of the axle and secure with the previously used hardware. Note: ALWAYS use new o-rings when servicing the machine. 5. Install new o-rings into the fittings. Lubricate the orings with clean hydraulic oil. 6. Uncap and connect the previously labeled hydraulic hoses (6) to their appropriate locations. 7. Tie the strings left in the outrigger housing during removal to each pressure switch wiring connector, and pull the harness through the outrigger housing. 8. Connect the wiring connectors to the outrigger cylinder pressure switches. Secure the harnesses to the cylinders with wire ties. 9. Check the hydraulic reservoir oil level. 10. Properly connect the battery. 11. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 12. Start the engine. Turn the steering wheel several times lock to lock, operate the frame tilt function several times in both directions and check the function of the brakes. Check for hydraulic leaks, and tighten or repair as necessary. c. Axle Removal The front and rear axle assemblies differ in that the front axle assembly is equipped with a parking brake mechanism and a limited-slip feature; the rear axle has neither. The following steps outline a typical axle removal procedure, suitable for either the front or the rear axle assembly. Cleanliness is extremely important. Before attempting to remove the axle, thoroughly clean the machine. Avoid spraying water or cleaning solution on the stabilizer solenoids and other electrical components. If using a steam cleaner, seal all openings before steam cleaning. Note: Clear the work area of all debris, unnecessary personnel, etc. Allow sufficient space to raise the machine and to remove the axle.
1
OH24112
1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake, straighten all wheels and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Remove the fender assembly (if equipped). 6. Models 10042 and 10054, Front Axle Only: Remove outrigger assembly. Refer to Section 5.4.6, a. Outrigger Removal (10042 & 10054 only).
7. If the axle will be disassembled after removal, place a suitable receptacle under the axle drain plug (1). Remove the drain plug and allow the axle oil to drain into the receptacle. Transfer the used axle oil into a suitable covered container, and label the container as Used Oil. Dispose of used oil at an approved recycling facility. 8. Label, disconnect and cap the steering and brake lines at the axle. Cap all fittings to prevent dirt and debris from entering the hydraulic system. Wipe up any spilled oil. 9. Block the front and rear of both tires on the axle that is not being removed. Ensure that the machine will remain in place during axle removal before proceeding. 10. Raise the machine using a suitable jack or hoist. Place suitable supports under both sides of the frame and lower the machine onto the supports. Ensure that the machine will remain in place during axle removal. 11. Support the axle that is being removed with a suitable jack, hoist or overhead crane and sling. DO NOT raise the axle or the machine.
6036, 6042, 8042, 10042, 10054
5-8

12. Remove both wheel and tire assemblies from the axle that is being removed. (Refer to Section 5.7.1, Removing Wheel and Tire Assembly from Machine.) Note: The wheel and tire assemblies must be re-installed later with the directional tread pattern arrows facing in the direction of forward travel. 13. Remove the drive shaft assembly. Refer to Section 5.6.3, Drive Shaft Removal. removing it from beneath the machine. Place the axle on a suitable support or holding stand. d. Axle Installation 1. Before proceeding, ensure that the machine will remain in place during axle installation. Block the front and rear of both tires on the axle that is already installed on the machine. 2. If applicable, raise the machine using a suitable jack or hoist. Place suitable supports beneath the frame and lower the machine onto the supports, allowing enough room for axle installation. Ensure that the machine will remain in place during axle installation. 3. Using a suitable jack, hoist or overhead crane and sling, remove the axle from its support or holding stand. Balance the axle and prevent it from tipping, turning or falling while positioning it beneath the machine. DO NOT raise or otherwise disturb the machine while installing the axle. Keep the axle supported and balanced on the jack, hoist or overhead crane and sling throughout the installation procedure. 4. Position the axle under the frame, and align the pivot pin bearings with the holes in the frame.
2 3 2 4 4
5. Coat the axle pivot pin (3) with a light film of clean engine or hydraulic oil; DO NOT use an anti-seize compound. 6. Install the axle pivot pin and shims (4). Add or remove shims until a maximum gap of 0.6 in (1.5 mm) is obtained. Balance the number and thickness of shims equally of both sides. Secure the pivot pin with one capscrew and a new locknut.
MH6270
14. Remove the capscrew and locknut securing the lower position cylinder-mount pin (2) to the cylinder. Tap the cylinder mount pin out, and move the cylinder to prevent it from interfering with axle removal. 15. Remove the capscrew and locknut securing the axle pivot pin (3) to the frame. Note: Record the number and location of shims (4) to ensure correct installation. 16. Remove the pivot pin and shims. 17. Remove the axles from the machine using the jack, hoist or overhead crane and sling supporting the axle. DO NOT raise or otherwise disturb the machine while removing the axle. Balance the axle and prevent it from tipping, turning or falling while
6036, 6042, 8042, 10042, 10054
11 10 9 8 7
12
1 2 3 4
MT0822
Note: If new frame sway (front) or stabilizer (rear) cylinder bearings (5) have been installed in the axles or machine frame, the fracture in the bearing race must be positioned at the 9 oclock position as shown below. 7. Move the cylinder into position on the axle cylinder anchor. Insert a cylinder-mount pin (2) through the cylinder and cylinder anchor. Secure the cylindermount pin with one capscrew and new locknut.
5-9

8. Apply multi-purpose grease through the self-tapping lube fitting to lubricate the self-align bearing and the cylinder-mount pin. 9. Install the drive shaft assemblies. Refer to Section 5.6.5, Drive Shaft Installation. 10. If reinstalling an axle previously removed from the machine, position the driveshaft yoke on the axle according to the alignment marks made earlier. If installing a new axle, note the position of the driveshaft yoke at the transmission. Align the driveshaft yoke on the axle in the same plane as the yoke on the transmission. 11. Install the wheel and tire assemblies. Refer to Section 5.7.2, Installing Wheel and Tire Assembly onto Machine. 12. Carefully remove the jack, hoist or overhead crane and sling supporting the axle. 13. Carefully raise the machine using a suitable jack or hoist. Remove the supports from beneath the frame and lower the machine to the ground. 14. Remove the blocks from the front and rear of both tires on the other axle. Note: ALWAYS use new o-rings when servicing the machine. 15. Install new o-rings into the fittings. Lubricate the o-rings with clean hydraulic oil. 16. Uncap and connect the steering and brake lines at their axle fittings. 17. Models 10042 and 10054, Front Axle Only: Install outrigger assembly. Refer to Section 5.4.6, b. Outrigger Installation. 18. Check the hydraulic reservoir oil level. 19. Properly connect the battery. 20. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 21. Start the engine. Turn the steering wheel several times lock to lock, operate the frame tilt function several times in both directions and check the function of the brakes. Check for hydraulic leaks, and tighten or repair as necessary. 22. Install the fender assembly (if equipped). 23. Close and secure the rear door. Note: The service brake circuit will need to be bled after axle installation. Refer to Section 8.7.4, Brake Test.
5-10
6036, 6042, 8042, 10042, 10054
5.5
AXLE ASSEMBLY AND DRIVE SHAFT TROUBLESHOOTING Problem Cause

1. Oil level too low.
Remedy
1. Fill oil to correct level. Refer to Section 2.4, Fluid and Lubricant Capacities. 2. Drain axle and/or wheel end housings and fill to correct level with Mobilfluid 424 ISO 46. Refer to Section 2.4, Fluid and Lubricant Capacities. 3. Correct alignment by adding or removing shims as needed. 4. Correct bearing preload by adding or removing shims as needed. 5. Replace bearings as needed. 6. Replace gears as needed. 7. Drain axle and/or wheel end housings and fill to correct level with Mobilfluid 424 ISO 46. Refer to Section 2.4, Fluid and Lubricant Capacities. 8. Replace damaged parts. 1. Repair or replace universal joints as needed. 2. Determine cause and repair as needed. 1. Tighten capscrews to correct torque. 2. Repair or replace universal joints as needed. 3. Replace drive shaft(s) as needed.
1. Excessive axle noise while driving.
2. Axle and/or wheel end housings filled with incorrect oil or oil level low.
3. Incorrect alignment of ring and pinion gears. 4. Incorrect pinion (input) shaft bearing preload. 5. Worn or damaged bearings. 6. Worn or broken gear teeth. 7. Contamination in the axle.
8. Axle housing damaged. 2. Intermittent noise when traveling. 1. Universal joint(s) worn or damaged. 2. Differential ring and/or pinion gears damaged. 3. Vibration or intermittent noise when traveling. 1. Drive shaft universal joint assembly(ies) incorrectly tightened. 2. Drive shaft universal joint(s) worn or damaged. 3. Drive shaft(s) damaged/ unbalanced.
6036, 6042, 8042, 10042, 10054
5-11
Problem
4. Oil leaking from axle (differential housing and/or axle housings).
Cause
1. Drain and/or inspection plugs loose and/or o-rings damaged or missing. 2. Hose fittings loose. 3. Axle shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces. 4. Input shaft multi-seal ring damaged or missing and/or worn or damaged pinion (input) shaft sealing surfaces. 5. Axle casing to brake housing and/or brake housing to differential assembly o-rings and/or seals worn or damaged. 6. Axle housing mounting nuts and capscrews loose. 7. Differential and/or axle housing(s) damaged.
Remedy
1. Replace o-rings as needed and tighten plugs to 96 lb-ft (130 Nm). 2. Tighten fittings. 3. Replace seal and/or joint coupling fork shaft (axle shaft).
4. Replace multi-seal ring and/or input shaft. Adjust ring and pinion alignment and bearing preload as described in the Dana Repair Manuals. 5. Replace o-rings and seals.
6. Tighten housing nuts and capscrews to 288 lb-ft (390 Nm). 7. Replace housing(s) as needed. 1. Replace o-rings as needed and tighten plugs to 96 lb-ft (130 Nm). 2. Replace o-ring.
5. Oil leaking from wheel end housing (planet carrier).
1. Oil level plugs loose and/or o-rings damaged or missing. 2. O-ring between hub and housing (planet carrier) damaged or missing. 3. Shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces. 4. Housing capscrews loose. 5. Housing (planet carrier) damaged.
3. Replace seal and/or fork joint shaft. 4. Tighten housing capscrews to 41 lb-ft (55 Nm). 5. Replace housing (planet carrier). 1. Tighten fittings. 2. Replace o-rings and seals. 3. Replace piston rod seal. 4. Replace cylinder tube.
6. Oil leaking from steering cylinder.
1. Hose fittings loose. 2. Steering cylinder o-rings and/or seals worn or damaged. 3. Piston rod seal worn or damaged. 4. Cylinder tube damaged.
5-12
6036, 6042, 8042, 10042, 10054
Problem
7. Axle overheating.
Cause
1. Oil level too high.
Remedy
1. Fill oil to correct level with Mobilfluid 424 ISO 46. Refer to Section 2.4, Fluid and Lubricant Capacities. 2. Drain axle and fill to correct level with Mobilfluid 424 ISO 46. Refer toSection 2.4, Fluid and Lubricant Capacities. 3. Adjust park brake cable as needed. 1. Refer to Section 8.4, Hydraulic Circuits. 2. Correct bearing preload by adding or removing shims as needed. 3. Replace swivel bearings as needed. 1. Refer to Section 8.4, Hydraulic Circuits. 2. Repair or replace steering cylinder as needed. 1. Check brake discs for wear. Refer to Section 5.8.1, Brake Disc Inspection. 2. Replace brake discs. 1. Refer to Section 8.4, Hydraulic Circuits. 2. Replace o-rings and seals. 1. Check brake discs for wear. Refer to Section 5.8.1, Brake Disc Inspection. 2. Refer to Section 8.4, Hydraulic Circuits. 3. Replace o-rings and seals.
2. Axle and/or wheel end housings filled with incorrect oil or oil contaminated or oil level low. 3. Dragging park brake. 8. High steering effort required. 1. Steering (hydraulic) system not operating properly. 2. Excessive joint housing swivel bearing preload. 3. Worn or damaged swivel bearings. 9. Slow steering response. 1. Steering (hydraulic) system not operating properly. 2. Steering cylinder leaking internally. 10. Excessive noise when brakes are engaged. 1. Brake discs worn.
2. Brake discs damaged. 11. Brakes will not engage. 1. Brake (hydraulic) system not operating properly. 2. Brake piston o-rings and seals damaged (leaking). 12. Brakes will not hold the machine or braking power reduced. 1. Brake discs worn.
2. Brake (hydraulic) system not operating properly. 3. Brake piston o-rings and seals damaged (leaking).
6036, 6042, 8042, 10042, 10054
5-13
5.6
5.6.1
DRIVE SHAFTS
TO TRANSMISSION
Drive Shaft Inspection and Service
Whenever servicing the machine, conduct a visual inspection of the drive shafts and cross and bearing assemblies (universal joints, or U-joints). A few moments spent doing this can help prevent further problems and down time later. Inspect areas where the drive shaft flange yokes and slip yokes mount to the drive shafts. Attempt to turn each drive shaft in both directions. Look for excessive looseness, missing parts, cracks or other damage. Worn or damaged drive shafts and cross and bearing assemblies may cause an excessive amount of vibration or noise. Note: Any bolt removed from the drive shaft assembly MUST be replaced. Do Not re-torque.
1 2
3
TO AXLE
MT0350
7. Remove the four bolts (1) and two straps (2) securing the bearing cross to the transmission output shaft flange. Discard bolts. 8. Remove the four bolts (3) and two straps (4) securing the bearing crosses to the axle. Discard bolts. 9. Remove the front drive shaft assembly. 10. Repeat the above procedure on the rear drive shaft.
5.6.2
Drive Shaft Maintenance
Refer to Section 2.4, Fluids and Lubricant Capacities, for information regarding the lubrication of the grease fittings on the drive shafts.
5.6.4
Drive Shaft Cleaning and Drying
5.6.3
Drive Shaft Removal
1. Disassemble and clean all parts using an approved cleaning fluid. Allow to dry. 2. Remove and burrs or rough spots from all machined surfaces. Re-clean and dry as required.
1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Block the wheels. 6. The drive shaft assembly is a balanced assembly. Mark the yoke and axle, transmission and the shaft and slip yoke so that these components can be returned to their original positions when reinstalled. Yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration.
5.6.5
Drive Shaft Installation
1. Raise the drive shaft assembly into position. The slip-yoke end of the drive shaft mounts toward the axle. If reinstalling a drive shaft previously removed, align the flange yokes according to the alignment marks made during removal. Note: The yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration. 2. Apply Loctite 242 to all mounting bolts. 3. Install the two straps (2) and four new bolts (1) securing the bearing crosses to the transmission. Torque bolts to 55-60 lb-ft (75-81 Nm). 4. Install the two straps (4) and four new bolts (3) securing the bearing crosses to the axle. Torque bolts to 55-60 lb-ft (75-81 Nm). 5. Repeat the above procedure on the rear drive shaft.
5-14
6036, 6042, 8042, 10042, 10054
5.7
WHEELS AND TIRES
WARNING
Mismatched tire sizes, ply ratings or mixing of tire types (radial tires with bias-ply tires) may compromise machine stability and may cause machine to tip over. It is recommended that a replacement tire to be the same size, ply and brand as originally installed. Refer to the appropriate parts manual for ordering information. If not using an approved replacement tire, It is recommended that replacement tires have the following characteristics: Equal or greater ply/load rating and size of original. Tire tread contact width equal or greater than original. Wheel diameter, width and offset dimensions equal to the original. Approved for the application by the tire manufacturer (including inflation pressure and maximum tire load). The rims installed have been designed for stability requirements which consist of track width, tire pressure and load capacity. Size changes such as rim width, center piece location, larger or smaller diameter, etc., without written factory recommendations, may result in unsafe condition regarding stability. Foam filled tires have a positive effect on the weight, stability and handling characteristics of the machine, especially under load. The use of hydrofill as a tire-fill substance is not recommended because of possible environmental impact. Large-bore valve stems are used to help expedite tire inflation and deflation. An inner tube may be used if a tire does not provide an airtight seal. Check tire inflation pressures when the tires are cold. When mounting a tire on the wheel, the tire must be mounted on the wheel respective of the directional tread pattern of the tire; this produces a left or right tire and wheel assembly.
MY4190
The wheel and tire assemblies must be installed with the directional tread pattern arrows (5) facing in the direction of forward travel.
5.7.1
Removing Wheel and Tire Assembly from Machine
1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place an Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Loosen but DO NOT remove the lug nuts on the wheel and tire assembly to be removed. 4. Place a suitable jack under the axle pad closest to the wheel being removed. Raise the machine and position a suitable support beneath the axle. Allow sufficient room to lower the machine onto the support and to remove the wheel and tire assembly. 5. Lower the machine onto the support. 6. Remove lug nuts and lug washers in an alternating pattern. 7. Remove the wheel and tire assembly from the machine.
6036, 6042, 8042, 10042, 10054
5-15
Axles, Drive Shafts, Wheels and Tires 5.7.2 Installing Wheel and Tire Assembly onto Machine
8042, 10042 & 10054
Note: The wheel and tire assemblies must be installed with the directional tread pattern arrows facing in the direction of forward travel.
10
3 1
5 7 9
TREAD ARROWS MUST POINT FORWARD
8 6 4
OY1220
4. Tighten lug nuts in an alternating pattern as indicated in figure. Torque to 450 20 lb-ft (610 27 Nm). 5. Remove machine from supports.
5.8
INSTALL TIRES ONTO WHEELS TO ROTATE IN PROPER DIRECTION
BRAKES
Brake Disc Inspection
5.8.1
Check the brake discs for wear every 1,000 hours of operation or yearly. For more information on brake disc inspection, refer to the appropriate axle repair manual.
MAH0460
1. Position wheel onto studs on wheel end of axle. 2. Install wheel lug washers. 3. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts.
6036 & 6042
a. Front Axle 1. Block all four wheels to help prevent the machine from moving after the parking brake is disabled.
3 1 8 6 4
OAH0990
5 7 2
MH4341
2. Attach a remote portable hydraulic pressurizing unit to the breather port (1) on the axle. Note: DO NOT turn the key switch to the ON position. DO NOT release the parking brake switch. Oil pressure will be lost and parking brake will be engaged. 3. Pressurize the parking brake with the pressurizing unit. Close the needle valve on the pressurizing unit.
5-16
6036, 6042, 8042, 10042, 10054

7. Fill the axle with Mobilfluid 424 Tractor Hydraulic Fluid (ISO 46) through the axle fill hole until the oil level is even with both axle level holes. Fill the axle slowly, allow time for the oil to run across the differential. 8. Reassemble the level plugs using new o-rings.
MT2851
9. Install the axle fill plug into axle housing. 10. Remove the remote portable hydraulic pressurizing unit from the port. b. Rear Axle 1. Block all four wheels to help prevent the machine from moving after the parking brake is disabled. 2. Working through the level plug hole (2), carefully use a screwdriver to spread the brake discs apart. Note: DO NOT damage the surfaces of the brake discs when spreading the brake discs. 3. Using a feeler gauge, check the gap (3) between the brake discs (4). If the gap is greater than 0.16 in (4,25 mm) for a 3 disc axle, replace the brake discs. If the gap is greater than 0.22 in (5,60 mm) for a 4 disc axle, replace the brake discs. Note: If the brake discs are worn beyond their tolerance, the brake disc must be replaced on both sides of the axle at the same time. 4. Repeat steps 2 and 3 for the other side of the axle.
4. Working through the level plug hole (2), carefully use a screwdriver to spread the brake discs apart. Note: DO NOT damage the surfaces of the brake discs when spreading the brake discs.
4 3
MT2841
5. Using a feeler gauge, check the gap (3) between the brake discs (4). If the measurement is greater than the maximum gap, replace the brake discs. Machine 6036, 6042 8042 10042, 10054 Maximum Gap 4,25 mm (0.16 in) (3 disc version) 5,60 mm (0.22 in) (4 disc version) 5,60 mm (0.22 in) 6,75 mm (0.26 in)
5. Fill the axle with Mobilfluid 424 Tractor Hydraulic Fluid (ISO 46) through the axle fill hole until the oil level is even with both axle level holes. Fill the axle slowly, allow time for the oil to run across the differential. 6. Reassemble the level plugs using new o-rings. 7. Install the axle fill plug into axle housing.
Note: If the brake discs are worn beyond their tolerance, the brake disc must be replaced on both sides of the axle at the same time. 6. Repeat steps 4 and 5 for the other side of the axle.
6036, 6042, 8042, 10042, 10054
5-17
5.9
TOWING A DISABLED MACHINE

8042, 10042 & 10054
Towing a disabled machine should only be attempted as a last resort, after exhausting all other options. Make every effort to repair the machine, and move it under its own power. Towing the machine improperly can result in damage to the machine drivetrain. Note: In the event the machine is disabled and cannot be moved under engine power, the situation must be properly evaluated and dealt with on an individual basis. Contact your local JLG distributor for specific instructions for your particular situation. If it is necessary to tow the machine a short distance to avoid a potentially hazardous situation such as being in an unsafe area on the worksite or on a roadway, prepare the machine for towing as follows: 1. Remove the load from the machine. 2. Block all four wheels to help prevent the machine from moving after the parking brake is disabled. 3. Remove the transmission covers. 4. Position the towing vehicle in place. Attach any chains needed to secure the disabled machine.
6036 & 6042
FRONT OF MACHINE
OH1841
5. Attach a remote portable hydraulic pressurizing unit to the parking brake gauge port (5) on the secondary function manifold (6) mounted on the inside wall of the frame on the left side next to the transmission. 6. Turn the key switch to the ON position, release the park brake, and have an operator seated in the seat. 7. Pressurize the park brake with the pressurizing unit. Close the pump needle valve on the pressurizing unit.
CAUTION
FRONT OF MACHINE
DO NOT exceed 575 psi (40 bar) when pressurizing the park brake. Applying too much pressure may damage the brake seals. 8. Clear the area of all unnecessary personnel. 9. Remove the blocks from the wheels. Tow the machine to a secure location. 10. Remove the hydraulic pressurizing unit. Note: Without engine power, service brake power is reduced. Only the rear service brakes will function when the brake pedal is depressed. Steering is not possible and the machine will only travel in the direction that the wheels were last turned. Tow or push the machine at a very slow speed.
6 5
OA1231
5-18
6036, 6042, 8042, 10042, 10054
Section 6 Transmission
Contents
PARAGRAPH 6.1 6.2 6.3 6.4 TITLE PAGE 6-2 6-3 6-3 6-3 6-3 6-3 6-3 6-4 6-5 6-5 6-7 6-8
6.5
6.6
Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.1 Transmission Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.2 Transmission Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5.1 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5.2 Transmission Inspection and Internal Repair . . . . . . . . . . . . . . . . . . . . . . 6.5.3 Transmission Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5.4 After Transmission Service or Replacement . . . . . . . . . . . . . . . . . . . . . . . Transmission Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6036, 6042, 8042, 10042, 10054
6-1
Transmission
6.1
TRANSMISSION ASSEMBLY COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the transmission. The following illustration identifies the components that are referred to throughout this section.
INLET (COOLER) HOSE OIL FILL TUBE AND DIPSTICK OIL COOLER
VALVE BLOCK (CONTROL CIRCUIT 1)
OIL FILTER RADIATOR VALVE BLOCK (CONTROL CIRCUIT 2) OUTPUT SHAFT
OUTLET (COOLER) HOSE
MH6280
6-2
6036, 6042, 8042, 10042, 10054
Transmission 6.4.2 Transmission Maintenance Schedule
WARNING
DO NOT service the machine without following all safety precautions as outlined in Section 1, Safety Practices, of this manual.
Complete transmission maintenance information is located in the appropriate Operation & Safety Manual. At ten hour intervals, check the transmission oil level. Refer to the appropriate Operation & Safety Manual. When the machine completes its first 50 hours of use, change the transmission filter. Change the filter only; DO NOT change the transmission oil at the first 50 hour maintenance level. Refer to the appropriate Operation & Safety Manual. At 1,000 hour intervals, change the transmission oil and filter. Refer to the appropriate Operation & Safety Manual. Periodically, depending on operating conditions and other factors, back flush the transmission oil cooler, which is located in or behind the radiator. ALWAYS back flush the transmission oil cooler after removing the transmission for repair or replacement. The transmission oil cooler outlet hose, routed to the lower oil cooler fitting, is located on the top of the transmission. The transmission oil cooler inlet hose, routed to the upper oil cooler fitting, is located on the top of the transmission. (Refer to Section 7.4.2, Radiator/Oil Cooler and Replacement.) Disconnect and back flush the oil cooler portion of the radiator or the oil cooler (located behind the radiator) with oil and compressed air until all foreign material is removed. If necessary, remove the radiator or oil cooler from the machine, and clean the oil cooler circuit using oil, compressed air and steam. Note: DO NOT use flushing compounds for cleaning purposes.
6.2
TRANSMISSION DESCRIPTION
Instructions in this section pertain mainly to general specifications, towing, maintenance information, and transmission removal and installation procedures. for internal transmission service instructions and detailed specifications contact your local authorized service distributor for a copy of the ZF 4 WG-98 TC Repair Manual P/N 5871 135 002 (JLG P/N 8990455).
6.3
TRANSMISSION SERIAL NUMBER
The transmission serial number plate is located on the pump side (front) of the transmission at the bottom right toward the machine frame. Information specified on the serial number plate includes the transmission model number, the transmission serial number and other data. Information on the serial number plate is required in correspondence regarding the transmission.
6.4
6.4.1
TRANSMISSION SPECIFICATIONS
Transmission Maintenance
Cleanliness is of extreme importance. Before attempting any repairs, thoroughly clean the exterior of the transmission to help prevent dirt from entering while performing maintenance checks and procedures. Section 6.4.2, Transmission Maintenance Schedule, provides a suggested maintenance schedule with references to pertinent procedures and instructions in this manual. To help prevent transmission problems before they occur, follow the maintenance schedule. Note: Lubrication and Maintenance chart decals are located inside the engine compartment access door. These decals contain a general maintenance schedule that should be followed to maintain the machine in good operating condition. Refer to Section 2, General Information and Specifications. The same schedule information is presented in the appropriate Operation & Safety Manual, with a detailed account of how to perform the procedures.
6.5
TRANSMISSION REPLACEMENT
Note: Contact your local JLG Service Department if internal transmission repair is required during the warranty period. Note: To help ensure safety and optimum performance, replace the transmission if it is damaged. Refer to the appropriate parts manual for ordering information. Cleanliness is of extreme importance. Before attempting to remove the transmission, thoroughly clean the exterior of the transmission to help prevent dirt from entering during the replacement process. Avoid spraying water or cleaning solution onto or near the transmission shift solenoids and other electrical components.
6036, 6042, 8042, 10042, 10054
6-3
Transmission 6.5.1 Transmission Removal

10. Transfer the used transmission oil into a suitable, covered container, and label the container as Used Oil. Dispose of used oil at an approved recycling facility. Clean and reinstall the transmission drain plug. 11. Remove the engine-totransmission and transmission-to-axle drive shafts. Refer to Section 5.6.3, Drive Shaft Removal. 12. Remove the hydraulic pump. Refer to Section 8.6.3, Pump Replacement.
2 4
WARNING
Risk of severe personal injury. NEVER lift a transmission alone; enlist the help of at least one assistant or use a suitable hoist or overhead crane and sling. 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, raise the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Temporarily block up or support the boom. 4. Open the rear door. Allow the system fluids to cool. 5. Drain the hydraulic oil reservoir. Refer to Section 8.5.1, Hydraulic Oil Reservoir Draining. 6. Properly disconnect the battery. 7. Remove the transmission covers. 8. Thoroughly clean the transmission and surrounding area, including all hoses and fittings, before proceeding.
MH3391
13. Label and disconnect the transmission temperature switch connector (2) and shift solenoid wiring harness connectors (3). 14. Remove the capscrew securing the black wire (4) to the transmission housing, and disconnect the wire. DO NOT reinstall the capscrew at this time. 15. Remove the capscrew securing the clamp (5) and wiring harness to the transmission housing and move the wiring harness safely out of the way. DO NOT reinstall the capscrew at this time.
1
OH2381
9. Place a suitable receptacle under the transmission drain plug (1). Remove the transmission drain plug, and allow the transmission oil to drain into the receptacle.
MH3401
6-4
6036, 6042, 8042, 10042, 10054
Transmission
16. Remove the capscrew (6) securing the lifting ring (7) to the transmission housing. Once the lifting ring has been removed, reinstall the capscrew into the hole. 17. Move the lifting ring to the holes (8) used to secure the black wire and clamp. Secure the lifting ring using the capscrews and tighten securely. 18. Label, disconnect and cap the transmission oil cooler inlet and outlet hoses on the transmission. 19. Connect a lifting strap or chain to the lifting eye at the top of the transmission and to a suitable hoist or overhead crane. Operate the hoist or crane to remove slack from the chain, but DO NOT raise the transmission at this time. 20. Place blocks under the transmission to help support it during removal.
1
27. Lift the transmission clear of the machine and lower it onto suitable supports or secure it to a stand built especially for the transmission or engine service. Secure the transmission so that it will not move or fall. 28. Remove any external transmission components as required, including the transmission temperature switch, and inlet and outlet cooler hose fittings. Cover all transmission openings. 29. Remove the transmission oil filter and dispose of properly. Clean the filter mounting surface. Cover or cap the oil filter mount.
6.5.2
Transmission Inspection and Internal Repair
Refer to the ZF 4 WG-98 TC Repair Manual P/N 5871 135 002 (JLG P/N 8990455). which can be obtained by calling your local authorized service distributor. If replacing the entire transmission, transfer the transmission temperature switch to the replacement transmission. The gear shift solenoids are included with a new transmission.
6.5.3
Transmission Installation
1. Install two rubber mounts and the rear transmission mount (1) in the machine frame. Secure the mount with the previously used hardware. 2. Use a hoist or overhead crane and sling attached to the lifting eye at the top of the transmission. Raise and position the transmission within the chassis.
MH6290
21. Remove the capscrews and lockwashers securing the front transmission mount (9) to the transmission. 22. Remove the two capscrews, hex locknuts and rebound washers. Remove the front transmission mount. 23. Remove the four capscrews and lockwashers securing the rear transmission mount (1) to the transmission. 24. Remove the two capscrews, hex locknuts and rebound washers. Remove the rear transmission mount. 25. Inspect the rubber mounts. Replace the mounts if damaged. 26. Carefully remove the transmission from the machine. Avoid causing damage to the transmission or surrounding parts.
3. Attach the transmission to the rear mounting bracket with the previously used hardware. Torque to 148 lb-ft (200 Nm). 4. Install the two front rubber mounts and the front transmission mounting bracket (9) on the transmission with the previously used hardware. Torque to 148 lb-ft (200 Nm) 5. Attach the front mounting bracket to the frame with the previously used hardware 6. Remove the hoist or overhead crane and sling.
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6-5
Transmission
12. Uncap and connect the previously labeled transmission oil cooler inlet and out hoses at the transmission. 13. Install the hydraulic pump. Refer to Section 8.6.3, Pump Replacement. 14. Install the engine-to-transmission and transmissionto-axle drive shafts. Refer to Section 5.6.5, Drive Shaft Installation. 15. Clean the transmission oil filter mounting surface. 16. Apply a thin film of clean Mobilfluid 424 (ISO Grade 46) to the new transmission filter gasket. Install the new filter and torque to 20-25 lb-ft (27-34 Nm).
MH3411
Note: The lifting ring (3) must be repositioned to allow the covers to be installed. 7. Remove the two capscrews securing the lifting ring to the transmission housing. Save the capscrews for later use. 8. Remove the capscrew and secure the lifting ring in the storage position (4) on the transmission housing as shown.
5 7
17. Transmission oil may be added through the dipstick tube. Remove the dipstick and add Mobilfluid 424 (ISO Grade 46). Check the oil level by taking intermittent dipstick readings as outlined in the appropriate Operation & Safety Manual. DO NOT overfill. Reinstall the dipstick when finished. 18. Install the transmission covers. 19. Properly connect the battery. 20. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 21. Close and secure the rear door.
6
MH3391
9. Connect the transmission temperature switch connector (5) and shift solenoid wiring harness connectors (6). 10. Attach the black wire (7) to the transmission housing with a capscrew removed in step 7. 11. Secure the wiring harness to the transmission housing using the clip and a capscrew removed in step 7.
6-6
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Transmission 6.5.4 After Transmission Service or Replacement

9. Reassemble all components and fill the transmission with clean, fresh Mobilfluid 424 (ISO Grade 46) through the dipstick tube opening (8). Check the level by taking intermittent dipstick readings as outlined in the appropriate Operation & Safety Manual. DO NOT overfill. Reinstall the dipstick when finished. 10. Run the engine for two minutes at idle to help prime the torque converter and the transmission oil lines. 11. Recheck the level of the fluid in the transmission with the engine running at idle. 12. Add Mobilfluid 424 (ISO Grade 46) as necessary to bring the fluid level up until it reaches the FULL mark on the dipstick. Recheck the oil level when it reaches operating temperature 180-200 F (83-94 C). 13. Recheck all drain plugs, lines, connections, etc., for leaks, and tighten where necessary.
Refer to the ZF 4 WG-98 TC Repair Manual P/N 5871 135 002 (JLG P/N 8990455). which can be obtained by calling your local authorized service distributor. In general: 1. Check the transmission oil level and add oil as required. 2. Install a new transmission filter. 3. Check the torque on the drive shaft yoke capscrews. 4. Wear suitable eye protection. When an overhauled or repaired transmission is installed, thoroughly clean the oil cooler lines to and from the transmission. 5. Drain and flush the entire system. 6. Disconnect and clean all transmission cooler hoses. When possible, remove transmission lines from the machine for cleaning. 7. Thoroughly clean transmission filter screens and cases, and replace transmission filter elements.
CAUTION
DO NOT exceed 165 psi (11,4 bar) when back flushing the oil cooler. Applying too much pressure may damage the oil cooler/radiator. 8. Back flush the transmission oil cooler portion of the radiator or the oil cooler (located behind the radiator) with oil and compressed air until all foreign material is removed. Flushing in the direction of normal oil flow does not adequately clean the cooler. If needed, remove the radiator or oil cooler from the machine. Note: DO NOT use flushing compounds for cleaning purposes.
MH6300
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6-7
Transmission
6.6
TRANSMISSION TROUBLESHOOTING
This section provides an easy reference guide covering the most common problems that may occur during operation of the transmission. Note: Contact the JLG Service Department if internal transmission repair is required during the warranty period. The transmission should be checked, serviced and repaired only by experienced service technicians who are aware of all safety instructions and particular component features.
Problem
1. Transmission will not engage or will not shift properly.
Cause
1. Oil level too high or low.
Remedy
1. Fill transmission to correct level with Mobilfluid 424 ISO Grade 46. Refer to Section 2.4, Fluid and Lubricant Capacities. 2. Refer to Section 9.5, Electrical System Schematics.
2. Transmission control lever not functioning properly and/or a fault in the wiring harness.Transmission control lever not functioning properly and/or a fault in the wiring harness. 3. Transmission valve body solenoids not functioning properly. 4. Pilot-operated shift valves not operating properly. 5. Pump output pressure low.
3. Refer to Section 9.5, Electrical System Schematics. 4. Clean the valve spool and housing. Replace return spring as needed. 5. Refer to Section 6.6, Transmission Troubleshooting, Problem 2. Low or no pump flow or pressure. 6. Replace o-rings. 7. Replace clutch discs. 8. Replace couplings.
6. Clutch piston o-rings damaged. 7. Clutch discs worn or damaged. 8. Coupling shafts or gear teeth damaged.
6-8
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Transmission
Problem
2. Low or no pump flow or pressure.
Cause
1. Low oil level.
Remedy
1. Fill transmission to correct level with Mobilfluid 424 ISO Grade 46. Refer to Section 2.4, Fluid and Lubricant Capacities. 2. Drain transmission and fill to correct level with Mobilfluid 424 ISO Grade 46. Refer Section 2.4, Fluid and Lubricant Capacities. 3. Clean, repair and/or replace suction pipe. 4. Replace central shaft. 5. Repair or replace pump assembly. 1. Fill transmission to correct level with Mobilfluid 424 ISO Grade 46. Refer to Section 2.4, Fluid and Lubricant Capacities. 2. Clean the valve spool and housing. 3. Replace coupling and/or o-rings. 4. Clean the valve spool and housing. 1. Refer to Section 8.4, Hydraulic Circuits. 2. Adjust the engine rpm to specifications. Refer to Transmission Service Manual. 3. Refer to Section 6.6, Transmission Troubleshooting, Problem 2. Low or no pump flow or pressure. 4. Replace clutch discs. 5. Refer to Section 6.6, Transmission Troubleshooting, Problem 5. Transmission overheating (oil above 120 C (248 F)).
2. Transmission filled with incorrect oil, or oil contaminated.
3. Pump suction pipe screen clogged. 4. Central shaft damaged. 5. Pump worn or damaged. 3. Low clutch pressure. 1. Incorrect oil level.
2. Main pressure valve stuck open. 3. Broken or worn coupling shaft or piston o-rings. 4. Pressure reducing valve stuck open. 4. Lack of power. 1. Park or service brake dragging. 2. Low engine rpm causes converter stall. 3. Pump output pressure is low.
4. Clutch discs worn or damaged. 5. Transmission overheating.
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6-9
Transmission
Problem
5. Transmission overheating (oil above 120 C (248 F)).
Cause
1. Low oil level.
Remedy
1. Fill transmission to correct level with Mobilfluid 424 ISO Grade 46. Refer to Section 2.4, Fluid and Lubricant Capacities. 2. Remove debris from the radiator. 3. Drain transmission and fill to correct level with Mobilfluid 424 ISO Grade 46. Refer to Section 2.4, Fluid and Lubricant Capacities. 4. Stop and idle the engine. 5. Replace cooler hoses. 6. Repair or replace pump assembly. 7. Replace engine thermostat. 1. Fill oil to correct level. Refer to Section 2.4, Fluid and Lubricant Capacities. 2. Drain transmission and fill to correct level with Mobilfluid 424 ISO Grade 46. Refer to Section 2.4, Fluid and Lubricant Capacities. 3. Refer to Section 9.10.3, Transmission Solenoid Valves. 4. Repair or replace parts as needed. 5. Replace diaphragm (flex plate). Refer to Section 6.5.1, Transmission Removal. 6. Tighten capscrews.
2. Clogged radiator. 3. Transmission filled with incorrect oil, or oil contaminated.
4. Excessive roading. 5. Restriction in oil cooler hoses. 6. Pump worn or damaged. 7. Engine thermostat stuck. 6. Grinding or clunking noise from transmission. 1. Oil level too low.
2. Transmission filled with incorrect oil.
3. Incorrect clutch engagement. 4. Internal damage. 5. Broken diaphragm (flex plate).
6. Loose diaphragm (flex plate) mounting capscrews.
6-10
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Transmission
Problem
7. Oil leaking from transmission.
Cause
1. Oil leaking from vent (high oil level).
Remedy
1. Remove drain plug and drain oil as needed, until oil is at correct level. Refer to Section 2.4, Fluid and Lubricant Capacities. Replace o-rings as needed and tighten plugs to 96 lb-ft (130 Nm). 2. Replace o-rings as needed and tighten plug to 26 lb-ft (35 Nm). 3. Tighten fittings. 4. Replace gaskets and/or tighten capscrews to 7 lb-ft (9,5 Nm).
2. Drain plug loose and/or o-rings damaged or missing. 3. Hose fittings loose. 4. Oil leaking at valve bodies (possible valve body gaskets damaged or missing and/or mounting capscrews not tight). 5. Housing capscrews loose. 6. Oil leaking at pump (possible pump-to-housing o-rings missing or damaged, and/or pump mounting capscrews not tight). 7. Oil leaking at converter bell (possible converter leak and/or input shaft seal damage). 8. Oil leaking at output shaft (output shaft seal damaged). 9. Housing damaged.
5. Tighten capscrews to 34 lb-ft (46 Nm). 6. Replace o-rings and/or tighten capscrews to 85 lb-ft (115 Nm).
7. Replace converter and/or input shaft seal. 8. Replace output shaft seal. 9. Replace housing as needed.
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6-11
Transmission
This Page Intentionally Left Blank
6-12
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Section 7 Engine - Cummins QSB3.3T/QSB4.5T
Contents
PARAGRAPH 7.1 TITLE PAGE 7-2 7-2 7-3 7-4 7-4 7-4 7-4 7-4 7-5 7-5 7-5 7-5 7-7 7-7 7-7 7-7 7-8 7-8 7-8 7-9 7-9 7-9 7-10 7-10 7-11 7-12
7.2 7.3 7.4
7.5 7.6
7.7
7.8
7.9
7.10
7.11
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.2 Component Terminology - Cummins - QSB3.3T/QSB4.5T . . . . . . . . . . . . Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.1 Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.2 Radiator/Oil Cooler and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6.2 Fuel/Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6.3 After Fuel System Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7.1 Exhaust System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7.2 Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8.1 Air Cleaner Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8.2 Air Cleaner Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9.1 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9.2 Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Isolation Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10.1 Isolation Coupler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10.2 Isolation Coupler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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7-1
Engine - Cummins QSB3.3T/QSB4.5T
7.1
7.1.1
INTRODUCTION
Disclaimer and Scope
These instructions are written for worldwide use. In territories where legal requirements govern engine smoke emission, noise, safety factors, etc., apply all instructions, data and dimensions provided herein in such a way that after maintenance, service and repair of the engine, engine operation does not violate local regulations. Note: These instructions cover only the routine maintenance, removal, installation and troubleshooting of the engine. Refer to the local Cummins Engine Distributor and the applicable Cummins Engine Service Manual for assistance with comprehensive engine diagnosis, repair and component replacement.A gradual running-in (break-in) of a new engine is not necessary. Full load can be applied to a new engine as soon as the engine is put into service and the coolant temperature is at least 140 F (60 C). Extended light-load operation during the early life of the engine is not recommended. DO NOT run the engine at high, no-load speeds. DO NOT apply an overload to the engine.
7-2
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Engine - Cummins QSB3.3T/QSB4.5T 7.1.2 Component Terminology - Cummins - QSB3.3T/QSB4.5T
To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the engine components. The following illustration identifies the components that are referred to throughout this section.
FUEL FILTER
THERMOSTAT OIL FILTER
STARTER
FUEL INJECTOR PUMP
TURBOCHARGER
ALTERNATOR
OIL FILTER
MAQ0060
6036, 6042, 8042, 10042, 10054
7-3
7.2
ENGINE SERIAL NUMBER
The Cummins QSB3.3T/QSB4.5T serial number is stamped on a plate which is typically located on the engine rocker cover, but may be located on the side of the gear housing. Information contained in the serial number is required in correspondence with the engine manufacturer.
2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the side and rear engine doors. Allow the system fluids to cool. 4. Disconnect the battery positive (+) and negative (-) cables from the appropriate battery terminals. Remove the battery or batteries.
7.3
SPECIFICATIONS AND MAINTENANCE INFORMATION

1
For engine, coolant and oil specifications, and maintenance information, refer to Section 2, General Information and Specifications. Note: Detailed Cummins engine service instructions (covering disassembly, inspection, internal repair, assembly, adjustment and troubleshooting information) are provided in the appropriate Cummins engine service manual.
3
7.4
7.4.1
ENGINE COOLING SYSTEM

2
Radiator Pressure Cap

MAQ0290
For a 210 F (99 C) system, use a 13 psi (90 kPa) radiator cap. An incorrect or malfunctioning cap can result in the loss of coolant and a hot-running engine.
7.4.2
Radiator/Oil Cooler and Replacement
5. Slowly turn the radiator cap (1) to the first stop and allow any pressure to escape. Remove the radiator cap. 6. Place a suitable container beneath the radiator drain. 7. Place a funnel at the base of the radiator to channel the drained coolant into a container. Loosen the drain petcock and slowly allow the coolant to drain. Transfer the coolant into a properly labeled container. Dispose of properly if coolant needs to be replaced. Tighten the radiator drain petcock. 8. Label and disconnect all hoses and tubes attached to the radiator (2), charge air cooler (3) and oil cooler (4). 9. Working at the rear of the machine, remove the capscrews and lockwashers securing the radiator assembly. 10. Remove the radiator assembly through the rear of the machine. b. Radiator/Oil Cooler Installation 1. Secure the radiator (2), charge air cooler (3) and oil cooler (4) to the machine frame with the previously used hardware.
6036, 6042, 8042, 10042, 10054
Before considering radiator or oil cooler replacement for other than obvious damage, conduct a cooling system pressure test check the coolant specific gravity, coolant level, fan belt tension and dash panel temperature indicator. If the engine runs hot, check the temperature of the upper radiator hose. If the hose is not hot, the thermostat may be stuck in the closed position. If the engine has overheated, performance may suffer, indicating other damage including a leaking cylinder head gasket, cracked cylinder head or block, and/or other internal engine damage. a. Radiator/Oil Cooler Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake, and shut the engine OFF.
7-4

2. Uncap and connect the all the previously labeled hoses and tubes to their appropriate locations. 3. Install the battery or batteries. Connect the battery positive (+) and negative (-) cables to the appropriate battery terminals. 4. Open the radiator cap (1) and fill the radiator completely with coolant. Replace and tighten the radiator cap. Refer to Section 2.4, Fluid and Lubricant Capacities, for proper capacities. 5. Run the engine to operating temperature. Visually check for leaks with the engine running. Check the coolant level in the overflow bottle and fill, or drain, as necessary. 6. Close and secure the side and rear engine doors. Use a low-sulfur content fuel with a cloud point (the temperature at which wax crystals form in diesel fuel) at least 10 below the lowest expected fuel temperature. The viscosity of the fuel must be kept above 1.3 centistrokes to provide adequate fuel system lubrication.
7.6.2
Fuel/Hydraulic Oil Tank
Note: The fuel/hydraulic oil tank is part of a one piece unit divided into a two compartment (tank) unit. It is located on the right side of the machine, across from the operators cab. If it is determined that either the fuel of hydraulic oil tank must be removed, both the fuel and hydraulic oil must be drained before tank removal. Always dispose of hydraulic oil or fuel properly. a. Fuel/Hydraulic OIl Tank Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake, and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 4. Properly disconnect the battery. Note: If replacing the tank, remove all internal and external components from the old tank, and retain for use on the replacement tank. Note: Have a dry chemical (Class B) fire extinguisher near the work area.
7.5
ENGINE ELECTRICAL SYSTEM
The engine electrical system, including the starter, alternator and primary wiring, is described in Section 9, Electrical System.
7.6
7.6.1
FUEL SYSTEM
Diesel Fuel
Fuel represents a major portion of machine operating costs and therefore must be used efficiently. ALWAYS use a premium brand of high-quality, clean diesel fuel. Low cost, inferior fuel can lead to poor performance and expensive engine repair. Note: Use only diesel fuel designed for diesel engines. Some heating fuels contain harmful chemicals that can seriously affect engine efficiency and performance. Note: Due to the precise tolerances of diesel injection systems, keep the fuel clean, and free of dirt and water. Dirt and water in the fuel system can cause severe damage to both the injection pump and the injection nozzles. Use ASTM #2 diesel fuel with a minimum Cetane rating of 40. #2 diesel fuel gives the best economy and performance under most operating conditions. Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to help prevent misfiring and excessive smoking. Inform the owner/operator of the machine to use #2 diesel fuel, unless ambient temperatures are below 32 F (0 C). When temperatures are below 32 F (0 C), a blend of #1 diesel and #2 diesel fuels (known as winterized #2 diesel) may be used. Note: #1 diesel fuel may be used, however, fuel economy will be reduced.
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WARNING
NEVER drain or store fuel in an open container due to the possibility of explosion or fire. Discard the fuel in an approved manner. 5. Remove the fuel/hydraulic oil tank top cover. 6. Remove the two frame top covers from above the frame.
7-5

c. Cleaning and Drying
7
If contaminated fuel or foreign material is in the tank, the tank can usually be cleaned. Note: If a leak is suspected in the fuel tank, contact your local authorized Service Department. To clean the fuel tank: 1. Have a dry chemical (Class B) fire extinguisher near the work area. 2. Depending on which side of the tank is contaminated (fuel or hydraulic oil), remove the fuel or oil tank drain plug, and safely drain any fuel or hydraulic oil into a suitable container. Dispose of fuel or hydraulic oil properly.
6 5
MAQ0330
3. Clean the fuel/hydraulic oil tank with a high pressure washer, or flush the tank with hot water for five minutes and drain the water. Dispose of contaminated water properly. 4. For the fuel tank side, add a diesel fuel emulsifying agent to the tank. Refer to manufacturers instructions for the correct emulsifying agent-towater mixture ratio. Refill the tank with water, and agitate mixture for 10 minutes. Drain the tank completely. Dispose of contaminated water properly. 5. Refill the fuel tank with water until it overflows. Completely flush the tank with water. Empty the fuel tank, and allow it to dry completely. d. Assembly The fuel/hydraulic oil tank is a one piece-unit and cannot be disassembled. The fuel level indicator and hydraulic filters can be removed and reused on the new replacement tank. Dispose of the old tank according to local regulations concerning hazardous materials disposal regulations. e. Inspection Note: If a leak is suspected in the fuel tank, contact your local authorized Service Department. 1. Inspect the tank thoroughly for any cracks, slices, leaks or other damage. 2. With the tank removed from the machine, plug all openings except one elbow fitting. Install the elbow fitting, and apply approximately 1-1.5 psi (7-10 kPa) of air pressure through the elbow. Check the reservoir for leaks by applying a soap solution to the exterior and look for bubbles to appear at the cracked or damaged area.
7. Remove fuel tank drain plug (5), and drain fuel into an approved and suitable container. Dispose of fuel properly. 8. Drain the hydraulic oil tank (6). Refer to Section 8.5.1, Hydraulic Oil Reservoir Draining. 9. Label, disconnect and cap the fuel and hydraulic lines from the tank. 10. Label and disconnect the electrical components from the fuel/hydraulic oil tank. 11. Position and connect a suitable chain support to tank lifting point (7) and take up slack in the chain. 12. While supporting the tank, remove nuts and lockwashers securing the tank to the machine frame. Pull tank away from the tank carriage bolts, and remove tank. b. Disassembly The fuel/hydraulic oil tank is a one-piece unit and cannot be disassembled. The fuel level indicator and hydraulic filters can be removed and reused on the new replacement tank. Dispose of the old tank according to local regulations concerning hazardous materials disposal.
7-6
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f. Fuel/Hydraulic Oil Tank Installation
7.7.1
Exhaust System Removal
1. Attach the tank to a suitable lifting device at the lift point. 2. Place the tank carriage bolts into the slotted holes in the frame. 3. Position the tank and insert carriage bolts through tank attachment holes. Install lockwashers and finger tighten nuts onto carriage bolts. Slide the tank and carriage bolts toward the front of machine, until carriage bolts are bottomed out into the slotted frame holes. 4. Connect the previously labeled electrical components to the tank. 5. Uncap and connect the previously labeled hydraulic hoses to their appropriate locations. 6. Fill the tank according to specifications. Refer to Section 2.4, Fluid and Lubricant Capacities. 7. Check tank for leaks. 8. Install the two frame top covers. 9. Install the fuel/hydraulic oil tank cover. 10. Properly connect the battery. 11. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 12. Close and secure the rear door.
1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake, and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 4. Properly disconnect the battery.
15
15 13
11 14 9 15
7.6.3
After Fuel System Service

8 10 12
1. Drain and flush the fuel tank if it was contaminated. 2. Vent air from the fuel system in accordance with the instructions found in the appropriate Operator & Safety Manual. 3. Fill the fuel tank with fresh, clean diesel fuel as required.
MAQ0310
5. Loosen the clamp (8) supporting the tail pipe (9) and muffler (10) from the muffler mounting bracket (11). 6. Loosen the clamp (12) supporting the exhaust pipe (13) and muffler (10) from the muffler mounting bracket (14). 7. Loosen the three clamps (15) on the exhaust pipe (13). 8. Remove the clamps (8 & 12) attaching the muffler (10) to the muffler mounting brackets (11 & 14). 9. Remove the muffler (10) and if needed, the exhaust pipe (13).
7.7
ENGINE EXHAUST SYSTEM
Rattles and noise vibrations in the exhaust system are usually caused by misalignment or parts. When aligning the system, leave all capscrews and nuts slightly loose until all parts are properly aligned, then tighten all fasteners working from the front of the system to the rear. When replacing the muffler, also replace the tail pipe. Before assembling components, use exhaust system sealer at all slip joint connections. When installing exhaust system components, allow sufficient clearance between the components and other pipes, hoses and wiring that could be adversely affected by excessive heat.
6036, 6042, 8042, 10042, 10054
7.7.2
Exhaust System Installation
Note: Install muffler in proper direction. Note: Keep all clamps loosened until entire exhaust system is in place. 1. Using clamps (8 & 12), install the muffler (10) to the muffler mounting brackets (11 & 14). 7-7

2. If previously removed, install the exhaust pipe (13). 3. Install the exhaust pipe (13) into the muffler (10). 4. Install the tail pipe (9) into the muffler (10). 5. Tighten all clamps (8 & 15). 6. Properly connect the battery. 7. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 8. Start engine and check for exhaust leaks at all exhaust connections. Adjust or repair as needed. 9. Close and secure the rear door. 5. Remove the clamp securing the air scoop (1) to the air cleaner inlet tube (2). 6. Remove the clamps securing the hose (3) to the air cleaner assembly. 7. Remove the capscrews and lockwashers securing the band (4) to the air cleaner bracket. Remove the air cleaner assembly.
7.8.2
Air Cleaner Assembly Installation
Note: Apply Loctite 242 threadlock to the capscrew threads before installation. 1. Secure the band (4) to the air cleaner bracket with the previously used hardware. 2. Install the air cleaner assembly. 3. Install the clamps to secure the hose (3) to the air cleaner assembly. 4. Install the clamp to secure the air cleaner inlet tube (2) to the air scoop (1). 5. Tighten all clamps. 6. Properly connect the battery. 7. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 8. Close and secure the rear door.
7.8
AIR CLEANER ASSEMBLY
CAUTION
NEVER run the engine with only the inner safety element installed. Note: Refer to the appropriate Operation & Safety Manual for your machine for the correct element change procedure.
7.8.1
Air Cleaner Assembly Removal
1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake, and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 4. Properly disconnect the battery.
1 2
MAQ0300
7-8
6036, 6042, 8042, 10042, 10054
7.9
7.9.1
ENGINE REPLACEMENT
Engine Removal
install the air conditioning hoses and to the air conditioning compressor. 13. Loosen the clamps on the sleeve reducer at the engine and on the air suction pipe. 14. Remove the air cleaner assembly. Refer to Section 7.8.1, Air Cleaner Assembly Removal. 15. Remove the exhaust pipe from the exhaust manifold. Refer to Section 7.7.1, Exhaust System Removal.
Note: The radiator and oil cooler must be removed from the machine before engine removal. Refer to Section 7.4, Engine Cooling System. Several additional components must be removed before engine removal. They will be addressed in the following procedures. 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake, and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Remove the rear door and engine side covers. 6. Drain and remove the radiator assembly. Refer to Section 7.4.2, Radiator/Oil Cooler and Replacement.
MAQ0320
7. Remove the radiator overflow tube, overflow tank and hose support. 8. Label, disconnect and cap the heater hoses attached to the engine (if equipped). Note: The engine harness is routed and attached to the engine using hold-down clamps and plastic wire ties at various places on the engine. Before removing engine, ensure that the harness has been completely separated (disconnected) from the engine. Move the harness clear of the engine, and with the help of an observer, ensure that the engine clears the harness during removal. 9. Label and disconnect all electrical wire connections on the engine. 10. Label, disconnect and cap the fuel inlet line at the fuel lift pump. 11. Label, disconnect and cap the fuel return line from the injector pump. 12. Remove the engine-to-transmission drive shaft. Refer to Section 5.6.3, Drive Shaft Removal. Note: Before the engine can be removed from the machine, the air conditioning hoses need to be removed from the air conditioning compressor. This procedure must be completed by an authorized air conditioning service technician. This service technician will also need to be available when the new engine is installed to re6036, 6042, 8042, 10042, 10054
16. At the front right engine mount (5), remove the hardware securing the mount to the frame. Repeat procedure for left engine mount (6). 17. Remove the hardware securing the rear engine mount (7). 18. Remove the exhaust pipe bracket. 19. Position a fork truck behind the machine, and drive forward, placing the forks underneath the rear engine mount and front engine mount brackets. Slightly lift the engine, and slowly back engine out of the machine. Have an assistant ensure that the engine clears all frame components during removal. 20. Place engine on a flat, level surface. 21. If replacing engine, attach a lifting chain to the front and rear engine lift brackets, and lift engine clear of the ground. 22. Remove the three engine mounting brackets.
7.9.2
Engine Installation
Note: The engine harness is routed and attached at various places on the engine using hold-down clamps and plastic wire ties. Before installing engine and with
7-9

the help of an assistant, ensure that the engine clears the harness during installation. 1. If replacing the engine, attach a lifting strap or chain to the front and rear engine lift brackets, and lift the engine clear of the ground. 2. Install the engine mounting brackets. Torque to 93-100 lb-ft (126-135 Nm). 3. Place the engine on a flat, level surface. 4. Position a fork truck behind the engine, and drive forward, placing the forks underneath the rear engine mount and front right and left engine mount brackets. Lift the engine and slowly drive it into the back of the machine. Have an assistant ensure that the engine clears all frame, hose and harness components during installation. Position the engine brackets over rear and front frame mounts. 5. Secure the rear engine mount (5) to the frame using the previously used hardware. Torque to 80-90 lb-ft (108-122 Nm). 6. Secure the front left (4) and right (3) engine mounts to the frame using the previously used hardware. Torque to 80-90 lb-ft (108-122 Nm). 7. Install the exhaust pipe mount bracket. 8. Install the radiator overflow tube, overflow tank and hose support. 9. Install the engine-to-transmission drive shaft. Refer to Section 5.6.5, Drive Shaft Installation. 10. Uncap and connect the previously labeled fuel return line to the injector pump. 11. Uncap and connect the previously labeled fuel inlet line to the fuel lift pump. 12. Connect the previously labeled electrical wire connections on the engine. 13. Uncap and connect the previously labeled heater hoses to the engine (if equipped). 14. Install the complete radiator assembly. Refer to Section 7.4.2, Radiator/Oil Cooler and Replacement. 15. Properly connect the battery. 16. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 17. Check that all hydraulic system, electrical system, cooling system, fuel system and exhaust system connections are correct and connected tightly. Note: Have an assistant stand by with a Class B fire extinguisher. 18. Start the engine and run to normal operating temperature then shut off the engine. While the engine is cooling, check for leaks. 19. Allow the engine to cool. Check the radiator coolant level, and add coolant if needed. Replace the radiator cap. 20. Check for leaks from the engine, main hydraulic pump and lines, transmission, hydraulic reservoir and fuel tank. Check the levels of all fluids and lubricants. Fill as required. Note: During the full throttle check: DO NOT operate any hydraulic function. DO NOT steer or apply any pressure to the steering wheel. Keep the transmission in (N) NEUTRAL. 21. Obtain and connect an appropriate engine analyzer or tachometer. Check the engine rpm at full throttle. 22. Purge the hydraulic system of air by operating all boom functions through their entire range of motion several times. Check the hydraulic oil level. 23. Check for proper operation of all components. 24. Turn the engine OFF. 25. Install the side and rear engine covers.
7.10
7.10.1
ISOLATION COUPLER
Isolation Coupler Removal
1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake, and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 4. Properly disconnect the battery. Note: Rotating the fan belt by hand gives greater access to removing the drive shaft mounting capscrews. 5. Remove the capscrews and straps that secure the drive shaft to the transmission yoke. 6. Remove the capscrews and lockwashers securing the drive shaft to the coupling flange. Note: It may be necessary to loosen/remove the motor mounts on either side of the engine to gain access to the bottom capscrews on the outer half of the coupler. Place
6036, 6042, 8042, 10042, 10054
7-10

a jack under the bell housing (use a wood block to support the engine) and carefully lift the engine until the bottom edge of the bell housing is at the top edge of the frame member that mounts the rear axle to the frame. Watch the fan-to-radiator clearance as your are lifting the engine. If necessary, turn the fan slightly by hand to gain additional clearance.
9
5. After all capscrews are in place, check to be sure the coupler is resting squarely in the indentation of the flywheel. Torque all the capscrews to 37 lb-ft (48 Nm). 6. Install the small access cover plate to the right side of the engine and tighten the hardware securely. Note: Before assembling the drive shaft to the coupling; be sure the access cover plate is placed on the engineside of the frame member that mounts the rear axle to the frame. Note: Apply Loctite 242 threadlock compound to all of the capscrews used during assembly. 7. Install the access cover plate over the drive shaft and assemble the drive shaft flange to the coupler using new hardware. Torque to 48 lb-ft (65 Nm). 8. If engine mounts were previously removed or loosened, carefully lower the engine down onto the front engine mounts. Reassemble the rebound washer and secure in place with a new locknut. Torque to 60 lb-ft (81 Nm). Repeat this procedure for the engine mount on the other side. 9. Thoroughly clean the transmission yoke and secure in place with new straps and hardware. Torque to 55-60 lb-ft (75-81 Nm). 10. After the drive shaft is in place, grease both u-joints and the slip joint using multi-purpose grease. 11. Properly connect the battery. 12. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 13. Close and secure the rear door.
MH6360
7. Remove the capscrews and lockwashers securing the outer half of the coupler (8). 8. Remove the capscrews securing the small access cover. 9. Remove the capscrews and locknuts securing the coupler (9) to the flywheel. Turn the engine by hand, using the fan belt, until the capscrews line up with the access hole. 10. At this time, use a suitable cleaner/solvent and thoroughly clean the mounting lip of the flywheel. Wipe any debris from the inside of the bell housing. Use the cleaner to clean the threaded holes around the flange of the bell housing.
7.10.2
Isolation Coupler Installation
1. Use cleaner to clean the backside of the coupler, where it comes in contact with the flywheel. Note: The new coupler is heavy and requires two people, one on each side, to install. 2. Place the new coupler into the indentation of the flywheel and use new hardware to secure the coupler to the flywheel. 3. Insert one capscrew into the access hole on the rear right side of the bell housing and through the flywheel and coupler. Assemble a new locknut onto the capscrew. DO NOT fully tighten at this time. 4. Turn the flywheel 180 and insert another capscrew and assemble with another new locknut. DO NOT fully tighten until all capscrews and locknuts are in place.
6036, 6042, 8042, 10042, 10054
7-11
7.11
TROUBLESHOOTING Possible Causes (see key, below)

1, 2, 3, 4 5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 31, 32, 33 5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 29, 31, 32, 33, 61, 63 8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 31, 32, 33, 61, 63 8, 9, 10, 12, 13, 14, 16, 18, 19, 20, 25, 26, 28, 29, 30, 32 11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33, 63 11, 13, 14, 16, 18, 19, 20, 22, 24, 25, 27, 28, 29, 31, 32, 33, 61, 63 4, 16, 18, 19, 20, 25, 27, 31, 33, 34, 35, 45, 56, 62 4, 36, 37, 38, 39, 40, 42, 43, 44, 58 9, 14, 16, 18, 19, 22, 26, 28, 29, 31, 33, 35, 36, 45, 46, 59 7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 23, 26, 28, 29, 30, 33, 35, 45, 59 13, 14, 20, 23, 25, 26, 29, 30, 33, 45, 47, 48, 49 4, 38, 41 11, 13, 14, 16, 18, 19, 24, 25, 45, 50, 51, 52, 53, 54, 57 25, 31, 33, 34, 45, 55, 60 11, 19, 25, 28, 29, 31, 32, 33, 34, 46, 59 10, 11, 12 Key to Possible Causes
Trouble
Low Cranking Power Will Not Start Difficult Starting Lack of Power Misfiring Excessive Fuel Consumption Black Exhaust Blue/White Exhaust Low Oil Pressure Knocking Erratic Running Vibration High Oil Pressure Overheating Excessive Crankcase Pressure Poor Compression Starts and Stops
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 7-12
Battery charge low Bad electrical connection Faulty starter motor Incorrect grade of lubricating oil Low cranking speed Fuel tank empty Faulty stop control operation Fuel inlet restricted Faulty fuel lift pump Clogged fuel filter Restricted air cleaner Air in fuel system Faulty fuel injection pump Faulty fuel injectors or incorrect type Incorrect use of cold start equipment Faulty cold start equipment Broken fuel injection pump drive Incorrect fuel pump timing Incorrect valve timing Poor compression
21. Blocked fuel tank vent 22. Incorrect grade of fuel 23. Sticking throttle or restricted movement 24. Exhaust pipe restriction 25. Leaking cylinder head gasket 26. Overheating 27. Cold running 28. Incorrect tappet adjustment 29. Sticking valves 30. Incorrect high pressure pipes 31. Worn cylinder bores 32. Pitted valves and seats 33. Broken, worn or sticking piston ring(s) 34. Worn valve stems and guides 35. Restricted air cleaner 36. Worn or damaged bearings 37. Insufficient oil in sump 38. Inaccurate gauge 39. Oil pump worn 40. Pressure relief valve sticking open 41. Pressure relief valve sticking closed 42. Broken relief valve spring
43. 44. 45. 46. 47. 48. 49.
50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63.
Faulty suction pipe Restricted oil filter Piston seizure/pick up Incorrect piston height Damaged fan Faulty engine mounting Incorrectly aligned flywheel housing or incorrectly aligned flywheel Faulty thermostat Restriction in water jacket Loose fan belt Restricted radiator Faulty water pump Restricted breather pipe Damaged valve stem oil deflectors (if fitted) Coolant level too low Blocked sump strainer Broken valve spring Exhauster or vacuum pipe leak Turbo impeller damaged or dirty Turbo lubricating oil seal leak Induction system leaks
6036, 6042, 8042, 10042, 10054
Section 8 Hydraulic System
Contents
PARAGRAPH 8.1 8.2 8.3 8.4 TITLE PAGE 8-2 8-4 8-4 8-5 8-5 8-6 8-16 8-21 8-21 8-21 8-21 8-22 8-22 8-22 8-22 8-23 8-23 8-25 8-26 8-27 8-27 8-28 8-29 8-31 8-32 8-32 8-34 8-35 8-36
8.5
8.6
8.7
8.8
Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.1 Pressure Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.1 Hydraulic Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.2 Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.1 Hydraulic Oil Reservoir Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.2 Hydraulic Oil Reservoir Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.3 Hydraulic Oil Reservoir Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.1 Pump Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.2 Pump Failure Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.3 Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valves and Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.2 Secondary Function Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.3 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.4 Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.5 Power Steering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.6 Steer Select Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.7 Unloader Valve (6036 & 6042 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.9 Extend Lockout Valve (10054 only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8.1 General Cylinder Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8.2 Cylinder Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8.3 Steering Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8.4 Cylinder Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6036, 6042, 8042, 10042, 10054
8-1
Hydraulic System
8.1
HYDRAULIC COMPONENT TERMINOLOGY
To understand the safety, operation and service information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the hydraulic components of the machine. The following illustration identifies the components that are referred to throughout this section.
6036 & 6042
LIFT/LOWER CYLINDERS SLAVE CYLINDERS
ATTACHMENT TILT CYLINDER
EXTEND/ RETRACT CYLINDER
UNLOADER VALVE HYDRAULIC FLUID RESERVOIR STEER SELECT VALVE
MAIN CONTROL VALVE FRAME SWAY CYLINDER MAIN PUMP STABILIZER CYLINDER (6042 ONLY)
SECONDARY FUNCTION MANIFOLD
SERVICE BRAKE VALVE
STEERING CYLINDER (REAR)
STEERING VALVE STEERING CYLINDER (FRONT)

MA9251
8-2
6036, 6042, 8042, 10042, 10054
Hydraulic System
8042, 10042 & 10054
LIFT/LOWER CYLINDERS SLAVE CYLINDERS
EXTEND LOCKOUT VALVE (10054 ONLY)
MAIN PUMP HYDRAULIC FLUID RESERVOIR
STEER SELECT VALVE FRAME SWAY CYLINDER STABILIZER CYLINDER
SECONDARY FUNCTION MANIFOLD SERVICE BRAKE STEERING VALVE VALVE
STEERING CYLINDER (REAR)
OUTRIGGER CYLINDERS (10042 & 10054 ONLY)
MAIN CONTROL VALVE STEERING CYLINDER (FRONT)
OUTRIGGER VALVE (10042 & 10054 ONLY)
MH3441
6036, 6042, 8042, 10042, 10054
8-3
Hydraulic System
8.2
SAFETY INFORMATION
WARNING
DO NOT service the machine without following all safety precautions as outlined in Section 1, Safety Practices, of this manual. Petroleum-based hydraulic fluids are used in this machine. The temperature of hydraulic fluid increases during the operation of various hydraulic functions. A heated petroleum-based hydraulic fluid presents a fire hazard, especially when an ignition source is present. Hydraulic fluid has a flash point that ranges from 300-600 F (150-318 C) and an auto-ignition temperature of 500-750 F (262-402 C). Accordingly, periodically inspect all hydraulic system components, hoses, tubes, lines, fittings, etc. Carefully examine any deterioration and determine whether any further use of the component would constitute a hazard. If in doubt, replace the component. Operate the hydraulic controls after the engine has stopped to relieve trapped pressure. Note: Residual pressure may remain in hydraulic cylinders, hoses, valve bodies, components, etc. If the hydraulic lines going to or coming from a component are taut, slowly and cautiously relieve (bleed off) pressure. Whenever you disconnect a hydraulic line, coupler, fitting or other component, slowly and cautiously loosen the part involved. A hissing sound or slow seepage of hydraulic fluid may occur in most cases. After the hissing sound has ceased, continue removing the part. Any escaping oil should be directed into an appropriate container. Cap or otherwise block off the part to prevent further fluid seepage. Hydraulic system maintenance will, at times, require that the engine be operated. Always follow safety precautions. A major cause of hydraulic component failure is contamination. Keeping the hydraulic fluid as clean as possible will help avoid downtime and repairs. Sand, grit and other contaminants can damage the finely machined surfaces within hydraulic components. If operating in an exceptionally dirty environment, change filters and inspect the fluid more often. When servicing the system, cap or plug hydraulic fittings, hoses and tube assemblies. Plug all cylinder ports, valves and the hydraulic reservoir, and pump openings until installation occurs. Protect threads from contamination and damage.
Some hydraulic functions are actuated by interfacing with electrical system components (switches, solenoids and sensors). When the hydraulic system is not functioning properly, check the electrical aspect of the malfunctioning circuit also.
8.3
HYDRAULIC PRESSURE DIAGNOSIS
JLG Parts Department has a kit available to use for hydraulic system maintenance and troubleshooting: the JLG Pressure Test Kit. The kit is contained in a durable polyethylene carrying case for demanding field service conditions. Hydraulic Pressure Test Kit The hydraulic pressure test kit is used to pressure test the various hydraulic components in the hydraulic system. The kit includes: Gauges for testing high and low pressure circuits Fittings, couplers and hoses
MZ1460
Contact JLG Parts Department Toll Free at 1-877-554-5438 or 717-485-6472 for ordering information.
Part Number 70000652 70000101 70027911 Description Dial Hydraulic Pressure Test Kit Digital Hydraulic Pressure Test Kit Digital Hydraulic Pressure Test Kit Approximate Weight 10 lbs. 7 lbs. 7 lbs. Price and Availability Consult Factory Consult Factory Consult Factory
8-4
6036, 6042, 8042, 10042, 10054
Hydraulic System
8.3.1
Pressure Checks and Adjustments
8.4
HYDRAULIC CIRCUITS
When diagnosing trouble in the hydraulic system, use the hydraulic testing information in Section 8.4.1, Hydraulic Pressures. In general, follow the steps below whenever conducting pressure checks and performing adjustments: 1. Park the machine on a firm, level surface. Engage the park brake, place the travel select lever in (N) NEUTRAL, level the boom and turn the engine OFF. 2. The test port is located at the top right corner of the main control valve. Install a pressure gauge capable of measuring at least 10% more pressure than that which the circuit being checked operates under. 3. Start the engine. Operate machine functions several times to allow hydraulic oil to reach operating temperature. The hydraulic oil temperature should be between 100-120F (38-49 C). If a temperature gauge or thermometer is unavailable, the hydraulic oil reservoir should be warm to the touch. 4. Refer to Section 8.4.1, Hydraulic Pressures, for testing procedures. 5. Fully depress the accelerator pedal if required. Place and hold the joystick in the position needed to operate the particular machine function being checked. Continue holding the joystick in position until pressure readings are taken. 6. Check the pressure gauge reading. It should read as specified in the Pressure Readings column of the charts found in Section 8.4.1, Hydraulic Pressures. If the reading is not as specified, turn the engine OFF and check other components in the system. Verify that all related hydraulic components and electrical switches, sensors, solenoids, etc. are operating correctly. 7. Adjust the relief valve by turning the adjustment screw Turning clockwise will increase the pressure; turning the screw counterclockwise will decrease the pressure. 8. Start the engine and check the pressure again. Turn the engine OFF. If there is pressure reading in the gauge, bleed it off then disconnect or remove the pressure gauge from the machine.
This section covers the hydraulic circuits and includes listings for all hydraulic function pressures, where and how to check those pressures and a hydraulic schematic. Electrical and hydraulic functions are often related. Verify that the electrical components of the circuit are functioning properly whenever troubleshooting the hydraulic circuit. Always check the following before beginning to troubleshoot a circuit that is not functioning correctly. 1. Check the hydraulic oil level in the reservoir. Oil level should be to the middle of the sight glass with all cylinders retracted. 2. Check hoses, tubes, fittings and other hydraulic components for leaks, bends, kinks, interference, etc. 3. Check for air in the hydraulic system. Erratic machine performance and/or spongy cylinder operation are signs of air in the hydraulic system. If air in the hydraulic system is suspected, you will hear air leakage when hydraulic fittings are loosened and see air bubbles in the hydraulic fluid. Loose fittings, faulty o-rings or seals, trapped oil, leaks, system opened for service, etc., can cause air in the system. Determine what is causing air to enter the system and correct it. Bleed air from the system.
6036, 6042, 8042, 10042, 10054
8-5
Hydraulic System 8.4.1 Hydraulic Pressures
a. Checking Pressure 1. Start the machine and warm the hydraulic system to operating temperature. 2. Shut off the machine and install a gauge of suitable pressure rating according to the following chart to the appropriate test port. Test Location 2, 3, 4, 5 6, 7, 8, 10 9 Gauge 4000 psi gauge (280 bar gauge) 1000 psi gauge (70 bar gauge) 4000 psi gauge (280 bar gauge) Fittings Unit equipped with fittings from factory. Unit equipped with fittings from factory. Requires a male or female quick disconnect coupler.
CAUTION
GAUGE DAMAGE may occur. Malfunctioning hydraulic system circuits may have excessive pressure and can cause hydraulic pressure spikes. Test circuit with the highest reading pressure gauge first. If this gauge cannot record an accurate pressure reading, use the next lower pressure gauge. 3. Start the machine, run the engine and follow the procedures in Section 8.4.1, e. Pressure Specifications (8042, 10042 &l 10054). b. Adjusting Hydraulic Pressure 1. Shut the machine off. Remove the cap on the relief (if necessary). 2. Start the machine and loosen the jam nut on the relief. Turn the relief clockwise to increase pressure or counter-clockwise to decrease pressure. Set to the correct pressure. 3. Tighten the jam nut and recheck the pressure at full throttle. If the reading is within specification, shut the machine off, install the safety cap and remove the gauge from the test port. 4. If the proper pressure cannot be set, use the accompanying hydraulic schematic and/or the electrical schematic to help troubleshoot and correct the problem.
8-6
6036, 6042, 8042, 10042, 10054
Hydraulic System
c. Pressure Specifications (6036)

ATTACHMENT TILT CYLINDER FTR FTB FRAME SWAY CYLINDER
FRONT AXLE
8
FRONT STEERING CYLINDER E R
BRAKE VALVE
T P LS
MAIN CONTROL VALVE
C 1
7
LFT/LWR ATTACH TILT FRAME AUX SHUTTLE VALVE RP LT POWER STEERING UNIT EXT/RET T LS
PUMP T B P A
STEER SELECT VALVE
IN T
HYDRAULIC RESERVOIR
OPERATOR'S CAB
E
SECONDARY FUNCTION MANIFOLD EXTEND/ RETRACT CYLINDER P
PS PSG PBG PP PPG
5
PB
R E
LEFT LIFT/LOWER CYLINDER
RIGHT LIFT/LOWER CYLINDER
R E
2
R E VG V SFV T
A D 3
LEFT SLAVE CYLINDER
P R E R E RIGHT SLAVE CYLINDER
LS
LSG
UNLOADER VALVE
REAR AXLE HYDRAULIC OIL COOLER
MA6241
6036, 6042, 8042, 10042, 10054
8-7
Hydraulic System
Test Location 1
Hydraulic Pump Flow Test To check flow readings, a flow meter capable of measuring 60 gpm (3,8 liter/sec) and a load valve capable of 6000 psi (413,4 bar) will be required. 2000 psi (137,8 bar) load @ Engine Speed of 2500 25 rpm - Flow rate should be 28-32 GPM (1,8-2,0 liter/sec)
Test Location 2
Adjust. Location A
Component Description Unloader Valve
Unloader Valve
N/A
Attachment Tilt Relief/ FORWARD or REARWARD Unloader Valve
Pressure Reading Main System Relief 3000100 psi (2077 bar) Lift/Lower Relief 3000100 psi (2077 bar) 320050 psi (2213,4 bar)
Pressure Test Procedures With engine at idle, use the boom control lever to fully retract the boom. Hold over relief and check pressure. If pressure is incorrect, adjust or replace cartridge. Remove the carriage if attached. With engine at full throttle, use the boom control lever to lower boom fully. Hold over relief and check pressure. If pressure is incorrect, adjust or replace cartridge. CONSULT FACTORY
N/A
Unloader Valve
Secondary Function Manifold Secondary Function Manifold
N/A
Brake Valve (Manual Brake Pressure)
With engine at idle and no functions operated, check standby pressure. If pressure is incorrect, adjust or replace the differential pressure sense cartridge on the unloader valve. With engine at idle, load sense at 0 psi. With engine at FULL throttle, use the boom control lever to fully retract the boom. Hold over relief. Pressure should be 2750-3000 psi (190-207 bar). Steering Relief With engine at FULL throttle, turn the steering wheel all the 2500100 psi way in one direction and hold while checking pressure. If pressure is incorrect, adjust or replace the pressure(1727 bar) reducing cartridge. Park Brake With engine at idle, park brake released and no functions 400 psi operated, pressure should be 400 psi (28 bar) (28 bar) minimum. With engine at idle, park brake released minimum and steering held over relief, pressure should be 550 psi 550 psi (38 bar) maximum. If pressure is incorrect, adjust or (38 bar) replace the pressure reducing valve in the secondary maximum function manifold. When adjusting the pressure reducing valve, connect gauge to location 6. With engine at idle and steering held over relief, adjust valve until gauge reads 500-550 psi (34-38 bar). 400 psi With engine OFF, pump brake pedal twice. DO NOT (28 bar) overstroke the brake pedal. If pressure is incorrect, check minimum for external leaks. If no leaks are found, refer to Section 8.7.3, Service Brake Valve.
Standby Pressure 250-300 psi (17-21 bar) Load Sense 0-3000 psi (0-207 bar)
8-8
6036, 6042, 8042, 10042, 10054
Hydraulic System
Test Location 7
Adjust. Location N/A
Component Description Brake Valve (Service Brake Pressure) Auxiliary Hydraulics
Pressure Reading 550 psi (38 bar) minimum 3000 psi (207 bar)
Pressure Test Procedures With engine at idle, depress and hold brake pedal. DO NOT turn the steering wheel. DO NOT overstroke the brake pedal. Check pressure. If pressure is incorrect, refer to Section 8.7.3, Service Brake Valve. With engine at low idle, move auxiliary control lever left or right. Hold auxiliary control lever over relief and check pressure. If pressure is incorrect, check unloader pressure per location 2. If location 2 is ok, check port reliefs on the aux section of main control valve.
6036, 6042, 8042, 10042, 10054
8-9
Hydraulic System
d. Pressure Specifications (6042)
FRONT AXLE
ATTACHMENT TILT CYLINDER AUXILIARY HYDRAULICS .040 E R
FRAME SWAY CYLINDER FTR FTB
.047
MAIN CONTROL VALVE
LFT/LWR
EXT/RET
ATTACH TILT
FRAME
T BRAKE VALVE .089
T P .089 LS .089
T IN
AUX
LS .029
8
SHUTTLE VALVE .089 UNLOADER VALVE LSG SFV P T VG V STEER SELECT VALVE B A
RP LS LT POWER STEERING UNIT OPERATOR'S CAB T P
4
LS
B A
R E
2 3
T P
PS PBG PSG PPG PP PB
1 5
LEFT LIFT/LOWER CYLINDER PUMP RIGHT LIFT/LOWER CYLINDER
SECONDARY FUNCTION MANIFOLD STABILIZER CYLINDER FTR V G1 PT
R E
R E
9 E
LEFT SLAVE CYLINDER
R E
R E
RIGHT SLAVE CYLINDER
REAR AXLE
HYDRAULIC OIL COOLER
HYDRAULIC RESERVOIR
MA9241
8-10
6036, 6042, 8042, 10042, 10054
Hydraulic System
Test Location 1
Hydraulic Pump Flow Test To check flow readings, a flow meter capable of measuring 60 gpm (3,8 liter/sec) and a load valve capable of 6000 psi (413,4 bar) will be required. 2000 psi (137,8 bar) load @ Engine Speed of 2500 25 rpm - Flow rate should be 34-40 GPM (2,1-2,5 liter/sec)
Test Location 2
Valve Port VG
Adjust. Component Location Description A Unloader Valve
Auxiliary Hydraulics
Pressure Reading Main System Relief 3000100 psi (2077 bar) 3000100 psi (2077 bar)
Pressure Test Procedures With engine at high idle, use the boom control lever to fully retract the boom. Hold over relief and check pressure. If pressure is incorrect, adjust or replace cartridge. With engine at high idle, move auxiliary control lever left or right. Hold auxiliary control lever over relief and check pressure. If pressure is incorrect, check unloader pressure per location 2. If location 2 is ok, check port reliefs on the aux section of the main control valve. CONSULT FACTORY
VG
N/A
VG
LSG
N/A
PSG
Note: DO NOT touch any functions while the pressure gauge is connected. You will damage the pressure gauge. With engine at idle and no functions operated, check standby pressure. If pressure is incorrect, adjust or replace the differential pressure sense cartridge on the unloader valve. Unloader Valve Load Sense With engine at idle, load sense is 0 psi. 0-3000 psi With the engine at FULL throttle, use the boom (0-207 bar) control lever to fully retract the boom. Hold over relief. Pressure should be 2750-3000 psi (190-207 bar). Secondary Steering Relief With engine at FULL throttle, turn the steering Function 2500100 psi wheel all the way in one direction and hold while Manifold (1727 bar) checking pressure. If pressure is incorrect, adjust or replace the pressure-reducing cartridge. Standby Pressure 250-300 psi (17-21 bar)
Attachment Tilt Relief/ FORWARD or REARWARD Unloader Valve
3000100 psi (2077 bar)
6036, 6042, 8042, 10042, 10054
8-11
Hydraulic System
Test Location 6
Valve Port PBG
Adjust. Location N/A
Component Description Secondary Function Manifold
Pressure Reading Park Brake 400 psi (28 bar) minimum 500-600 psi (34-41 bar) maximum
Pressure Test Procedures With engine at idle, park brake released and no functions operated, pressure should be 400 psi (28 bar) minimum. With engine at idle, park brake released and steering held over relief, pressure should be 500-600 psi (34-41 bar) maximum. After releasing steering wheel, the pressure MUST NOT drop more than 50 psi in one minute. If pressure drop is incorrect, refer to Section 8.7.3, Service Brake Valve. If pressure is incorrect, adjust per test 7. With engine at idle, park brake released and steering held over relief while checking pressure. If pressure is incorrect, adjust or replace the pressure reducing valve in the secondary function manifold. With engine OFF, pump brake pedal twice. DO NOT overstroke the brake pedal. If pressure is incorrect, check for external leaks. If no leaks are found, refer to Section 8.7.3, Service Brake Valve. With engine at idle, depress and hold brake pedal. DO NOT turn steering wheel. DO NOT overstroke the brake pedal. Check pressure. If pressure is incorrect, refer to Section 8.7.3, Service Brake Valve. With engine at idle, check the pressure on the cylinder.
PBG
Secondary Function Manifold
500-600 psi (34-41 bar)
N/A
400 psi (28 bar) minimum
N/A
Brake Valve (Service Brake Pressure)
550 psi (38 bar) minimum
G1
Stabilizer Cylinder
75-150 psi (5,2-10,3 bar)
8-12
6036, 6042, 8042, 10042, 10054
Hydraulic System
e. Pressure Specifications (8042, 10042 &l 10054)
LEFT OUTRIGGER CYLINDER RIGHT OUTRIGGER CYLINDER
E R
R E
FRONT AXLE
AUXILIARY COUPLERS FTR FTB FRAME SWAY CYLINDER
BRAKE VALVE
T P LS
MAIN CONTROL VALVE
3
LFT/LWR EXT/RET
D
1
B A
STEER SELECT VALVE PUMP T B P A
8
FRAME SWAY ATTACH TILT
P
RP LT POWER STEERING UNIT
IN T
AUX
SHUTTLE VALVE
LS
OPERATOR'S CAB
HYDRAULIC RESERVOIR
5
C P PS
7
PSG G
6
PBG
PLT PB
A1 T LS P
B1
A2
B2
4
R E
OUTRIGGER VALVE (10042 & 10054 ONLY)
LEFT LIFT/LOWER CYLINDER
RIGHT LIFT/LOWER CYLINDER
STABILIZER CYLINDER FTR V G
R E
R E
10
PT
LEFT SLAVE CYLINDER
R E
R E
RIGHT SLAVE CYLINDER
REAR AXLE
HYDRAULIC OIL COOLER
MH6170
6036, 6042, 8042, 10042, 10054
8-13
Hydraulic System
Test Location 1
Hydraulic Pump Flow Test To check flow readings, a flow meter capable of measuring 60 gpm (3,8 liter/sec) and a load valve capable of 6000 psi (413,4 bar) will be required. 2000 psi (137,8 bar) load @ Engine Speed of 2500 25 rpm - Flow rate should be 48.9 GPM (3 liter/sec)
Test Location 2
Adjustment Location A
Component Description Pump Standby Pressure
Pressure Reading 550-600 psi (38-41 bar)
Pressure Test Procedures Loosen load sense line at location B to bleed off pressure, and then retighten line. With engine at idle and no hydraulic functions operated, check pump standby pressure. If pressure is incorrect, adjust top screw on compensator. With engine at idle, turn steering wheel all the way in one direction. Hold over relief and check maximum pump pressure. If pressure is incorrect, consult factory. With engine at FULL throttle, use the boom control lever to fully retract the boom. Hold over relief and check pressure. If pressure is incorrect, adjust and replace cartridge. CONSULT FACTORY
N/A
Pump Pressure Compensator
3300 psi (228 bar)
Main Control Valve
System Relief 3000 100 psi (2077 bar) 3000100 psi (2077 bar)
N/A
N/A
Attachment Tilt Relief/ FORWARD or REARWARD Secondary Function Manifold Secondary Function Manifold Secondary Function Manifold Secondary Function Manifold
N/A
N/A
With engine at idle, load sense is 0 psi. With engine at idle, use the boom control lever to fully retract the boom. Hold over relief and check pressure. Pressure should be 3000 psi (207 bar). Steering Relief With engine at idle, turn the steering wheel all the 2500100 psi way in one direction. Hold over relief and check (1727 bar) pressure. If pressure is incorrect, adjust or replace the pressure reducing cartridge. Park Brake With engine at idle and no hydraulic functions Release operated, disengage the park brake, check pressure. 55050 psi This is not an adjustment. (383,4 bar) With engine at idle and park brake released, turn the Park Brake steering wheel all the way in one direction. Hold over Pressure relief and check pressure. If pressure is incorrect, 55050 psi (383,4 bar) adjust or replace the pressure reducing cartridge in the secondary function manifold. 400 psi With engine OFF, pump brake pedal twice. DO NOT minimum overstroke the brake pedal. If pressure is incorrect, (28 bar) check for external leaks. If no leaks are found, refer to Section 8.7.4, Brake Test. Load Sense 0-3000 psi (0-207 bar)
8-14
6036, 6042, 8042, 10042, 10054
Hydraulic System
Test Location 8
Adjustment Location N/A
Component Description Brake Valve (Service Brake Pressure) Auxiliary Hydraulics
Pressure Reading 550 psi minimum (38 bar) 3000 psi (207 bar)
Pressure Test Procedures With engine at idle, depress and hold brake pedal. DO NOT turn steering wheel. DO NOT overstroke the brake pedal. Check pressure. If pressure is incorrect, refer to Section 8.7.4, Brake Test. With engine at low idle, move auxiliary control lever left or right. Hold control lever over relief and check pressure. If pressure is incorrect, check main relief per location 3. With the engine at idle, check the pressure of the cylinder.
10
N/A
Stabilizer Cylinder
75-150 psi (5,2-10,3 bar)
6036, 6042, 8042, 10042, 10054
8-15
8-16
7 6 5 4 3 2 1
FRAME TILT CYL 4.50 X 2.25 X 8.69
SLAVE CYLINDERS - 3.75 X 1.50 X 11.40
8.4.2
HOIST CYLINDER - 5.00 X 2.75 X 39.65
EXTEND CYLINDER - 4.50 X 3.00 X 102.50
FTB
4000 PSI FRONT 3.93 BASE 1.97 ROD 4.4B STROKE
a. Model 6036
4000 PSI
FTR
R P a A B b STEERING SELECTOR VALVE MANIFOLD 4 WHEEL STEER
4000 PSI L R
CRAB STEER
L P FORK CYLINDER 5.00 X 2.00 X 16.75 STEERING VALVE T REAR
Hydraulic System
4000 PSI
Hydraulic Schematics
TANK
B A B
3250 PSI 3250 PSI 3250 PSI 3250 PSI
B A A A B A
PRESSURE PORT
LOAD SENSE OUT
AUX FUNCTION QUICK DISCONNECT AT BOOM GOSENECK OPTIONAL
PSG PS PP PPG PB
PBG
TANK
65 PSI
LOAD SENSE
.090 DIA
2500 PSI 550 PSI
.090 DIA
LOAD SENSE OUT
SHUTTLE IN
P
14 GPM MAX 6 GPM MAX 14 GPM MAX
650 PSI
E
T
PRESSURE PORT
3500 PSI
HOIST
EXTEND AUX HYD FRAME TILT FORK TILT
INLET TANK
MAIN CONTROL VALVE
250 PSI
T
2750 PSI
C
B2 .089 FRONT WHEEL BRAKE
3.5 IN
LOW IDLE 1050 RPM BYPASS TO TANK
15.9 GPM
HIGH IDLE 2750 RPM
41.7 GPM
RATED SPEED 2500 RPM
37.9 GPM
B1
.089
B
60um
25 PSI
B
L5 REAR WHEEL BRAKE
10um
.073
10um
SERVICE BRAKE VALVE
MAQ0070
7 6
6036, 6042, 8042, 10042, 10054

5
V FTR 3 2A .03
G2 G3
.040
HOIST CYLINDER - 5.00 X 2.75 X 44.36 EXTEND CYLINDER - 4.50 X 3.00 X 102.50 FRAME TILT CYL 4.50 X 2.25 X 8.69 SLAVE CYLINDERS - 3.75 X 1.50 X 11.40 FTB 3.93 BASE 1.97 ROD 4.4B STROKE
CYL2
b. Model 6042
H
4000 PSI FRONT
CYL1
4000 PSI
FTR R P a A B b 4 WHEEL STEER
2B
12A 11 11
4A
4B 12B
4000 PSI L R
.047
STABILIZER CYL 4.50x8.69x2.25
CRAB STEER
STEERING SELECTOR VALVE MANIFOLD
1 .06
100 PSI

P G1
L P FORK CYLINDER 5.00 X 2.00 X 16.75 STEERING VALVE T REAR
6036, 6042, 8042, 10042, 10054

R
4000 PSI
TANK
B A B
3250 PSI 3250 PSI 3250 PSI 3250 PSI
B A A A B A
PRESSURE PORT
LOAD SENSE OUT
AUX FUNCTION QUICK DISCONNECT AT BOOM GOSENECK OPTIONAL
PSG PS
PP
PPG
PB
PBG
F
TANK
65 PSI
LOAD SENSE LOAD SENSE OUT
.090 DIA 2500 PSI 550 PSI
SHUTTLE IN
P
.029
650 PSI
E
EXTEND AUX HYD FRAME TILT FORK TILT
E
T
PRESSURE PORT
3500 PSI
HOIST

INLET TANK
MAIN CONTROL VALVE .089
250 PSI
T
2750 PSI
B2
.089
FRONT WHEEL BRAKE
3.5 IN
LOW IDLE 1050 RPM BYPASS TO TANK
15.9 GPM
HIGH IDLE 2750 RPM
41.7 GPM
RATED SPEED 2500 RPM
37.9 GPM
B1
.089
25 PSI
B
60um
B
L5
REAR WHEEL BRAKE
10um
.073
10um
SERVICE BRAKE VALVE
Hydraulic System
MAQ0080
7 6
8-17
8-18
7 6 5 4 3 2 1
SLAVE CYLINDERS - 4.25 x 1.75 x 13.75 V FTR 3 .03 G2 G3
c. Model 8042
HOIST CYLINDER - 6.00 x 3.00 x 42.41
EXTEND CYLINDER - 5.00 x 3.00 x 131.25
H
2A 4000 PSI CYL2 3.93 BASE 1.97 ROD 4.48 STROKE
4000 PSI
FRONT
.040
P T CRAB b STEER a A B 4000 PSI R L
CYL1 2B L 2A 11 11 FTB FORK CYLINDER 6.00 x 2.50 x 16.75 L R 4A 4B 2B FRAME TILT CYL 4.50x2.25x8.69 R 4 WHEEL STEER STEERING SELECTOR VALVE MANIFOLD
STABILIZER CYL 4.50x2.25x8.69 IF NEEDED
T P FTR AUX FUNCTION QUICK DISCONNECT AT BOOM GOSENECK OPTIONAL STEERING VALVE G1
1 .06
100 PSI
REAR
P T
G
.047
Hydraulic System
4000 PSI
FEMALE DISCONNECT ON L.H.SIDE OF BOOM

B A B A A 3250 PSI 3250 PSI 3250 PSI A 3250 PSI 3500 PSI B B B A
MALE DISCONNECT ON R.H.SIDE OF BOOM

PSG PB G
PBG
F
TANK
65 PSI LOAD SENSE 2500 PSI
3000 PSI
.090 DIA
SHUTTLE IN
550 PSI
P 6 GPM MAX 14 GPM MAX 14 GPM MAX T HOIST EXTEND INLET MAIN CONTROL VALVE FORK TILT AUX FRAME TILT C PLT
650 PSI
.0890
125 PCI
LOW IDLE 18.3 GPM HI IDLE 44.9 GPM RATED 41.6 GPM 3 3.84 IN/REV LOW IDLE-1100 RPM HIGH IDLE-2700 RPM RATED-2500 RPM
25 PSI
3300 PSI
575 PSI STAND BY
T FRONT WHEEL BRAKE B2
C
.089
60~am 10um
10~am
B1
.089
HIGH HYD. OIL TEMP
195 F REAR WHEEL BRAKE L5
.073
SERVICE BRAKE VALVE
MAQ0090A
7 6
6036, 6042, 8042, 10042, 10054

5
SLAVE CYLINDERS - 4.25 x 1.75 x 13.75
H
EXTEND CYLINDER - 5.00 x 3.00 x 131.25 V FTR 3 2A 4000 PSI CYL2 3.93 BASE 1.97 ROD 4.48 STROKE .03 G2 G3
d. Model 10042
4000 PSI
FRONT
.040
P T b A B a 4000 PSI R L
CYL1 2B L 2A 11 11 FTB FORK CYLINDER 6.00 x 2.50 x 16.75 L R 4A 4B 2B FRAME TILT CYL 4.50x2.25x8.69 R 4 WHEEL STEER STEERING SELECTOR VALVE CRAB MANIFOLD STEER
6036, 6042, 8042, 10042, 10054

STABILIZER CYL 4.50x2.25x8.69 IF NEEDED
G
T P FTR AUX FUNCTION QUICK DISCONNECT AT BOOM GOSENECK STEERING VALVE G1 1 .06 100 PSI
G
REAR
.047
4000 PSI
FEMALE DISCONNECT ON L.H.SIDE OF BOOM MALE DISCONNECT ON R.H.SIDE OF BOOM

B A 3250 PSI 3250 PSI 3250 PSI PSG B A B A A 3250 PSI 3500 PSI B B A
PB
PBG
LS
TANK
T
3000 PSI LOAD SENSE
OUTRIGGER VALVE
65 PSI SHUTTLE IN
.090 DIA 2500 PSI
.156
550 PSI
E
650 PSI
T HOIST EXTEND INLET MAIN CONTROL VALVE FORK TILT AUX FRAME TILT C PLT SECONDARY FUNCTION MANIFOLD
LS
.0890
B2
A2
A1
B1
D
125 PCI
LOW IDLE 18.3 GPM HI IDLE 44.9 GPM RATED 41.6 GPM 3 3.84 IN/REV LOW IDLE-1100 RPM HIGH IDLE-2700 RPM RATED-2500 RPM
25 PSI
3300 PSI
R.H.
L.H.
575 PSI STAND BY
T FRONT WHEEL BRAKE B2
OUTRIGGER CYLINDER 5.00 X 3.00 X 13.31
.089
60~am 10um
10~am
B1
.089
HIGH HYD. OIL TEMP
195 F
B
L5
REAR WHEEL BRAKE
.073
SERVICE BRAKE VALVE
Hydraulic System
MAQ0100
7 6
8-19
8-20
7 6 5 4 3 2 1
V FTR SLAVE CYLINDERS - 4.25 x 1.75 x 13.75 .03 2A CYL2 3 EXTEND CYLINDER - 5.00 x 3.00 x 131.25 G2 G3
e. Model 10054
4000 PSI 4000 PSI .040 2B 4000 PSI L R 2A 11 11 FTB P T b A B a L .06 G1 FTR FORK CYLINDER 6.00 x 2.50 x 16.75 L R R 4 WHEEL STEER STEERING SELECTOR VALVE CRAB MANIFOLD STEER 4A 4B 2B FRAME TILT CYL 4.50x2.25x8.69
CYL1
STABILIZER CYL 4.50x2.25x8.69 IF NEEDED 3.93 BASE 1.97 ROD 4.48 STROKE
FRONT
T P
100 PSI
.047
REAR
P STEERING VALVE AUX FUNCTION QUICK DISCONNECT AT BOOM GOSENECK T
G
BOOM LOCKOUT VALVE C1
Hydraulic System
4000 PSI
T V1
FEMALE DISCONNECT ON L.H.SIDE OF BOOM MALE DISCONNECT ON R.H.SIDE OF BOOM B A 3250 PSI 3250 PSI 3250 PSI PSG G B A B A 3250 PSI
B A
B A
PB
PBG
F
TANK
3500 PSI
LS
T
3000 PSI LOAD SENSE
OUTRIGGER VALVE
65 PSI SHUTTLE IN
.090 DIA 2500 PSI 550 PSI
.156
E
650 PSI
T HOIST EXTEND INLET MAIN CONTROL VALVE FORK TILT AUX FRAME TILT C PLT SECONDARY FUNCTION MANIFOLD .0890
LS
B2
A2
A1
B1
D
125 PSI
LOW IDLE 18.3 GPM HI IDLE 44.9 GPM RATED 41.6 GPM 575 PSI STAND BY
3300 PSI
R.H.
L.H.
C
25 PSI
OUTRIGGER CYLINDER 5.00 X 3.00 X 13.31
3 3.84 IN/REV LOW IDLE-1100 RPM HIGH IDLE-2700 RPM RATED-2500 RPM
FRONT WHEEL BRAKE
C
B2 .089
60~am 10um
10~am B1 HIGH HYD. OIL TEMP 195 F
.089
L5
REAR WHEEL BRAKE
SERVICE BRAKE VALVE
.073
MAQ0110
7 6
6036, 6042, 8042, 10042, 10054

5
Hydraulic System
8.5
HYDRAULIC RESERVOIR
1 2
5. Open the filler cap on the hydraulic oil reservoir. Remove the drain plug on the side of the hydraulic oil reservoir. 6. Transfer the used hydraulic oil into a suitable covered container, and label as "Used Oil". Dispose of used oil at an approved recycling facility. Clean and reinstall the drain plug. 7. Wipe up any hydraulic fluid spillage in, on, near and around the machine and the work area.
8.5.2
Hydraulic Oil Reservoir Filling
1. Be sure the reservoir is clean and free of all debris. 2. Install a new hydraulic oil filter. 3. Fill the reservoir with Mobilfluid 424 (ISO Grade 46) oil. Refer to Section 2.4, Fluid and Lubricant Capacities. 4. Properly connect the battery.
MH6180
5. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 6. Close and secure the rear door.
The hydraulic reservoir (1) and the fuel tank are one unit. They are located on the right side of the frame under a cover. Occasionally, fluid may seep, leak or be more forcefully expelled from the filter head (2) when system pressure exceeds the rating of the filter head or breather. If the return filter becomes plugged, return hydraulic oil will bypass the filter when pressure reaches 25 psi (1,7 bar) and return to the reservoir unfiltered. Carefully examine fluid seepage or leaks from the hydraulic reservoir to determine the exact cause. Clean the reservoir and note where any seepage occurs. Leaks from a cracked or damaged reservoir require that the reservoir be removed from the machine, flushed completely with water and repaired by a certified welder using approved techniques. If these conditions cannot be met, the reservoir must be replaced in its entirety.
8.5.3
Hydraulic Oil Reservoir Replacement
The hydraulic reservoir and fuel tank are one unit and are removed together. Refer to Section 7.6.2, Fuel/Hydraulic Oil Tank, for information on hydraulic reservoir/fuel tank replacement.
8.5.1
Hydraulic Oil Reservoir Draining
1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 4. Properly disconnect the battery.
6036, 6042, 8042, 10042, 10054
8-21
Hydraulic System
8.6
8.6.1
HYDRAULIC SYSTEM PUMP

Pump Description
3
Hydraulic system pressure begins at the pump. Various factors are involved in creating the relatively high pressure used in the hydraulic system. Pump rpm, controlled via a transmission input shaft (and dependent on engine rpm), the internal pump passageways and the differential between pump inlet and outlet openings, all contribute to pressure supplied. For internal service instructions contact your local authorized service distributor.
MH6490
8.6.2
Pump Failure Analysis
7. Thoroughly clean the pump (3) and surrounding area, including all hoses and fittings before proceeding. 8. Label, disconnect and cap the hydraulic hoses attached to the pump. 9. Remove the bolts, lockwashers and washers securing the pump to the transmission. Remove the o-ring located between the transmission and the pump. Wipe up any hydraulic oil spillage. 10. Remove the hydraulic fittings from the pump to use for later installation. Note: Before removing any fittings from the pump, note their orientation to ensure correct installation. Note: DO NOT disassemble the operating pump. The pump is pre-set from the manufacturer. Any adjustments or repairs performed by anyone other than an authorized dealer could void the warranty. b. Pump Installation
The pump is the heart of the hydraulic system, and whenever there is a problem in the system, the pump often is blamed. However, pump failure is seldom due to failure of pump components. Pump failure usually indicates another problem in the hydraulic system. According to pump manufacturer statistics, 90-95 percent of pump failures are due to one or more of the following causes: Aeration Cavitation Contamination Excessive Heat Over-Pressurization Improper Fluid
In the event of pump failure, investigate further to determine the cause of the problem.
8.6.3
Pump Replacement
a. Pump Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, raise the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Temporarily block up or support the raised boom. 4. Open the rear door. Allow the system fluids to cool. 5. Properly disconnect the battery. 6. Drain the hydraulic reservoir. Refer to Section 8.5.1, Hydraulic Oil Reservoir Draining.
1. Install the fittings on the pump in the same orientation as noted during removal. 2. Place the pump and a new, oiled o-ring into position on the transmission. Align the pump shaft with the internal transmission gear, so that the machined teeth mesh together. 3. Align the bolt holes with the pump mount holes. Secure the pump to the transmission with the previously used hardware. 4. Uncap and connect the previously labeled hydraulic hoses to their appropriate locations. 5. Fill the hydraulic reservoir. Refer to Section 8.5.2, Hydraulic Oil Reservoir Filling. 6. Prime the pump by filling the case drain port with fresh, filtered hydraulic oil from a clean container before installing the case drain connector and hose.
8-22
6036, 6042, 8042, 10042, 10054
Hydraulic System
7. Check all routing of hoses and tubing for sharp bends or interference with any rotating members. All tube and hose clamps must be tight. 8. Properly connect the battery. 9. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 10. Close and secure the rear door. 11. Start the engine and run at approximately one-third to one-half throttle for about one minute without moving the machine or operating any hydraulic functions. 12. Inspect for leaks and check all fluid levels. The hydraulic reservoir oil level must be to the middle of the sight gauge. c. Pump Test Refer to Section 8.3.1, Pressure Checks and Adjustments.
MH6190
8. Label, disconnect and cap all the hydraulic hoses, tubes and wires at the main control valve (1). 9. Wipe up any hydraulic fluid spillage in, on, near and around the machine and the work area.
8.7
8.7.1
VALVES AND MANIFOLDS

Main Control Valve
The main control valve is mounted on the frame under the lower transmission cover. The main control valve assembly consists of individual working sections with their own valve assemblies, each providing a specific hydraulic function. a. Main Control Valve Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, raise the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Temporarily block up or support the raised boom. 4. Open the rear door. Allow the system fluids to cool. 5. With the engine OFF, operate all the hydraulic functions to relieve trapped pressure. 6. Remove the transmission covers. Thoroughly clean the main control valve and surrounding area, including all hoses and fittings, before proceeding. 7. Place a suitable container to catch hydraulic fluid drainage beneath the frame.
2 3
MA8482
10. Record the distance (2) from the outer jam nut to the end of the ferrule on all cables, to ensure correct adjustment when reinstalling cables. Note: Record the location, and label all cables to ensure correct installation. 11. Disconnect the control cables: a. Remove the spring pin (3) and anchor pin. Save the spring pin and anchor pin for installation. b. Loosen the outer jam nut (4), and remove the control cable from the bracket. Save the jam nut for installation.
6036, 6042, 8042, 10042, 10054
8-23
Hydraulic System
c. Route the cable clear of the main control valve. d. Repeat steps for the remaining control cables. 12. Remove the bolts and nuts (3) securing the main control valve to the frame. 13. Remove the main control valve from the frame. b. Main Control Valve Disassembly 1. To disassemble the individual sections of the main control valve, remove the nuts from one end of the tie rods. Pull the tie rods out through the sections. 2. Disassemble each section assembly as required. Some sections include a pre-adjusted relief valve that regulates pressure in a specific circuit. Note: DO NOT adjust any of the relief valve assemblies. Tampering with a relief valve will irrevocably alter pressure in the affected circuit, requiring recalibration or a new relief valve. Disassemble each Valve Section 1. Carefully separate the load sense outlet section from the next section. 2. Remove the o-rings from between the two sections. 3. Carefully separate each remaining sections, being careful not to lose the load sense shuttle ball. 4. Remove both end caps from each end of the valve sections then remove each control spool. 5. Remove any check valves, compensator valves, anti-cavitation valves or shock valves from individual valve section if equipped. 6. Keep all parts being removed from individual valve sections tagged and kept together. c. Main Control Valve Parts Cleaning
6
e. Main Control Valve Assembly Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. Assemble each Valve Section 1. Reassemble any check valves, compensator valves, anti-cavitation valves or shock valves from each individual valve sections if equipped. 2. Install the control spool being careful not to nick or scratch the valve section bore or the control spool. 3. Install the end caps on each end of the valve section. Assemble the Main Control Valve. 1. Place all three tie rods with the nuts through the end main control valve section. 2. Stand the end main control valve section on end. 3. Install the proper o-rings and load sense shuttle on the inner face of the end main control valve section. Align the next valve section over the three tie rods and slide onto the end main control valve section. 4. Using the proper o-rings and load sense shuttle, repeat step three for the remaining valve sections and lastly the inlet end valve section.
Clean all components with a suitable cleaner, such as triclorethylene, before continuing. Blow dry. d. Main Control Valve Parts Inspection Inspect all parts and internal passageways for wear, damage, etc. If inner surfaces of any component DO NOT display an ultra-smooth, polished finish, or are damaged in any way, replace the damaged part. Often, dirty hydraulic fluid causes failure of internal seals, damage to the polished surfaces within the component, and wear of and/or harm to other parts.
MH6200
5. Install the three nuts on the tie rods. Torque the two bottom nuts (5) to 43-53 lb-ft (58-72 Nm). Torque the top nut (6) to 66-82 lb-ft (89-111 Nm).
8-24
6036, 6042, 8042, 10042, 10054
Hydraulic System
f. Main Control Valve Installation 7. Start the engine and run at approximately one-third to one-half throttle for about one minute without moving the machine or operating any hydraulic functions. 8. Inspect for leaks and check the level of the hydraulic fluid in the reservoir. Shut the engine OFF. Note: Check for leaks and repair as required before continuing. Add hydraulic fluid to the reservoir as needed. 9. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools. 10. Install the transmission covers. 11. Close and secure the rear door. g. Main Control Valve Test
8
1. Install the main control valve onto the frame, aligning the bolts with the holes in the end sections of the main control valve. Slide the main control valve into position, and tighten the bolts. 2. Prime the main control valve by filling the inlet openings with fresh, filtered hydraulic oil from a clean container, before attaching the hoses. 3. Use new oiled o-rings as required. Uncap and connect all previously labeled hoses, clamps, etc. to the main control valve.
Conduct a pressure check of the hydraulic system in its entirety. Adjust pressure(s) as required. Refer to Section 8.3.1, Pressure Checks and Adjustments.
7
8.7.2
Secondary Function Manifold
The secondary function manifold is a directional control valve. Hydraulic oil from the pump flows into the secondary function manifold where the pressure is reduced before the oil is directed to the power steering unit or the park brake.
MA8482
4. Connect the control cables to the main control valve: a. Slide the outer jam nut (7) over the end of the control cable, and install the cable in the bracket with one nut on either side of the bracket. DO NOT tighten the jam nuts at this time. b. Connect the end of the cable to the shaft from the control valve. Secure with an anchor pin and spring pin (8). c. Adjust the jam nuts until the distance (9) from the outer jam nut to the end of the ferrule is the same as recorded during removal. Tighten the jam nuts. d. Repeat steps for remaining control cables. 5. Check the routing of all hoses, wiring and tubing for sharp bends or interference with any rotating members, and install tie wraps and/or protective conduit as required. Tighten all tube and hose clamps. 6. Fill the hydraulic fluid reservoir. Refer to Section 8.5.2, Hydraulic Oil Reservoir Filling.
The secondary function manifold is a machined block with the ports for two pressure reducing valves, a pressure relief valve, two park brake solenoid valves (one normally open and one normally closed), a check valve and diagnostic test nipples. The secondary function manifold is secured on the left side of the frame with two carriage bolts and two hex flange nuts. Verify the correct operation of the solenoids before considering replacement of the secondary function manifold. The manifold itself is not serviceable and must be replaced if defective. Note: DO NOT loosen, disassemble or attempt to adjust any of the pressure valves unless specifically instructed by the manufacturer to do so. Tampering with a pressure valve will irrevocably alter pressure in the affected circuits.
6036, 6042, 8042, 10042, 10054
8-25
Hydraulic System 8.7.3 Service Brake Valve

b. Service Brake Valve Installation 1. Install the service brake valve with the four capscrews and four lockwashers onto the steering column support. Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. 2. Use new oiled o-rings as required. Uncap and connect the previously labeled hoses to the service brake valve. 3. Check the routing of all hoses, and tubing for sharp bends or interference with any rotating members, and install tie wraps and/or protective conduit as required. Tighten all tube and hose clamps. 4. Properly connect the battery. 5. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 6. Start the engine and run at approximately one-third to one-half throttle for about one minute, without moving the machine or operating any hydraulic functions. 7. Inspect the service brake valve and connections for leaks, and check the level of the hydraulic fluid in the reservoir. Shut the engine OFF. Note: Check for leaks, and repair as required before continuing. Add hydraulic fluid to the reservoir as needed. 8. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools. 9. Install the lower and front dash panels. 10. Close and secure the rear door.
a. Service Brake Valve Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Remove the lower and front dash panels.
MH6210
6. Label, disconnect and cap all hose attached to the service brake valve (1). 7. Remove the four capscrews and four lockwashers mounting the service brake valve to the steering column support. Note: DO NOT disassemble the service brake valve. The service brake valve is not serviceable and must be replaced in its entirety, if defective.
8-26
6036, 6042, 8042, 10042, 10054
Hydraulic System 8.7.4 Brake Test 8.7.5 Power Steering Valve

3
Carefully bleed the brake lines as soon as the brake valve is installed in the machine. Air in the system will not allow the brakes to apply properly. There are four brake bleeder locations on the axles. Work with an assistant to perform this procedure. 1. Place the travel select lever in (N) NEUTRAL, engage the park brake, and start the engine.
MZ0370
The power steering valve (3) is located at the base of the steering wheel shaft, concealed by the lower dash cover. The valve is not serviceable and must be replaced in its entirety if defective. For detailed information refer to Section 4.3.1, Steering Column and Steering Valve.
MH6220
2. Remove the plastic cap from the brake bleeder (2). Attach one end of a length of transparent tubing over the brake bleeder. Place the other end of this tubing in a suitable transparent container that is partially filled with hydraulic oil. The end of the tubing must be below the oil level in the container. 3. DO NOT open the brake bleeder without holding the tubing firmly on the bleeder. There is pressure at the brakes. Carefully open the bleeder with a wrench. Have the assistant depress the brake pedal. Close the brake bleeder when air bubbles no longer appear in the oil. Release the brake pedal. Remove the tubing from the brake bleeder. 4. Repeat Steps 2 and 3 for the remaining brake bleeders. 5. Conduct a pressure and function check of the service brake. Refer to Section 8.4.1, Hydraulic Pressures.
6036, 6042, 8042, 10042, 10054
8-27
Hydraulic System 8.7.6 Steer Select Valve

b. Steer Select Manifold and Valve Disassembly, Cleaning, Inspection and Assembly 1. Place the steer select assembly on a suitable work surface. 2. Separate the steer select valve from the manifold by removing the four socket head capscrews. Discard the four o-rings. 3. Remove the solenoid valves and cartridges from the steer select housing. 4. Clean all components with a suitable cleaner before inspection. 5. Inspect the solenoid cartridges for proper operation. Check by shifting the spool to ensure that it is functioning properly. Check that the spring is intact. Inspect the cartridge interior for contamination.
MH6190
The machine can be used in the front-wheel, four-wheel or crab steering mode. The steer select valve (4) controls the direction of hydraulic fluid flow to the steering cylinders mounted on each axle. The steer select valve is attached to a manifold mounted to a mounting plate inside the frame near the fuel tank. Verify the correct operation of the steer select valve solenoids before considering replacement of the valve. The housing of the steer select valve is not serviceable and must be replaced if defective. a. Steer Select Manifold and Valve Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, raise the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Temporarily block up or support the raised boom. 4. Open the rear door. Allow the system fluids to cool. 5. Properly disconnect the battery. 6. Remove the transmission covers. 7. Label, disconnect and cap the hydraulic hoses and the electrical plugs connected to the steering select valve. 8. Remove the bolts holding the steer select valve to the mounting plate on the frame. 9. Remove the steer select manifold with the attached steer select valve from the machine. Wipe up any hydraulic fluid spillage in, on, near and around the machine. 8-28
6. Inspect internal passageways of the steer select manifold and valve for wear, damage, etc. If inner surfaces of the manifold DO NOT display an ultrasmooth, polished finish, or components are damaged in any way, replace the manifold or appropriate part. Often, dirty hydraulic fluid causes failure of internal seals and damage to the polished surfaces within the secondary function manifold. Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. 7. Install the solenoid valves and cartridges in the steer select housing. 8. Attach the steer select valve to the manifold using four new, oiled o-rings and the four socket head capscrews. c. Steer Select Valve and Manifold Installation 1. Install the steer select valve to the mounting plate on the frame using two capscrews. 2. Connect all the previously labeled hydraulic hoses, fittings, solenoid wire terminal leads, etc., to the steer select valve. 3. Check the routing of all hoses, wiring and tubing for sharp bends or interference with any rotating members, and install tie wraps and/or protective conduit as required. Tighten all hose clamps. 4. Properly connect the battery. 5. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
6036, 6042, 8042, 10042, 10054
Hydraulic System
6. Start the engine and run at approximately 1/3-1/2 throttle for about one minute without moving the machine or operating any hydraulic functions. 7. Inspect for leaks and check the level of the hydraulic fluid in the reservoir. Shut the engine OFF. Note: Check for leaks and repair as required before continuing. Add hydraulic fluid to the reservoir as needed. 8. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools. 9. Install the transmission covers. 10. Close and secure the rear door. d. Steering Test Refer to Section 8.4.1, Hydraulic Pressures. 1. Conduct a pressure check of the steering hydraulic circuit. 2. Check each steering mode for proper function. b. Unloader Valve Disassembly DO NOT loosen, disassemble or attempt to adjust any cartridges unless specifically instructed by the manufacturer. Tampering with the cartridges will irrevocably alter pressure in the affected circuits. c. Unloader Valve Installation 1. Place the unloader valve in its original orientation on the machine frame and secure with the previously used hardware. Torque capscrews to 31 lb-ft (42 Nm). 2. Uncap and connect the previously labeled hydraulic hoses to their appropriate locations. Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. 3. Check the routing of all hoses, wiring and tubing for sharp bends or interference with any rotating members. 4. Properly connect the battery.
MA8391
2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Temporarily block up or support the raised boom. 4. Open the rear door. Allow the system fluids to cool. 5. Properly disconnect the battery. 6. Label, disconnect and cap the hydraulic hoses attached to the unloader valve. Cap all fittings to prevent dirt and debris from entering the hydraulic system. 7. Remove the hardware securing the unloader valve to the machine frame. 8. Remove the unloader valve.
8.7.7
Unloader Valve (6036 & 6042 only)
The unloader valve (1) creates system pressure and distributes the hydraulic fluid for various machine functions via its load sense, by to tank (via the oil cooler), and primary and secondary valve ports. The unloader valve is secured to the frame toward the front of the machine near the main control valve. a. Unloader Valve Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, raise the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.
6036, 6042, 8042, 10042, 10054
5. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 6. Start the engine and run at approximately 1/3-1/2 throttle for about one minute without moving the machine or operating any hydraulic functions. 7. Inspect for leaks and check the level of the hydraulic fluid in the reservoir. Shut the engine OFF. Note: Check for leaks and repair as required before continuing. Add hydraulic fluid to the reservoir as needed. 8. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools. 8-29
Hydraulic System 8.7.8 Outrigger Valve (10042 & 10054 only)

3
The outrigger valve allows the left and right outriggers to be raised or lowered depending on the position of the outrigger switches located on the side console in the cab. Verify the correct operation of the outrigger valve solenoids before considering replacement of the valve. a. Outrigger Valve Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, raise the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Temporarily block up or support the raised boom. 4. Open the rear door. Allow the system fluids to cool. 5. Properly disconnect the battery. 6. Remove the transmission covers. 7. Label, disconnect and cap the hydraulic hoses and the electrical plugs connected to the outrigger valve. 8. Remove the two flange nuts and two carriage bolts securing the outrigger valve to the frame. Remove the outrigger valve from the machine. 9. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools. b. Outrigger Valve Disassembly, Cleaning, Inspection and Assembly 1. Place the outrigger valve assembly on a suitable work surface.
P S T
MH3881
2. Remove the solenoid valve assemblies (2) from the outrigger valve by removing the four capscrews (3). Discard the four o-rings. 3. Remove the shuttle cartridges (4) from the outrigger valve. 4. Clean all components with a suitable cleaner before inspection. 5. Inspect the solenoid cartridges for proper operation. Check by shifting the spool to ensure that it is functioning properly. Check that the spring is intact. Inspect the cartridge interior for contamination. 6. Inspect internal passageways of the outrigger valve for wear, damage, etc. If inner surfaces of the valve DO NOT display an ultra-smooth, polished finish, or components are damaged in any way, replace the valve or appropriate part. Often, dirty hydraulic fluid causes failure of internal seals and damage to the polished surfaces within the secondary function manifold. Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. 7. Install the shuttle cartridges into the outrigger valve. Torque to 35 lb-ft (48 Nm). 8. Attach the solenoid assemblies to the outrigger valve using four new, oiled o-rings and the previously used capscrews.
8-30
6036, 6042, 8042, 10042, 10054
Hydraulic System
c. Outrigger Valve Installation 1. Insert the previously used bolts through the bottom of the outrigger valve and loosely attach the flange nuts to the carriage bolts. 2. Position the outrigger valve so that the heads of the carriage bolts go through the slots in the frame. Tighten the flange nuts. 3. Connect all the previously labeled hydraulic hoses, fittings, solenoid wire terminal leads, etc., to the outrigger valve. 4. Check the routing of all hoses and wiring for sharp bends or interference with any rotating members, and install tie wraps and/or protective conduit as required. Tighten all hose clamps. 5. Properly connect the battery. 6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 7. Start the engine and run at approximately 1/3-1/2 throttle for about one minute without moving the machine or operating any hydraulic functions. 8. Inspect for leaks and check the level of the hydraulic fluid in the reservoir. Shut the engine OFF. Note: Check for leaks and repair as required before continuing. Add hydraulic fluid to the reservoir as needed. 9. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools. 10. Install the transmission covers. 11. Close and secure the rear door. b. Extend Lockout Valve Disassembly, Cleaning, Inspection and Assembly
7 5
V1 C1
Model 10054 has an extend lockout valve (5) which prevents the boom from being extended beyond 42 feet unless the outriggers are lowered onto firm terrain. Once the outriggers are lowered, pressure switches located on each outrigger cylinder close and energize the solenoid on the boom extend lockout valve. The boom can then be fully extended. a. Extend Lockout Valve Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, raise the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Temporarily block up or support the raised boom. 4. Open the rear door. Allow the system fluids to cool. 5. Properly disconnect the battery. 6. Remove the transmission covers. 7. Label, disconnect and cap the hydraulic hoses and the electrical plugs connected to the extend lockout valve. 8. Remove the nut and bolt securing the extend lockout valve to the frame. Remove the valve from the machine. 9. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools.
8.7.9
Extend Lockout Valve (10054 only)
6
MH3792
1. Secure the extend lockout valve assembly in a suitable bench vise if possible. Remove the solenoid nut, coil and cartridge (6) from the valve. Remove the pressure sense valve (7) from the valve. 2. Clean all components with a suitable cleaner before inspection.
MH6190
3. Inspect the solenoid cartridge for proper operation. Check by shifting the spool to ensure that it is 8-31
6036, 6042, 8042, 10042, 10054
Hydraulic System
functioning properly. Check that the spring is intact. Inspect the cartridge interior for contamination. 4. Inspect internal passageways and the extend lockout valve overall for wear, damage, etc. If inner surfaces of the component DO NOT display an ultrasmooth, polished finish, or are damaged in any way, replace the extend lockout valve. Often, dirty hydraulic fluid causes failure of internal seals and damage to the polished surfaces within the valve. Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. 5. Install the solenoid valve. 6. Install the pressure sensing valve. Torque to 65 lb-ft (88 Nm). c. Extend Lockout Valve Installation 1. Place the extend lockout valve into position on the mounting plate on the machine frame. 2. Install the bolt and nut securing the valve to the frame. 3. Connect all the previously labeled hydraulic hoses, fittings, solenoid wire terminal leads, etc., to the outrigger valve. 4. Check the routing of all hoses and wiring for sharp bends or interference with any rotating members, and install tie wraps and/or protective conduit as required. Tighten all hose clamps. 5. Properly connect the battery. 6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 7. Start the engine and run at approximately 1/3-1/2 throttle for about one minute without moving the machine or operating any hydraulic functions. 8. Inspect for leaks and check the level of the hydraulic fluid in the reservoir. Shut the engine OFF. Note: Check for leaks and repair as required before continuing. Add hydraulic fluid to the reservoir as needed. 9. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools. 10. Install the transmission covers. 11. Close and secure the rear door. d. Extend Lockout Valve Test Conduct a test of the extend lockout valve. 1. Park the machine on a firm, level surface. 2. With the boom fully retracted and lowered, lower the outriggers. 3. Extend the boom to 54 ft. The boom should extend fully and should not stop at 42 ft.
8.8
8.8.1
HYDRAULIC CYLINDERS
General Cylinder Instructions
a. Cylinder Removal 1. Remove any attachment from the machine. Park the machine on a firm level surface and fully retract the boom. Allow sufficient work space around the hydraulic cylinder being removed. Support the boom if the lift/lower cylinder is being removed. Place the travel select lever in (N) NEUTRAL, engage the park brake, shut the engine OFF and chock wheels. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 4. Label, disconnect and cap or plug hydraulic hoses in relation to the cylinder. 5. Attach a suitable sling to an appropriate lifting device and to the cylinder. Make sure the device used can actually support the cylinder. 6. Remove the lock bolt and/or any retaining clips securing the cylinder pins. Remove the cylinder pins. 7. Remove the cylinder. 8. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools.
8-32
6036, 6042, 8042, 10042, 10054
Hydraulic System
b. Cylinder Disassembly 1. Clean the cylinder with a suitable cleaner before disassembly. Remove all dirt, debris and grease from the cylinder. Note: When sliding the rod and piston assembly out of the barrel, prevent the threaded end of the barrel from damaging the piston. Keep the rod centered within the barrel to help prevent binding. 6. Carefully pull the rod assembly along with the head gland out of the cylinder barrel. 7. Fasten the rod eye in a soft-jawed vise, and place a padded support under and near the threaded end of the rod to prevent any damage to the rod. 8. Remove the set screw from the piston head. Note: It may be necessary to apply heat to break the bond of the sealant between the piston and the rod before the piston can be removed. Some cylinder parts are sealed with a special organic sealant and locking compound. Before attempting to disassemble these parts, remove any accessible seals from the area of the bonded parts. Wipe off any hydraulic oil, then heat the part(s) uniformly to break the bond. A temperature of 300-400 F (149-204 C) will destroy the bond. Avoid overheating, or the parts may become distorted or damaged. Apply sufficient torque for removal while the parts are still hot. The sealant often leaves a white, powdery residue on threads and other parts, which must be removed by brushing with a soft brass wire brush prior to reassembly. 9. Remove the piston head from the rod and carefully slide the head gland off the end of the rod. 10. Remove all seals, back-up rings and o-rings from the piston head and all seals, back-up rings and o-rings from the head gland. Note: The head gland bearing will need to be inspected to determine if replacement is necessary. DO NOT attempt to salvage cylinder seals, sealing rings or o-rings. ALWAYS use a new, complete seal kit when rebuilding hydraulic components. Consult the parts catalog for ordering information. c. Cylinder Cleaning Instructions 1. Discard all seals, back-up rings and o-rings. Replace with new items from seal kit to ensure proper cylinder function. 2. Clean all metal parts with an approved cleaning solvent such as trichlorethylene. Carefully clean cavities, grooves, threads, etc. Note: If a white powdery residue is present on threads or parts, it can be removed by using a soft brass wire brush. Wipe clean with Loctite Cleaner prior to reassembly. 8-33
MH6520
2. Clamp the barrel end of the cylinder in a soft-jawed vise or other acceptable holding equipment if possible.
WARNING
Significant pressure may be trapped inside the cylinder. Exercise caution when removing a counterbalance valve or a pilot-operated check valve from a cylinder. Note: Avoid using excessive force when clamping the cylinder in a vise. Apply only enough force to hold the cylinder securely. Excessive force can damage the cylinder tube. 3. If applicable, remove the counterbalance valve from the side of the cylinder barrel. Note: DO NOT tamper with or attempt to adjust the counterbalance valve cartridge. If adjustment or replacement is necessary, replace the counterbalance valve with a new part. 4. Extend the rod as required to allow access to the base of the cylinder. Note: Protect the finish of the rod at all times. Damage to the surface of the rod can cause seal failure. 5. Using a pin spanner wrench, unscrew the head gland from the tube. A considerable amount of force will be needed to remove the head gland. Carefully slide the head gland down along the rod toward the rod eye, away from the cylinder barrel.
6036, 6042, 8042, 10042, 10054
Hydraulic System
d. Cylinder Inspection 1. Inspect internal surfaces and all parts for wear, damage, etc. If the inner surface of the cylinder barrel does not display a smooth finish, or is scored or damaged in any way, replace the barrel. 2. Remove light scratches on the piston, head gland, rod or inner surface of the cylinder barrel with a 400600 grit emery cloth. Use the emery cloth in a rotary motion to polish out and blend the scratch(es) into the surrounding surface. 3. Check the piston rod assembly for run-out. If the rod is bent, it must be replaced. e. Cylinder Assembly Instructions 1. Use the proper tools for specific installation tasks. Clean tools are required for installation. 2. Install new seals, back-up rings and o-rings on the piston and new seals, back-up rings, o-rings and bearing on the head gland. Note: The extend/retract cylinder has a spacer that MUST be installed over the rod AFTER the head gland and BEFORE the piston head. 3. Fasten the rod eye in a soft-jawed vise, and place a padded support under and near the threaded end of the rod to prevent any damage to the rod. Note: Protect the finish on the cylinder rod at all times. Damage to the surface of the rod can cause seal failure. 4. Lubricate and slide the head gland over the cylinder rod. Install the piston head on to the end of the cylinder rod. Loctite and install the set screw in the piston head. Refer to Section 8.8.4, Cylinder Torque Specifications for torque specifications for the piston head and the set screw. Note: Avoid using excess force when clamping the cylinder barrel in a vise. Apply only enough force to hold the cylinder barrel securely. Excessive force can damage the cylinder barrel. 5. Place the cylinder barrel in a soft-jawed vise or other acceptable holding devise. Note: When sliding the rod and piston assembly into the cylinder barrel, prevent the threaded end of the cylinder barrel from damaging the piston head. Keep the cylinder rod centered within the barrel to prevent binding. 6. Carefully insert the cylinder rod assembly into the cylinder barrel. 7. Screw the head gland into the cylinder barrel and tighten with a spanner wrench. Refer to Section 8-34
6036, 6042, 8042, 10042, 10054
8.8.4, Cylinder Torque Specifications for torque specifications for the head gland. 8. If applicable, install new counter balance valve into block on the cylinder barrel. f. Cylinder Installation
1. Grease the bushings at the ends of the hydraulic cylinder. Using an appropriate sling, lift the cylinder into its mounting position. 2. Align cylinder bushing and install pin, lock bolt or retaining clip. 3. Connect the hydraulic hoses in relation to the labels or markings made during removal. 4. Before starting the machine, check fluid level of the hydraulic fluid reservoir and if necessary fill to full mark with Mobilfluid 424 (ISO 46). 5. Start the machine and run at low idle for about one minute. Slowly activate hydraulic cylinder function in both directions allowing cylinder to fill with hydraulic oil. 6. Inspect for leaks and check level of hydraulic fluid in reservoir. Add hydraulic fluid if needed. Shut the engine OFF. 7. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools. 8. Close and secure the rear door.
8.8.2
Cylinder Pressure Checking
Attach a 4000 psi (276 bar) gauge to the test port on the hydraulic pump to check the system pressure. For more information, refer to Section 8.3.1, Pressure Checks and Adjustments. Note: If a hydraulic cylinder pressure is greater than the main control valve pressure, increase the main control valve pressure by adjusting the main relief. Generally, one half turn clockwise will be adequate to check an individual circuit. Activate the circuit and if pressure is obtained turn the main relief counter clockwise one half turn. Re-check the main relief setting and adjust if necessary.
Hydraulic System 8.8.3 Steering Cylinders
The steer cylinder is attached to each axle center housing.The steer cylinder assembly can be found in Section 5.4, Axle Assemblies. The steer cylinder is covered in the appropriate manufacturers axle literature.
STEERING CYLINDER
AXLE CENTER SECTION
6036, 6042, 8042, 10042, 10054
8-35
Hydraulic System 8.8.4 Cylinder Torque Specifications
a. Lift/Lower Cylinder Model 6036, 6042 8042, 10042, 10054 Nut 1750-2000 lb-ft (2373-2712 Nm) 1735-1885 lb-ft (2352-2556 Nm) Valve 30-35 lb-ft (41-47 Nm) 30-35 lb-ft (41-47 Nm) Locking Collar 300-400 lb-ft (407-542 Nm) 300-400 lb-ft (407-542 Nm)
b. Extend/Retract Cylinder Model 6036 6042 8042, 10042, 10054 Head 300-400 lb-ft (407-542 Nm) 300-400 lb-ft (407-542 Nm) 300-400 lb-ft (407-542 Nm) Piston 300-400 lb-ft (407-542 Nm) 330-390 lb-ft (447-529 Nm) 390-460 lb-ft (529-624 Nm) Valve 45-50 lb-ft (61-68 Nm) 40-50 lb-ft (54-67 Nm) 150-160 lb-ft (1203-217 Nm) Set Screw 12-13 lb-ft (18-19 Nm) 10-26 lb-ft (13-35 Nm) 9-11 lb-ft (12-15 Nm)
c. Tilt Cylinder Model 6036, 6042 8042, 10042, 10054 d. Sway Cylinder Head 300-400 lb-ft (407-542 Nm) e. Stabil-TRAK Cylinder Model Locknut Check Valve Guide Set Screw Pressure Reducing/ PO Check Valve 35-40 lb-ft (47-54 Nm) 35-40 lb-ft (47-54 Nm) Solenoid Coil Locknut 1100-1250 lb-ft (1491-1695 Nm) Valve 35-40 lb-ft (47-54 Nm) Head 300-400 lb-ft (407-542 Nm) N/A Piston 200-300 lb-ft (271-407 Nm) N/A Locknut N/A 1735-1885 lb-ft (2352-2556 Nm) Locking Collar N/A 300-400 lb-ft (407-542 Nm) Valve 30-35 lb-ft (41-47 Nm) 30-35 lb-ft (41-47 Nm) Set Screw 30-35 lb-ft (41-48 Nm) N/A
6042 8042, 10042, 10054 8-36
1175-1400 lb-ft (1593-1898 Nm) N/A
20-25 lb-ft (27-34 Nm) 20-25 lb-ft (27-34 Nm)
300-350 lb-ft (407-475 Nm) 300-350 lb-ft (407-475 Nm)
3-4 lb-ft (4-5 Nm) 3-4 lb-ft (4-5 Nm)
25-30 lb-ft (34-41 Nm) 25-30 lb-ft (34-41 Nm)
6036, 6042, 8042, 10042, 10054
Hydraulic System
f. Slave Cylinder Model 6036 6042 8042, 10042, 10054 Head 250-300 lb-ft (339-407 Nm) 300-350 lb-ft (407-475 Nm) 300-400 lb-ft (407-542 Nm) Locknut 675-750 lb-ft (915-1017 Nm) 650-700 lb-ft (881-949 Nm) 900-1050 lb-ft (1220-1424 Nm) Set Screw N/A 3-4 lb-ft (4-5 Nm) N/A
g. Swing Carriage Cylinder (If Equipped) Model 6036, 6042 8042, 10042, 10054 Piston 440-500 lb-ft (597-678 Nm) N/A Head 250-350 lb-ft (339-474 Nm) 250-350 lb-ft (339-474 Nm) Set Screw 85-95 lb-ft (115-129 Nm) 85-95 lb-ft (115-129 Nm) Valves 30-35 lb-ft (41-47 Nm) 30-35 lb-ft (41-47 Nm)
h. Side Tilt Carriage Cylinder (If Equipped) Head 300-400 lb-ft (407-542 Nm) i. Outrigger Cylinder Model 10042, 10054 Head 250-350 lb-ft (339-474 Nm) Locknut 1650-1800 lb-ft (2237-2440 Nm) Valves 30-35 lb-ft (41-47 Nm) Locknut 550-650 lb-ft (745-881 Nm) Valve 30-35 lb-ft (41-47 Nm)
6036, 6042, 8042, 10042, 10054
8-37
Hydraulic System
8-38
6036, 6042, 8042, 10042, 10054
Section 9 Electrical System
Contents
PARAGRAPH 9.1 9.2 9.3 9.4 TITLE PAGE 9-2 9-2 9-3 9-3 9-3 9-3 9-4 9-5 9-12 9-12 9-13 9-13 9-14 9-14 9-15 9-16 9-16 9-16 9-17 9-17 9-18 9-19 9-19 9-20 9-21 9-22 9-23 9-23 9-23 9-24 9-24 9-25 9-26 9-26 9-26 9-26 9-27
9.5 9.6 9.7 9.8
9.9 9.10
9.11 9.12
9.13
Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1.1 General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4.1 Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4.2 Cab Harness Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Start Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6.1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7.1 Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . 9.8.1 Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8.2 Skylight Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8.3 Windshield Washer Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9.1 Cab Heater Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoids, Sensors and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.1 Coolant Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.2 Hydraulic Oil Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.3 Transmission Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.4 Transmission Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.5 Service Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.6 Boom Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.7 Boom Extend Interlock Sensor (10054 only). . . . . . . . . . . . . . . . . . . . . . . 9.10.8 Outrigger Pressure Switches (10054 Only). . . . . . . . . . . . . . . . . . . . . . . . Display Monitor and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.1 Instrument Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12.1 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12.2 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13.1 Fault Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13.2 Flash-Out of Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13.3 Offboard Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13.4 Engine Fault Codes Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6036, 6042, 8042, 10042, 10054
9-1
Electrical System
9.1
ELECTRICAL COMPONENT TERMINOLOGY
To understand the safety, operation, and service information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the electrical components of the machine. The following illustration identifies the components that are referred to throughout this section.
9.1.1
General Overview
COOLANT TEMPERATURE SWITCH DASH SWITCHES ALTERNATOR STARTER CAB HEATER CONTROLS
TRANSMISSION TEMPERATURE SENDER
IGNITION SWITCH
TRANSMISSION SOLENOID VALVES
SERVICE BRAKE SWITCH
BOOM EXTEND INTERLOCK SENSOR (10054 ONLY)
BOOM ANGLE SENSOR (FOUR SECTION BOOM SHOWN)
MAQ0360
9-2
6036, 6042, 8042, 10042, 10054
Electrical System
9.2
SPECIFICATIONS
9.4
9.4.1
FUSES AND RELAYS

Engine Compartment
Electrical system specifications are listed in Section 2, General Information and Specifications.
9.3
SAFETY INFORMATION
WARNING
DO NOT service the machine without following all safety precautions as outlined in Section 1, Safety Practices, of this manual.
3 2
MAQ0120
The starter relay (1), one 250 amp fuse (2) and one 200 amp relay (3) for the cold start grid heater (if equipped) are located inside the engine compartment and are mounted on a bracket on the left side of the frame rail.
6036, 6042, 8042, 10042, 10054
9-3
Electrical System 9.4.2 Cab Harness Fuses and Relays

6036, 6042, 8042 & 10042 10054
9
11 2 13 24 12 14 15 3 6 16 17 4 7 18 10 28 25 27 26
11 2 12
13 14 15
6 16 17
7 18
10
19 5 8 20 23 22 29
19 20
30 21
MAQ0350
21
MAQ0340
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 9-4
Volt/ Amp 12 Volt 12 Volt 12 Volt 12 Volt 12 Volt 12 Volt 12 Volt 12 Volt 12 Volt 12 Volt 7.5 Amp 20 Amp 15 Amp 10 Amp 10 Amp 10 Amp 7.5 Amp 10 Amp 7.5 Amp 40 Amp
Circuit Oil Temperature Headlight Switch Light Switch Stabilizer Lock Boom Switch Park Brake Disengage Neutral Start Back up Water Temperature Ignition Transmission Lights Horn/Heater Wiper (if equipped) Stabilizer Steer Select Optional Cab/ Outrigger (if equipped) Park Brake Optional Main
No. 21 22 23 24 25 26 27 28 29 30
Volt/ Amp 40 Amp 7.5 Amp 7.5 Amp 12 Volt 12 Volt 12 Volt 12 Volt 12 Volt 12 Volt 12 Volt Outrigger Outrigger
Circuit Road/Worklights (if equipped)
Park Brake Interlock Boom Extend Lockout Stabil-TRAK Interlock Stabil-TRAK Lock Up Boom Extend Interlock Right Outrigger Lock Left Outrigger Lock
6036, 6042, 8042, 10042, 10054
9.5
9.5.1
BATT1-12V
11B BATT1_NEG
SS_8F
BATT_POS FRAME_GND
+ sht1
2JJ
7 8 STM_2F
-7 1
8 8_C
A B
+8
C2
STM_CR
STM_2F
SS_8F
1
2C
BATT2_POS
BATT2_12V
sht 1
6036, 6042, 8042, 10042, 10054

sht2
FRAME_GND
3 A B SS_8F
12V_BUSSBAR
2 STM_2M
GHP1 11A 9 9_C

C3
STM_4
STM_2M
+ 2
SS_8F
BATT2_NEG
1
ENG_BULK1_15
12V, 1.33A
SR_NO
NOTE: BATTERY 2, CABLES & WIRES GHP1, GHP2 ARE FOR COLD START OPTION ONLY. 2B
sht 1
3
ENG_BULK1_15
SS_8F
162 161
30
87
STARTER_SOL
12V, 1.33A
ENG_GND BUSSBAR
STAB_BRAKE_SW
SS_NO
STR_STAB
STEER SELECT SWITCH
M
FUSIBLE_LINK
10 AMPS
CG2 CG3 46 45B 45A

45
B
150 AMPS
STARTER
G
3A
STARTER GND
sht1
45
45A2
SEE SHEET 3 FOR ALT. BRAKE {SWITCH CONNECTIONS FOR} RDLIGHT/WLIGHT OPTION
27F_TERM_1_M
D ALT
LIGHTS
LSR_NO sht1
5
34 5
12B_F
AG1 AG2 112

112
86 SLR 85
27F 114A
114
27F_B 114B 2CC

3A
27F
27F_D
29
30
87
12A
12A
12B
sht 1
40AAMPS
27F_TERM_1_F
12A_F
12AA 38_C
CONNECTS TO WIRE 1 OF ROADLIGHT CIRCUIT (SHEET3)
sht 2
112A
86 NSR 85
27F_TERM_2_M
12C
B1
2FF
27F_A 34
A FUSE_2F
27F_C
FUEL_SYSFUSE_2F
B
12C_F
34A
6_C
sht 1
BOOM_3F
27F_TERM_2_F
CONNECTS TO ROADLIGHT CIRCUIT WIRE 32L (SHEET 3)
sht 2
2B
ENG_BULK2_15
7.5
AMPS
sht 1 sht1
ENG_BULK1_15
BR
2AA
86 85
10
C4
10_C
BOOM_3F C A
27B_TERM_F
21C 2KK
HDLTS
86 HSR 85
sht 1
41-B 41-A 41
41
A B
SF_M SFA_2F
27B 41A 2E
20A
1 SF_F
27B_B 2C
HSR_NO 27A 30 87 23_C

A2
SFA
SFA_2F
2T
sht 1
BOOM_SENSOR
sht 1 sht 1
7 157 35
35F 7F 157M1 157M2
27B_TERM_M
20 AMPS
HSR_2F
ENG_BULK1_15
12V, 1.33A
SFB_2F
PBD_M
27D
C 2 3 PBD_F B PB_8F INST_M PB_8F IGN_5F
B5
MAIN
IGN_5F
1GN_5M
S
PB_8F
PARK BRAKE SWITCH

1
1
86 PBD 85
27D_C 34_C
E
100
27
3
12V, 1.33A
STAB
26B 39
30 87
26
26A
P
2
107B
A B
41B 2F 20A
SFB
SFB_2F
20B
B4
35_C
28
sht1
20D 28A
A 12A_2F
107A 152B
ENG_BULK2_15
4 5
5 INST_F
40 AMPS
19
R O 58
BR_NO
28
ENG_BULK1_15 B3 28_C ENG_BULK1_15
STAB_FLOAT_A B
12A_2F
2L
12V, 1.7A
20D
20E
1GN_5M
152A1
6036 & 6042 Electrical Schematic
sht 2 sht 2
ENG_BULK1_15 1A
VP3 F
106B
A4
sht 2
2YY
10 AMPS
COBO IGN SWITCH

E
6
P
2-BAR LENS 6
45A2
27C 42-B
8
8 PB_8F
A4
27C_C 111
111
IGN_3M
R 15 O
sht 1
B2
106A
C VP3
86
sht 1 sht 1
30 30 87A
FUSEBOX_BUSSBAR 20A_C 2GG
28B
A 12B_2F
STAB_FLOAT_B
B 12B_2F
2P
12V, 1.7A
ENG_BULK2_15
1-SYMBOL 7
7
26 111A
30 87
SR
85
NSR_NO
106_C
106
106
106D 2Y
30 ENG_BULK2_15
PB_8F
BR_NC
48
87A
SLR_NC
47
A3
47_C
ENG_BULK1_15
47
47A
A 4A_2F
STAB_REST_A
B 4A_2F
2M
12V, 1.7A
The following Ladder Diagrams may be used to further investigate electrical circuits. If a resolution cannot be found contact your local authorized service distributor
IGN_START
S P
R
IGN_MAIN
1 2EE 2HH
20A_C
ELECTRICAL SYSTEM SCHEMATICS
50
2MM
IGN_3M
3C 42-A
sht1
113A CAB_GND 102B_C
86 BAR 85
2JJ
SLR_NO
30 87
47B 40A
40
STAB_REST_B
2N 40B 40
A1 ENG_BULK1_15
sht 2
40_C
A 4B_2F
12V, 1.7A STAB_LOCK

A LOCK_2F
B 4B_2F
3A
2K
12V, 1.7A
B LOCK_2F
2BB 2KK 2NN
INSTR
TR_12F
22
S1 NEUTRAL
4
10 AMPS
1A
GREY
sht 2
112
113C
sht 1
104A
C TR_16B VP2 VP2
TRANS
3A
RED
153A
2 3 1
1 TR_12F 2
PBD_NO
1 2
TR_12F
12/4
F
1A
2D
sht1 sht 1 sht1

2FF
NOTE: STABILITY CIRCUIT ONLY USED ON 6042 MACHINES
sht1 sht1 sht1 sht 2 sht 2
2Y 2YY
30
87
113B 104B 104_C 104

104 12V, 0.54A
113
113
Y1
S2 FORWARD YELLOW
7.5
AMPS
12/1
C4 ENG_BULK2_15
TR_16B VP1 VP1
sht1
52
52_F
12/2
C F
102A
1A
20_C
20 20_C
ENG_BULK2_15
A3
2LL
CONNECTS TO 2_H WIRE OF HEATER CIRCUIT (SHEET 3)
PHG1 PHG2 20B
3D_F
2
S7 1 REVERSE
2 TR_12F
2T
20B
3B 102B 102A_C 102

102 12V, 0.54A
Y2
20C
HORN_HTR
PINK
3
102_C 102_C 2DD 20D
C2
12/3
TR_16A 5
sht 1 sht 2 sht 1

2AA
2CC
BACKUP_ALARM
24
15 AMPS
BAR_NO 30 87 31
159A
159
A5 ENG_BULK2_15
31_C
2 BLACK
5
101_C
101 12V, 0.54A
ENG_BULK2-15 C1 101
101B
20
Y5
A BU_2F
2G 2A
B BU_2F
2X
ENG_GND BUSSBAR
NOT USED ON 6036/ 6042 MACHINES

3 4 S3
12/5
ENG_BULK2_15
TR_12F
HORN
24A_C
B2
HORN_SW
24A
B A
101A
B TR_16A VP1
1A
FUSEBOX_BUSSBAR
2 3 GREEN
6 4
TR_12F
sht 2
sht 1
158 159B
CAB
A5 ENG_BULK1_15
HORN_2F HORN_2F
158_C
ENG_BULK1_15
105_C 105
105 12V, 0.54A
C5
105B 105A
B TR_16B VP2
Y4
12/6
ENG_BULK2_15 1A
3D
S5
86
IR
85
2NN
D1
TR_12F
4 1
2J
32
sht 1
D2
7
sht1
7
159
XXAMPS
32_F
CONNECT TO WIRE 6C OF WIPER CIRCUIT (SHEET 3)
HORN_GND
2 3 BLUE
103_C 103
103
3
C3
103B
12V, 0.54A
Y3
51_F
TR_12F
51
A TR_16A VP1
153 103A
1A
TR_12F
WHITE 1 2 VIOLET
8 6 7
4
TR_16B
S4
12/7 ENG_BULK2_15
12/9
OPT2
150_C 150
150 12V, 0.54A
B3
150B 150A
1A
A VP2 TR_16A
Y6
2H
50
3
NOT USED ON 6036/ 6042 MACHINES

12/8
ENG_BULK2_15
4 S6
7.5
AMPS
50_F
ZF DW3 TRANSMISSION SWITCH
OPT1
12
86 LSR 85
2DD_C
7.5
AMPS
ENG_BULK3_1M
IR_NO
160
160_A
30
87
159
sht 1
Electrical System
MAQ0150
ENG_BULK3_1F
9-5
9-6
Electrical System
6036 & 6042
VP1_4F
GH1
A INSTR_15F
J11 STAB TRAK
INSTR_15F 5
3A
sht1
GH_FUSE_1
40B
11
2GG sht 1 GH1_NO GH1J

30 87
B
PREHEAT 14VDC
NOT USED FOR 6036/6042 TIER 2 MACHINES
sht1
125 AMPS
C A A PH_2M
P19 P19 INSTR_15F
J7 PARK BRAKE
GHP1
CS_4M PH_2F PH_2M
1B
GH1H PH1B
C
GRID HEATER 1
VP1_4F
152A2 PH1A PH1

1A
PHG
B
PHG1
PH_2F
3A
sht 1 sht 1
PB_1F
GH_FUSE_2
GH2_NO GH2J
30 87
D D
sht1
125 AMPS
INSTR_15F
J15 TURN SIGNAL
152A1
7
152A3 GH2H PHG2
GRID HEATER 2
3A
TS_1F
CONNECTS TO WIRE 27 OF ROADLIGHT CIRCUIT (SHEET 3) 155

15
ENG_GND
A A
GH2
F
B B CS_4F
106B
HB_1F VP1_4F
INSTR_15F
J14 HI BEAM
3A
sht 1
CONNECTS TO WIRE 24 OF ROADLIGHT CIRCUIT (SHEET 3) 154

14 INSTR_15F
J2 BACKLIGHT
BL_1F
TEMP_SENDER
A TS_2F B
CONNECTS TO WIRE 20F OF ROADLIGHT CIRCUIT (SHEET 3) OR WIRE 3A OF WORKLIGHT CIRCUIT (SHEET 4) 156
2
HEATER CONTROL MODULE

C2
A B HM_2M
TS1 HMG 34D

GH1_COIL
275
85 86
TSG
TEMP. SENSOR A
TS_2F
VBAT B C1
A B C D E A
INSTR_15F 3
INSTR_15F
sht1
ENG_BULK1_15
22 38 sht 1
WAIT LAMP B C D SOL 1 SOL 2
HR GH1A
285
B5
38_C GHG1 PHG3 GH1C GH2C GH1B

3A
VP2_6F
VBAT + A
J8 ALT
INSTR_15F 8
6 sht 1
HM_6M
C1
6_C
CRANK CASE E
ENG_BULK1_15
GHG3
3A
F VP2_6F
J9 ENG OIL PRESS
16_C 16
280
B
C5
10 PSI
GH2B
VP2_6F
ENG_BULK1_15
INSTR_15F
ENG_OIL_PRESS_SW
GH2_COIL
86
J6 ENG WATER TEMP 85
GH2A
6
GHG2
15 15_C 106C
ENG_BULK2_15
A1
210F
INSTR_15F
ENG_WATER_TEMP_SW
J10 HYD OIL TEMP
10
151 151_C
ENG_BULK2_15
B4
195 F
COLD START OPTION

CAB_GND 3A_WL
B
LEFT FRONT WORKLIGHT 12V/4.4A
INSTR_15F
J12 TRANS TEMP
HYD_OIL_TEMP_SW INT_GND
CONNECT TO INSTR. PANEL CONNECTOR PIGTAIL WIRE 156 (SHEET 2)
156_M
12
18_C 18 2G
B1
250 F
sht 1
ENG_BULK1_15
INSTR_15F
3A1_WL 4A_WL
3_WL
3B_WL
P WLO_LF_P
2B1_WL
WLO_LF_N
2_WL
2A_WL
TRANS_TEMP_SW
FUEL_SEND
INSTR_15F 4
17 17_C sht 1
WLO_8F 8
A2
RIGHT FRONT WORKLIGHT 12V/4.4A
2A
8
WLO_8F 3 6 WLO_8F
3C_WL
1 3 6
WLOC_2M BWLO_2M
P WLO_RF_P
2B2_WL
WLO_RF_N
FUEL
ENG_BULK2_15
INSTRUMENT PANEL/SENSOR CIRCUIT
3D_WL
2
BOOM WORKLIGHT BWLO_2M 12V/4.4A
2B4_WL
A A WLOC_2F A A BWLO_2F
B BWLO_2F B B B WLOC_2F WLOC_2M
WORKLIGHT 1 SWITCH
7
WLO_8F 7
2
2 WLO_8F
5
5 WLO_8F
LEFT REAR WORKLIGHT 12V/4.4A
4_WL
4B_WL
P WLO_LR_P
2B3_WL
WLO_LR_N
1A_WL
1B_WL
1C_WL 4C_WL 2C_WL

P WLO_RR_P
RIGHT REAR WORKLIGHT 12V/4.4A
N WLO_RR_N
MAQ0160
2B5_WL
CONNECTS TO FUSEBLOCK PIGTAIL WIRE 12A (SHEET 1)

12AW_M
6036, 6042, 8042, 10042, 10054
1_WL
1_WL
WORKLIGHTS ONLY CIRCUIT
6036 & 6042
BM_4F 154_M 1 12C_M
CONNECTS TO FUSEBLOCK PIGTAIL WIRE 12C (SHEET 1)

HBEAM_LFT 12V, 4A
CONNECTS TO INSTR. PANEL PIGTAIL WIRE 154 (SHEET2) 24C_RL

LRL_6F 6
BLWR_5F
BLWR_5F
32_RL
LRL_6F
HBEAM_RT 12V, 4A
CONNECTS TO FUSEBLOCK PIGTAIL WIRE 52 (SHEET 1)

4 3
2_H
24L
HAZ_10F 1 3
18 8 HAZ_10F 17
M 1J_RL CONNECTS TO FUSEBLOCK

RRL_6F
LBEAM_LFT 12V, 3.5A
BLOWER MOTOR 24B_RL

RRL_6F
4
23C_RL 22C_RL 24A_RL 2J_RL

6
52_M 2 BM_4F
C 1 3 17 18 8
6036, 6042, 8042, 10042, 10054

1_H 4_H 3_H 2H_RL 24_RL 25_RL 21A_RL
LRL_6F
LBEAM_RT 12V, 3.5A
BLOWER SWITCH
5_H
OFF
1
+
1
HSR_2M A
PIGTAIL CONNECTOR WIRES 23_C & 21C (SHEET 1) 21C_RL

21L
HEATER CIRCUIT
ON HAZARD SWITCH 2 5 10 B
(ALL COMPONENTS SUPPLIED BY ANGUS PALM)

21B_RL
RRL_6F
LT_SIDE 12V, 0.25A
CONNECTS TO FUSEBLOCK PIGTAIL WIRE 32 (SHEET 1) 21_RL 28A_RL 20_RL

LRL_6F
11 TSL_12F 1 3 5 TSL_12F TSL_12M 8 8 5 TSL_12M 6 3 TSL_12M 1 6 TSL_12F TSL_12F
RT_SIDE 12V, 0.25A
HAZ_10F
2 5 10
6F_W 20A_RL 28B_RL 33_RL

TSL_12M 11
32_M
30_W
6_W
RRL_6F
20B_RL
CAB_GND
LF_TAIL 12V, 0.42A
6A_W 6E_W CAB_GND 28_RL

28_RL
6D_W 3_W 2_W 4_W

PARK SW3 SW1 SW2 FLASH HI LO SW4
I P
20C_RL
LRL_6F
2_
2F_RL
RT_TAIL 12V, 0.42A
2A
2A_RL
9 FW_8F 8 FW_8F 3
FWP_10F
0 I P
20_RL
+9
4 3
+8
H
3
POWER L X FLASHER MODULE P
LH RH
20D_RL
RRL_6F
M
TURN SIGNAL LEVER
9 10 TSL_12M 10 TSL_12F 155_M 9
FRONT WIPER MOTOR
0
20F_RL
BL_M
2
GRD
1 1
M
GROUND
FRONT/TOP WASHER PUMP
27_RL
CONNECTS TO INSTR. PANEL CONNECTOR PIGTAIL WIRE 156 (SHEET 2)
-7
FRONT WIPER SWITCH

2B_RL
-7
FW_8F 7 2 FW_8F
2
1F_W 10_W 1_W 1C_W
2_W
FRONT WASHER SWITCH

CONNECT TO INSTR. PANEL CONNECTOR PIGTAIL WIRE 155 (SHEET 2) 23_RL
FWP_10F
RF_TURN_HAZ 12V, 1.75A
RTL_4F
23_RL
23A_RL
RTL_4F
1
RR_TURN_HAZ 12V, 1.75A
1A_W 23B_RL 1D_W 22_RL

WL_8F
6B_W
3 RTL_4F
22_RL
2E_RL
LR_TURN_HAZ 12V, 1.75A
LTL_4F
6C_W
WL_8F
3
5_W 9_W
22A_RL
LTL_4F
1
LF_TURN_HAZ 12V, 1.75A
TW_10F
+9
WL_8F 8
6
RUN TOP M WIPER MOTOR
4 3
8 1 6 3
1
6
22B_RL
LTL_4F
3
LT_BRAKE 12V, 1.75A
PARK GROUND
26_RL
2
2
7 2 5
5 WL_8F 2 WL_8F WL_8F 7
1
1E_W
WORKLIGHT 1 SWITCH
26_RL
26A_RL
LTL_4F
4
RT_BRAKE 12V, 1.75A
26B_RL
RTL_4F
-7
TOP WIPER SWITCH

1E_RL 1B_W
1_RLL
2C_RL
WL_2F WLC_2M
TW_10F
1A_RL 3A_RL 1C_RL 1D_RL

A A WLC_2F WL_2M A A
WL_BOOM WL_2M 12V, 4.4A
WLC_2F B B WL_2F
WL_LR 12V, 4.4A
1F_RL 1B_RL
B WLC_2M
WIPER/WASHER CIRCUIT
1_RL
12AR_M
(MOTORS & HARNESS SUPPLIED BY ANGUS PALM)

4 5
4A_RL
4_RL
4B_RL
WL_LR_F1 WL_LR_F2
2D_RL
51_M
WL_RR 12V, 4.4A
51_BS CONNECTS TO FUSEBLOCK PIGTAIL WIRE 51 (SHEET 1)

BEACON STROBE
CONNECTS TO FUSEBLOCK PIGTAIL WIRE 12AA (SHEET 1)
4C_RL
WL_RR_F1
2G_RL 2K_RL
WL_RR_F2
LIGHTING BRAKE SWITCH
DISCONNECT WIRES 46& 45B FROM STAB BRAKE SWITCH (SHEET 1). RECONNECT WIRE 46 TO TERMINAL 1 & WIRE 45B TO TERMINAL 2 OF LIGHTING BRAKE SWITCH
8_M
8_BS 3A_BS
A BS_2F B
ROADLIGHT/WORKLIGHT CIRCUIT
2A_BS
3_BS
BS_2F
BS_8F 8
BS_8F
3_M 3_F
BSJ
BEACON/STROBE SWITCH
BS_8F
BS_8F
Electrical System
MAQ0170
2_BS
BEACON & STROBE CIRCUIT
9-7
Electrical System
8042, 10042 & 10054
9-8
6036, 6042, 8042, 10042, 10054
OPEN CAB/MACHINE CIRCUIT MAQ0190
Electrical System
8042, 10042 & 10054
INSTRUMENT PANEL/SENSOR CIRCUIT
MAQ0180
ECM CIRCUIT
6036, 6042, 8042, 10042, 10054
9-9
9-10
8042, 10042 & 10054
Electrical System
HEATER CIRCUIT
WIPER/WASHER CIRCUIT
ROAD LIGHT/WORK LIGHT CIRCUIT
MAQ0200
6036, 6042, 8042, 10042, 10054
BEACON & STROBE CIRCUIT
6036, 6042, 8042, 10042, 10054
8042, 10042 & 10054
WORK LIGHTS ONLY CIRCUIT
OUTRIGGER CIRCUIT (10042 MACHINES ONLY) LOGIC/OUTRIGGER CIRCUIT (10054 MACHINE ONLY)
Electrical System
MAQ0210
9-11
Electrical System
9.6
9.6.1
ENGINE START CIRCUIT

Starter
3. If the starter only clicks it may indicate that the battery is discharged, or that there is a loose or corroded battery cable connection. Check the battery state of charge and battery condition first, then check the cables and cable connections. 4. For additional information on the starting circuit, refer to Section 9.5, Electrical System Schematics. c. Starter Removal Remove the starter only if it fails. To remove the starter: 1. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.
1
2. Open the rear and side engine covers. Allow the system fluids to cool. 3. Properly disconnect the battery. 4. Remove the wires from the solenoid stud. Remove the positive (+) battery cable from the starter. Label and disconnect the wire from the starter solenoid housing stud. Record how the wires are installed to ensure correct installation later. 5. Loosen, but DO NOT remove, the fasteners securing the starter to the flywheel housing. Support the starter securely, as it is relatively heavy and will fall if not supported. 6. Support the starter and remove the fasteners securing the starter to the engine. Remove the negative (-) ground cable from its starter mounting bolt. 7. Remove the starter from the machine. d. Starter Installation 1. Position the starter in its mounting opening on the flywheel housing. Position the ground cable over the correct starter mounting bolt. Secure the starter with the previously used hardware. 2. Connect the positive (+) battery cable to the upper solenoid stud. Install the wires to the upper solenoid stud, and secure with lock washer and nut. 3. Connect the wire to the solenoid mounting stud. 4. Properly connect the battery. 5. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 6. Close and secure the rear and side engine covers.
MAQ0220
The starter (1) is located on the left side of the engine. a. Testing the Starter on the Engine If the starter does not engage when the ignition key switch is turned, check the following: 1. The main fuse may be blown, requiring replacement. Check for the cause of the blown fuse. 2. There may be a defect in the ignition key switch, ignition wiring or starter solenoid. 3. Check battery condition. Clean the battery posts and the connectors at each end of the battery cables. 4. Check for broken wiring and damaged insulation on the wiring. Replace all broken or damaged wiring. 5. Check all connections at the starter solenoid, key switch and wiring harness plugs. Clean and tighten all connections. 6. If the starter still does not operate after these checks have been performed, check the starting circuit. b. Starter Circuit Checks 1. Check wires and connections for looseness, corrosion, damage, etc. 2. If a whirring noise is heard but the engine does not turn over, the starter is spinning but not engaging the flywheel. The starter drive or solenoid that pushes the drive forward to engage the flywheel may be defective. Missing or damaged teeth on the flywheel can also prevent the starter from cranking the engine.
9-12
6036, 6042, 8042, 10042, 10054
Electrical System
9.7
CHARGING CIRCUIT
2
Note: Record how the alternator is installed to ensure correct installation later. 6. Label and disconnect the wire leads attached to the alternator. 7. Remove the lower mounting capscrew securing the alternator to the lower mounting hole on the engine. 8. While supporting the alternator with one hand, remove the upper (longer) mounting hardware from the upper alternator mount. Remove the alternator from the machine. b. Alternator Installation 1. Position the alternator and align with the upper alternator mount on the engine bracket. Insert the upper (longer) mounting hardware through the alternator mount. Thread the longer capscrew into the alternator front mount. DO NOT tighten completely at this time. 2. Align the lower alternator mount hole with the lower mounting bracket on the engine, and insert the lower mounting capscrew. Tighten the lower capscrew and upper capscrew securely. 3. Place a drive ratchet into the square hole on the serpentine belt tensioner bracket. Apply pressure against the tensioner bracket and route the serpentine belt onto the alternator and engine pulleys. Release and check the tensioner pulley to verify that it is pivoting freely in order to provide the proper tension on the belt. Check for proper belt alignment. (Refer to the appropriate Operation & Safety Manual.) 4. Connect the previously labeled wire leads to the alternator. 5. Properly connect the battery. 6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 7. Close and secure the rear and side engine covers.
MAQ0230
Before using a battery charger, an attempt can be made to recharge the battery by jump-starting the machine (Refer to the appropriate Operation & Safety Manual). Allow the engine to run, which will enable the alternator (2) to charge the battery. If the engine alternator charging warning indicator illuminates, perform the following checks: 1. Check all battery cable connections at the battery, and verify that they are clean and tight. 2. Check the external alternator wiring and connections, and verify that they are in good condition. 3. Check the fan belt condition and tension. 4. Run the engine and check the alternator for noise. A loose drive pulley, loose mounting hardware, worn or dirty internal alternator bearings, a defective stator or defective diodes can cause noise. Replace a worn or defective alternator.
9.7.1
Alternator
a. Alternator Removal 1. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 2. Open the rear and side engine covers. Allow the system fluids to cool. 3. Properly disconnect the battery. 4. Install a drive ratchet into the square hole in the serpentine belt tensioner bracket. 5. While lifting the automatic belt tensioner away from the belt, remove the fan serpentine belt.
6036, 6042, 8042, 10042, 10054
9-13
Electrical System
9.8
WINDOW WIPER/WASHER WINDSHIELD WIPER MOTOR

Windshield Wiper Motor
12. Remove the metal hex jam nut and metal washer from the motor shaft. 13. Remove the motor mounting bolts, panto adapter and gasket from the motor shaft. Note: Retain all hardware removed from the wiper assembly for possible reuse on the replacement motor housing. 14. Remove the motor from the inside of the cab. b. Disassembly DO NOT disassemble the motor. The motor is not serviceable. Replace motor if found to be defective. c. Inspection and Replacement Inspect the motor terminals for continuity. Replace motor if continuity is not found. d. Installation and Testing 1. Install all required hardware to the motor assembly. Align spacer and wiper motor bracket, and apply masking tape in order to hold the two components together during installation. 2. Align motor with the mounting holes and insert motor through cab. 3. Have an assistant insert gasket, panto adapter onto the motor shaft. Insert bolts through front cab holes and thread into motor housing. Tighten bolts. 4. Install metal washer and metal hex jam nut. Tighten metal hex jam nut. Install rubber cap and knurled driver onto the motor shaft.
9.8.1
a. Removal Note: It may be necessary to remove several hydraulic hoses from behind the dash in order to remove and install the wiper motor housing. (Refer to Section 4.3.1, Steering Column and Steering Valve.) 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Remove the right side instrument panel. 6. Remove the lower access panel below the instrument panel. 7. Disconnect the right side defroster hose from the dash panel hose connector.
3
Note: Align the wiper blade arm with the hex jam nut. Tighten shaft to ensure wiper stroke covers window area, and it does not swipe past the glass area. 5. Install wiper blade arm at 90 from the motor shaft flat.
MA8431
6. Connect the cab harness connectors to windshield wiper motor connectors. 7. Properly connect the battery. 8. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
8. Disconnect the cab harness connectors from the wiper motor (3). 9. From the outside and front of the cab, remove the windshield wiper blade arm (4) nuts and washer from the motor shaft. 10. Disconnect the washer hose from the hose connector. 11. Remove the wiper arms, knurled driver and rubber cap from the motor shaft. 9-14
6036, 6042, 8042, 10042, 10054
Electrical System
9. Turn ignition key switch to the RUN position, and operate windshield wiper in both LOW and HIGH speeds to ensure proper operation and that correct wiper travel is achieved. 10. If previously removed, install hydraulic hoses under the dash. (Refer to Section 4.3.1, Steering Column and Steering Valve.) 11. Install the previously removed dash panels. 12. Close and secure the rear door. 8. Unclip the plastic motor cover (6) and remove. 9. From the top of the cab, remove the nut from the wiper motor shaft. 10. From inside the cab, pull the wiper motor down and away from the roof. 11. Label and disconnect the cab harness connectors from the wiper motor. b. Disassembly DO NOT disassemble the motor. The motor is not serviceable. Replace motor if found to be defective. c. Inspection and Replacement Inspect the motor terminals for continuity. Replace motor if continuity is not found. d. Installation and Testing 1. Hold wiper motor up toward cab top and install the cab harness connectors. 2. With the help of an assistant, insert the wiper motor through the roof hole and have the assistant thread the nut onto the wiper motor shaft. Ensure that the motor housing is facing the front of the cab. 3. Install the wiper arm onto the wiper motor shaft. 4. Install the screws through the plastic motor cover and into the top locknut plate and tighten. 5. Connect washer hose to top hose fitting. 6. Properly connect the battery.
5
9.8.2
Skylight Wiper Motor
a. Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the rare door. Allow the system fluids to cool. 4. Properly disconnect the battery.
7. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 8. Turn the ignition key to the RUN position and turn skylight wiper switch to the ON position. Ensure wiper stays on the window through a full stroke. Turn the skylight wiper switch to the OFF position. 9. Engage the washer switch and ensure washer fluid is sprayed on the skylight window. Turn the ignition key switch to the OFF position. 10. Close and secure the rear door.
MA8361
5. Remove the wiper arm (5) from the wiper motor shaft. 6. Disconnect the washer hose from the top hose fitting. 7. From inside the cab, remove screws from top locknut plate.
6036, 6042, 8042, 10042, 10054
9-15
Electrical System 9.8.3 Windshield Washer Reservoir

c. Installation and Testing 1. Connect the windshield washer hoses to the reservoir. 2. Connect the cab wiring harness connectors to the reservoir connectors.
7
3. Install the reservoir tank onto the welded studs. 4. Install the lock washers and nuts and secure. 5. Fill the washer fluid reservoir with washer fluid. 6. Properly connect the battery. 7. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 8. Turn the ignition key switch to the RUN position and press the washer switch. Verify that fluid is sprayed on both the windshield and rear glass. 9. Close and secure the rear door.
MA8351
The windshield washer motor and reservoir (7) is a unit and cannot be serviced separately. a. Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Remove the nuts and the lock washers from the washer mounting bolts. 6. Pull the washer reservoir out and away from the mounting bracket. 7. Rotate the washer reservoir, label and remove the cab harness connectors from the washer reservoir connectors. 8. Remove the windshield washer hose from the reservoir. b. Disassembly DO NOT disassemble the pump. The pump is not serviceable. Replace pump if found to be defective.
9.9
9.9.1
CAB HEATER AND FAN

Cab Heater Controls
Note: If the suspect component is found to be within the heater box, the heater box must be removed as a complete unit and replaced. a. Cab Heater Controls Removal
MA8701
1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Remove the setscrew from the variable speed fan control knob or temperature control knob. 6. Remove the right side control panel screws. 7. Remove the screws and backing locknuts from the cab heater and fan control panel.
9-16
6036, 6042, 8042, 10042, 10054
Electrical System
8. Pull the control panel out from the dash panel, and if removing variable speed fan control, remove the cab harness connector. 9. If removing the temperature control knob, disconnect the cable connector and remove control knob. 10. Remove the locknut from the suspect control shaft. 11. Remove the control panel from the panel. b. Disassembly DO NOT disassemble the cab heater and fan controls. The controls are not serviceable. Replace controls if found to be defective. c. Installation and Testing 1. Check that the variable speed fan control is in the OFF position. 2. If installing the temperature control, attach the control cable to the back of the control. 3. Insert the control shaft through the panel, ensuring that the knob is in the VERTICAL position. 4. Install the locknut on the shaft and tighten. 5. Connect the cab harness connector to the variable speed fan control. 6. Install the screws and backing locknuts securing the control panel to the dash panel. 7. Install the setscrew securing the knob to the control. 8. Install the right side control panel. 9. Properly connect the battery. 10. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 11. Turn the ignition key to the ON position and check the fan speeds. If further repair is needed, refer to Section 9.5, Electrical System Schematics. 12. Start the machine and allow engine to warm to operating temperature. Check heat control at different levels. 13. Close and secure the rear door.
MAQ0140
9.10
SOLENOIDS, SENSORS AND SENDERS

Coolant Temperature Switch
9.10.1
a. Coolant Temperature Switch Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, raise the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 4. Temporarily block up or support the boom. 5. Properly disconnect the battery.
6. Label and disconnect the wiring connector from the Coolant Temperature Switch (8). 7. Unthread the switch from the engine. b. Coolant Temperature Switch Disassembly DO NOT disassemble the Coolant Temperature Switch. Replace a defective switch with a new part. c. Coolant Temperature Switch Installation 1. Thread the switch into the engine. Tighten securely. 2. Connect the previously labeled wiring connector to the switch. 3. Properly connect the battery. 4. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
6036, 6042, 8042, 10042, 10054
9-17
Electrical System
5. Start the engine. Allow it to reach operating temperature and observe the operators instrument cluster for warning indication. If the switch is not defective, the problem could be elsewhere; possibly in a shorted wire, improper running engine, improper or low coolant, obstructed or faulty radiator, coolant pump, loose fan belt, defective instrument cluster, etc. 6. Close and secure the rear door.
9.10.2
Hydraulic Oil Temperature Switch
The hydraulic oil temperature switch (9) is threaded into a fitting at the lower inside wall of the hydraulic oil tank. a. Hydraulic Oil Temperature Switch Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Drain oil from the hydraulic tank reservoir into a clean container for reuse. 6. Label and disconnect the temperature switch wiring connector from the harness connector. 7. Unthread the switch from the hydraulic reservoir. b. Disassembly DO NOT disassemble the switch. The switch is not serviceable. Replace switch if found to be defective.
9
MA7671
c. Hydraulic Oil Temperature Switch Installation 1. Thread the switch into its fitting on the hydraulic reservoir. Tighten securely. 2. Fill hydraulic oil reservoir with hydraulic oil. 3. Connect the switch wiring connector to the harness connector. 4. Properly connect the battery. 5. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 6. Start the engine, check for hydraulic fluid leaking at the hydraulic oil temperature switch and allow the hydraulic fluid to reach operating temperature. Cycle the boom several times and check whether the hydraulic oil temperature warning indicator illuminates on the operators display panel.
9-18
6036, 6042, 8042, 10042, 10054
Electrical System 9.10.3 Transmission Solenoid Valves

5. Open the rear door. Allow the system fluids to cool. 6. Remove the transmission covers.
11
7. Unplug the transmission temperature sender connector from the wiring harness connector. 8. The sender is threaded into the transmission housing. Remove the sender. b. Transmission Temperature Sender Inspection and Replacement
10
Inspect the sender and the wiring harness connector terminals for continuity. Replace a defective or faulty sender with a new part. c. Transmission Temperature Sender Installation and Testing 1. Thread the transmission temperature sender into the transmission housing snugly, then connect the sender connector to the wiring harness connector. 2. Properly connect the battery. 3. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 4. Check for proper fluid level. 5. Start the engine, allow it to reach operating temperature and observe the operators display cluster for warning indication. If the sender is not defective, the problem could be elsewhere; possibly in a shorted wire, damaged transmission, improper or low fluid, etc. 6. Install the transmission covers. 7. Close and secure the rear door.
MH6380
Note: If the transmission is not shifting properly, the transmission shift control switch (travel select lever), wiring harness or transmission shift solenoids (10) should be checked in order to determine which component is defective. Specific information to determine which travel position and corresponding component is not responding can be found in the detailed transmission service instructions (covering repair, disassembly, reassembly and adjustment information) are provided in the ZF 4 WG-98 TC Repair Manual P/N 5871 135 002 (JLG P/N 8990455). and can be obtained by calling your local Authorized Service Department. The transmission should be checked, serviced and repaired only by experienced service technicians who are aware of all safety instructions and particular component features. Note: Contact your local authorized Service Department if internal transmission repair is required during the warranty period.
9.10.4
Transmission Temperature Sender
a. Transmission Temperature Sender Removal The transmission temperature sender (11) is threaded into the top of the transmission housing. 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, raise the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Properly disconnect the battery. 4. Temporarily block up or support the boom.
6036, 6042, 8042, 10042, 10054
9-19
Electrical System 9.10.5 Service Brake Switch

b. Service Brake Switch Installation 1. Ensure that there is only one thread showing above the locknut on the shaft of the switch body.
12 13
2. Insert switch body through the top of the service brake switch bracket. 3. Thread the switch dust cover onto the switch body until finger tight against the service brake switch bracket. 4. Use a wrench and fully tighten the locknut against the service brake switch bracket. There should now be approximately two or three threads showing above the locknut. 5. Thread the bottom lip of the switch plunger through the hole in the bottom of the dust cover. 6. Connect the cab harness electrical connectors to the service brake switch connectors. 7. Properly connect the battery.
MH6210
8. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 9. Adjust the brake switch. Refer to Section 9.10.5, c. Service Brake Switch Adjustment. c. Service Brake Switch Adjustment Note: The service brake switch adjustment will require two people. Enlist the help of an assistant before attempting to follow the adjustment procedure. 1. Remove the lower access panel. 2. Loosen locknut securing the switch body to the service brake switch bracket. 3. Connect a 1000 psi (69 bar) pressure gauge to the test port on the service brake valve.
The service brake switch (12) works in conjunction with the Stabil-TRAK system. With the boom above 40, the transmission shifter in either forward or reverse, and the service brake depressed, the Stabil-TRAK system engages. If the Service Brake Switch is suspect in the proper operation of the Stabil-TRAK system, refer to Section 10.5, Stabil-TRAK System Test.. a. Service Brake Switch Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Label and disconnect the electrical connectors attached to the service brake switch. 6. Loosen locknut and remove switch dust cover (13). Remove switch body.
WARNING
NEVER attempt to adjust the service brake switch without an assistant. Anytime the engine is running and the parking brake is disengaged, there must be an operator located in the cab and the two front tires must be blocked. 4. Block both front tires. 5. Start the engine and run at low idle. 6. Position the boom above 40, release the park brake and place the transmission control lever in forward 4th gear. 7. Slowly depress and hold the brake pedal to maintain 150 50 psi (10,3 3,4 bar) brake pressure.
9-20
6036, 6042, 8042, 10042, 10054
Electrical System
8. Using the switch dust cover and the locknut in combination, position the brake switch so the StabilTRAK dash light comes ON at the 150 50 psi (10,3 3,4 bar) brake pressure. 9. Repeat steps 6 through 8 until the Stabil-TRAK dash light comes ON at 150 50 psi (10,3 3,4 bar) brake pressure. 10. After the required pressure is achieved, use a wrench and fully tighten the locknut against the service brake switch bracket. In order to test the switch for proper operation, the boom must be raised above the 40 position, the parking brake switch must be in the OFF position and the machine must be in a forward or reverse gear mode. Proper operation of the switch will activate the Stabil-TRAK dash panel indicator. If the Stabil-TRAK indicator does not activate when all conditions are met, the boom angle sensor must be adjusted. Refer to Section 9.10.6, c. Boom Angle Sensor Installation. 11. Shut off the engine. 12. Remove the blocks from the front tires. 13. Remove the pressure gauge. 14. Install the lower access panel.
15
2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Unplug the engine boom angle sensor connector from the wiring harness connector. 6. Loosen and remove the sensor locknut. 7. Remove the sensor from the outside of boom frame. b. Disassembly DO NOT disassemble the sensor. The sensor is not serviceable. Replace the sensor if found to be defective. c. Boom Angle Sensor Installation 1. Install boom angle sensor through outside of boom frame. 2. Install locknut onto sensor.
9.10.6
Boom Angle Sensor
MH6310
14
3. Measure the clearance between the sensor and frame, and adjust sensor distance (15) to 0.120 (3,05 mm) and tighten locknut. 4. Properly connect the battery. 5. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 6. Close and secure the rear door.
MAQ0240
The boom angle sensor (14) is located at the rear of, and on the right side of the machine. When the boom is lifted above 40, the boom sensor sends a signal to the StabilTRAK indicator on the instrument cluster. a. Boom Angle Sensor Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.
6036, 6042, 8042, 10042, 10054
9-21
Electrical System 9.10.7 Boom Extend Interlock Sensor (10054 only)

7. Loosen the inside locknut (17) on the sensor (18). 8. Slide the sensor out of the bracket and remove. b. Boom Extend Interlock Sensor Installation 1. Partially install inside locknut (17) onto the sensor (18). 2. Make sure that there are four to six threads, approximately 0.975 in (24,7mm) and 1.0 in (25,4mm)(19), between the outside locknut (20) and the end of the sensor. 3. Make sure that the wire harness is between the bracket and the sensor, and slide the sensor into the bracket. 4. Connect the boom extend interlock sensor connector (16) to the boom extend harness connector. 5. Replace wire ties as necessary. 6. Properly connect the battery. 7. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 8. Close and secure the rear door.
The boom extend interlock sensor is located on the left side of the machine, on the outer boom frame and just behind the cab. The boom extend interlock sensor prohibits the last boom section from extending unless both outriggers are down and pressure is applied to the ground surface. a. Boom Extend Interlock Sensor Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Make note of wire tie locations and clip wire ties where necessary.
17
20
18
19
16
MH6121
6. Disconnect the boom interlock sensor electrical connector (16). 9-22

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Electrical System
9.10.8
Outrigger Pressure Switches (10054 Only)
9.11
9.11.1
DISPLAY MONITOR AND GAUGES

Instrument Cluster
a. Removal 1. Park the vehicle on a firm, level surface. Level the vehicle, ground the attachment, place the travel select lever in the (N) NEUTRAL position, place the neutral lock lever in the (N) NEUTRAL LOCK position and engage the parking brake switch. 2. Raise both outriggers fully, and shut the engine OFF. 3. Open the rear door. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.
a. Instrument Cluster Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Remove the right access panel.
3
MAQ0260
6. Unscrew the locking ring from below the instrument cluster (4). Pull the instrument cluster up and away from the cut-out, and unplug the harness connector. b. Instrument Cluster Bulb Removal 1. Remove the instrument cluster from the cab. Refer to Section 9.11.1, a. Instrument Cluster Removal. 2. Remove the instrument cluster rear cover plate. 3. Rotate the bulb assembly 1/4 turn counterclockwise and remove bulb. c. Instrument Cluster Installation and Testing 1. Connect the harness connector to the instrument cluster terminal. 2. Place the instrument cluster into the cut-out, and install the plastic retaining ring and secure. 3. Install the right access panel. 4. Properly connect the battery. 5. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 6. Turn the ignition to the RUN position. All lights must illuminate for 3 seconds. 7. Close and secure the rear door. 9-23
MAQ0250
6. Disconnect the pressure switch wiring connector (1) from the harness connector (2). 7. Remove the outrigger pressure switch (3) from the outrigger cylinder. 8. Wipe up any spilled hydraulic oil. b. Installation 1. Install the pressure switch (3), and torque to 25-38 lb-ft (34-41 Nm). 2. Connect the pressure switch wiring connector (1) to the harness connector (2). 3. Properly connect the battery. 4. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 5. Close and secure the rear door.
6036, 6042, 8042, 10042, 10054
Electrical System
9.12
DASH SWITCHES
c. Inspection and Replacement To determine the proper operation of the ignition key switch, test the terminals on the back of the switch for continuity with an ohmmeter. Test the ignition key switch for continuity, by checking from the ignition (BLUE) wire to each of the following wires in each corresponding switch position. Continuity (X) should be present as indicated in the following chart: Switch Position Test from BLUE wire to: WHT Wire, Pin B on 3 Pin Connector OFF RUN START X
Note: For information on the front windshield wiper, rear window wiper and washer systems, refer to Section 9.8, Window Wiper/Washer Windshield Wiper Motor.
9.12.1
Ignition Key Switch
a. Ignition Switch Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on the steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 4. Properly disconnect the battery.
Test the ignition key switch for continuity, by checking from the ignition (RED) wire to each of the following wires in each switch position. Continuity (X) should be present as indicated in the following chart: Switch Position Test from RED wire to: PUR Wire, Pin B on 5 Pin Connector RED/BLK Wire, Pin C on 5 Pin Connector OFF RUN X X START X X
If all terminals do not show proper continuity, replace the ignition switch.
6
d. Ignition Switch Installation

MAQ0270
1. Connect the ignition key switch to the previously labeled connectors. 2. The ignition switch has a drain hole located on the shaft, between the backing nut and the face of the ignition switch cylinder, behind the dash panel. Align the ignition switch so that when it is in the OFF position, the key slot is positioned vertically (straight up and down) and the indicator mark for the drain hole, is pointing down. Install the nut securing the ignition switch to the dash. DO NOT overtighten. 3. Install the lower access panel. 4. Properly connect the battery. 5. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 6. Close and secure the rear door. Note: If further information is needed, refer to Section 9.5, Electrical System Schematics.
5. Remove the lower access panel (5). 6. From under the dash, remove the hex nut securing the ignition key switch (6) to the dash. 7. Label and disconnect the ignition switch connectors and remove the switch from the machine. b. Disassembly DO NOT disassemble the ignition switch. Replace a defective switch with a new part.
9-24
6036, 6042, 8042, 10042, 10054
Electrical System 9.12.2 Dash Switches

c. Inspection and Replacement Inspect the switch terminals for continuity and shorting in both the engaged and disengaged positions. Replace a defective or faulty switch with a new switch. d. Switch Installation 1. Connect the switch to the cab harness connector. 2. Position the switch over the rectangular switch bezel and snap into position. 3. Properly connect the battery. 4. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 5. Start the machine and check the replaced switch for proper function.
7
a. Switch Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 4. Properly disconnect the battery.
6. Close and secure the rear door.
MAQ0280
5. Carefully pry the switch and wiring (7) out of the mounting plate (8). 6. Label and disconnect the wiring from the switch. Remove the switch. b. Disassembly DO NOT disassemble the dash switch. Replace a defective switch with a new part.
6036, 6042, 8042, 10042, 10054
9-25
Electrical System
9.13
9.13.1
TROUBLESHOOTING
Example Fault Code Sequences
Fault Detection
Fault Code 244:
Faults are detected while the key switch is in the RUN position, during operation of the machine itself. If a fault becomes active (currently detected) at this time, a fault is logged in memory and a snapshot of the engine parameters is logged. In addition, certain faults may illuminate the warning lamp (amber) or the stop lamp (red) depending upon the severity of the active fault. For more information, contact your local authorized Cummins service distributor.
P= Pause
1 Blink 2 Blinks Fault Code 112:
4 Blinks
4 Blinks
1 Blink
3 4
9.13.2
Flash-Out of Fault Codes
1 Blink
1 Blink
1 Blink
2 Blinks
1 Blink
MU5441
Fault flash-out mode can be entered through the use of a diagnostic switch or the accelerator pedal. To enter the fault flash-out mode, the key switch must be in the RUN position with the engine not running. When a diagnostic switch is used to enter the fault flashout code mode, the ECM will automatically flash the first fault code after the switch is turned to the RUN position. The diagnostic increment/decrement is used to sequence forward or backwards through the active faults. To enter fault flash-out mode using the accelerator pedal, fully depress and release the pedal 3 times. Once in diagnostic mode, cycling the accelerator pedal will sequence forward through the active faults. The following graphic depicts the pattern of the fault code flash-out scheme as indicated by the stop lamp.
Stop Lamp (3) - The stop lamp provides critical operator messages. These messages require immediate and decisive operator response. The stop lamp is also used to diagnose flash-out fault codes. Warning Lamp (4) - The warning lamp provides important operator messages. These messages require timely operator attention. The warning lamp is also used to delineate diagnostic fault codes.
9.13.3
INSITETM,
Offboard Diagnostics
is the Windows-based PC service/ programming/diagnostic tool for the Cummins engine. It is used to help troubleshoot and repair the engine with extended fault diagnostics and processing power. INSITETM allows the user to view active and inactive faults and clear the inactive faults. It provides a monitor function that allows the service technician to monitor measured parameters, actuator status and some calculated values. It also provides the technician with the capability to turn on certain drivers such as the grid heaters and lift pump as well as running diagnostic tests such as single cylinder cutout.
9-26
6036, 6042, 8042, 10042, 10054
Electrical System 9.13.4 Engine Fault Codes Chart

SPN Code FMI Code Description Exhaust Gas Pressure Sensor Number 1 Circuit - High Exhaust Gas Pressure Sensor Number 1 Circuit - Low Exhaust Gas Pressure Sensor Number 1 Circuit - Erratic Exhaust Gas Temperature Sensor Number 1 Circuit - Erratic Exhaust Gas Temperature Sensor Number 1 Circuit - Low Exhaust Gas Temperature Sensor Number 1 Circuit - High 629 612 102 102 91 91 974 974 100 100 100 110 110 110 12/12 2 3/3 4/4 0/16 3/3 4/4 3/3 4/4 3 4/4 1/18 3/3 4/4 0/16 1 0 110 105 105 105 1080 111 111 111 108 108 1080 190 111 644 611 84 84 0/0 3/3 4/4 0/0 4/4 3/3 4/4 1/18 3/3 4/4 3/3 0/0 1 2 4/4 2/2 10/10 Engine Control Module Engine Magnetic Crankshaft Speed/Position Intake Manifold Pressure Sensor Circuit - High Intake Manifold Pressure Sensor Circuit - Low Intake Manifold 1 Pressure Sensor Circuit Accelerator Pedal or Lever Position Sensor Circuit - High Accelerator Pedal or Lever Position Sensor Circuit - Low Remote Accelerator Pedal or Lever Position Sensor Circuit - High Remote Accelerator Pedal or Lever Position Sensor Circuit - Low Oil Pressure Sensor Circuit - High Oil Pressure Sensor Circuit - Low Engine Oil Rifle Pressure Engine Coolant Temperature 1 Sensor Circuit - High Engine Coolant Temperature 1 Sensor Circuit - Low Engine Coolant Temperature - High - Warning Accelerator Pedal or Lever Position 1 Sensor Circuit - Low Accelerator Pedal or Lever Position 1 Sensor Circuit - High Engine Coolant Temperature - High - Critical Intake Manifold Air Temperature Sensor Circuit - High Intake Manifold Air Temperature Sensor Circuit - Low Intake Manifold 1 Temperature Sensor Supply Voltage Number 2 Circuit - Low Coolant Level Sensor Circuit - High Coolant Level Sensor Circuit - Low Coolant Level - Low Barometric Pressure Sensor Circuit - High Barometric Pressure Sensor Circuit - Low Sensor Supply 2 Circuit - High Engine Crankshaft Speed/Position Coolant Level - Low External Speed Command Input (Multiple Unit Synchronization) Sensor Supply 3 Circuit - Low Vehicle Speed Sensor Circuit Vehicle Speed Sensor Circuit Tampering Has Been Detected 9-27
Fault Code 0001 0002 0003 0004 0005 0006 111 115 122 123 124 131 132 133 134 135 141 143 144 145 146 147 148 151 153 154 155 187 195 196 197 221 222 227 234 235 237 238 241 242
6036, 6042, 8042, 10042, 10054
Electrical System
Fault Code 245 253 268 269 271 272 275 281 284 285 286 287 288 291 292 293 294 295 296 297 298 319 322 323 324 325 331 332 334 341 342 343 351 352 386 387 412 415 418 426 427 428 9-28
SPN Code 647 98 94 1195 1347 1347 1347 1347 1043 639 639 91 974 625 441 441 441 108 1388 1388 1388 251 651 651 653 656 652 654 110 630 630 629 627 1079 1079 1043 608 100 97 639 639 97
FMI Code 4/4 1 2 2 4 3 7 7 4/4 9 13 19 19 9 14 3 4 2 14 3 4 2/2 5 5 5 5 5 5 2 2/2 13 12/12 12 4/4 3/3 3/3 2 1/1 0/15 2 9 3/3 Fan Control Circuit - Low Engine Oil Level
Description
Injector Metering Rail 1 Pressure Antitheft Password Valid Indicator High Fuel Pressure Solenoid Valve Circuit - Low High Fuel Pressure Solenoid Valve Circuit - High Fuel Pumping Element Number 1 (Front) Fuel Pump Pressurizing Assembly 1 Engine Speed/Position Sensor (Crankshaft) Supply Voltage Circuit SAE J1939 Multiplexing PGN Timeout Error SAE J1939 Multiplexing Configuration Error SAE J1939 Multiplexing Accelerator Pedal or Lever Sensor System Error SAE J1939 Multiplexing Remote Accelerator Pedal or Lever Data Proprietary Datalink Error Auxiliary Temperature Sensor Input 1 - Special Instructions Auxiliary Temperature Sensor Input 1 - High Auxiliary Temperature Sensor Input 1 - Low Barometric Pressure - Erratic Auxiliary Pressure Sensor Input 1 - Special Instructions Auxiliary Pressure Sensor Input 1 Circuit - High Auxiliary Pressure Sensor Input 1 Circuit - Low Real-Time Clock Power Interrupt Injector Solenoid Driver Cylinder 1 Circuit - Low Injector Solenoid Driver Cylinder 5 Circuit - Low Injector Solenoid Driver Cylinder 3 Circuit - Low Injector Solenoid Driver Cylinder 6 Circuit - Low Injector Solenoid Driver Cylinder 2 Circuit - Low Injector Solenoid Driver Cylinder 4 Circuit - Low Engine Coolant Temperature Engine Control Module Data Lost Electronic Calibration Code Incompatibility Engine Control Module Warning Internal Hardware Failure Injector Power Supply Sensor Supply Voltage Number 1 Circuit - Low Sensor Supply Voltage Number 1 Circuit - High Accelerator Pedal or Lever Position Sensor Supply Voltage Circuit - High SAE J1587/J1922 Data Link - Can not Transmit Engine Oil Rifle Pressure - Low Water-In-Fuel Indicator - High SAE J1939 Data Link - Can not Transmit J1939 Datalink - Abnormal Update Rate Water-In-Fuel Indicator Sensor Circuit - High
6036, 6042, 8042, 10042, 10054
Electrical System
Fault Code 429 431 432 433 434 435 436 441 442 443 449 451 452 471 488 497 498 499 523 527 528 529 545 551 553 554 559 584 585 595 596 597 598 599 649 687 688 689 691 692 731 757
SPN Code 97 558 558 102 627 100 105 138 138 1043 157 157 157 98 105 1137 98 98 611 702 093 703 1188 558 157 157 157 677 677 103 167 167 167 640 1378 103 98 190 1172 1172 723 611
FMI Code 4/4 2/2 13/13 2 2/2 2/2 2 1/18 0/16 4/4 0 3 4 1/17 0/16 2 3 4 2 3 2 3 7 4/4 0/16 2 1/18 3/3 4/4 0 0/16 1/18 1/1 14 11/31 18 0 2/2 3/3 4/4 7/7 11/31
Description Water-In-Fuel Indicator Sensor Circuit - Low Accelerator Pedal or Lever Idle Validation Circuit - Erratic Accelerator Pedal or Lever Idle Validation Circuit - Out of Calibration Intake Manifold Pressure Sensor Circuit - Data incorrect Power Supply Lost with Ignition On - Erratic Oil Pressure Switch Sensor Circuit - Erratic Intake Manifold 1 Temperature - Erratic Battery 1 Voltage - Low Battery 1 Voltage - High Accelerator Pedal or Lever Position Sensor Supply Voltage Circuit - Low Injector Metering Rail Number 1 Pressure - High Injector Metering Rail Number 1 Pressure Circuit - High Injector Metering Rail Number 1 Pressure Circuit - Low Engine Oil Level - Low Intake Manifold 1 Temperature - High Multiple Unit Synchronization Switch - Erratic Engine Oil Level Sensor Circuit - High Engine Oil Level Sensor Circuit - Low Auxiliary Intermediate (PTO) Speed Switch Validation - Erratic Auxiliary Input/Output 2 Circuit - High Auxiliary Alternate Torque Validation Switch - Erratic Auxiliary Input/Output 3 Circuit - High Turbocharger 1 Wastegate Control - Not Responding Accelerator Pedal or Lever Idle Validation Circuit - Low Injector Metering Rail 1 Pressure - High Injector Metering Rail 1 Pressure - Erratic Fuel Pump Delivery Pressure Low Starter Relay Circuit - High Starter Relay Circuit - Low Turbocharger Number 1 Speed High Electrical Charging System Voltage High Electrical Charging System Voltage Low - Moderately Severe Electrical Charging System Voltage Low - Most Severe Auxiliary Commanded Dual Output Shutdown - Special Instructions Change Lubricating Oil and Filter Turbocharger Number 1 Speed Low Engine Oil Level - High Engine Crankshaft Speed/Position - Erratic Turbocharger Number 1 Compressor Inlet Temperature Sensor - High Turbocharger Number 1 Compressor Inlet Temperature Sensor - Low Engine Speed Sensor/Position Camshaft and Crankshaft Misalignment Engine Control Module Data Lost 9-29
6036, 6042, 8042, 10042, 10054
Electrical System
Fault Code 778 779 784 951 957 958 1117 1139 1141 1142 1143 1144 1145 1228 1229 1239 1241 1242 1633 1639 1654 1655 1656 1657 1658 1659 1663 1664 1665 1666 1667 1668 1669 1671 1673 1674 1675 1676 1677 1678 1679 1681 9-30
SPN Code 723 703 1590 166 27 2795 627 651 652 653 654 655 656 27 2795 2623 2623 091 625 703 1323 1324 1325 1326 1327 1328 3241 3050 3241 3241 3241 1761 1761 1761 1761 3249 3249 3249 3031 3031 3031 3361
FMI Code 2 11 2 2 2 2 2/2 7 7 7 7 7 7 2/2 2/2 3/3 4/4 2/2 2 11 11/31 11/31 11/31 11/31 11/31 11/31 11/31 11/31 4 3 2 4/4 3 1/18 1 4 3 2 4 3 2 12
Description Engine Speed Sensor (Camshaft) Error - Erratic Auxiliary Equipment Sensor Input #3 (OEM Switch) Loss of Communication with Adaptive Cruise Control Cylinder Power Imbalance Between Cylinders EGR Valve Position - Erratic VGT Position Sensor - Erratic Power Lost Without Ignition Off - Erratic Injector Solenoid Driver Cylinder 1 - Not Responding Injector Solenoid Driver Cylinder 2 - Not Responding Injector Solenoid Driver Cylinder 3 - Not Responding Injector Solenoid Driver Cylinder 4 - Not Responding Injector Solenoid Driver Cylinder 5 - Not Responding Injector Solenoid Driver Cylinder 6 - Not Responding EGR Valve Position - Erratic VGT Position Sensor - Erratic Accelerator Pedal or Lever Position Sensor 2 Circuit - High Accelerator Pedal or Lever Position Sensor 2 Circuit - Low Accelerator Pedal or Lever Position Sensor Number 1 and 2 - Erratic Komnet Datalink Cannot Transmit Auxiliary Equipment Sensor Input Number 3 (OEM Switch) Engine Misfire Cylinder 1 Engine Misfire Cylinder 2 Engine Misfire Cylinder 3 Engine Misfire Cylinder 4 Engine Misfire Cylinder 5 Engine Misfire Cylinder 6 Catalyst Inlet Temperature Sensor Swapped with Outlet Catalyst Missing Exhaust Gas Temperature 1 Circuit - Low Exhaust Gas Temperature 1 Circuit - High Exhaust Gas Temperature 1 - Erratic Catalyst Tank Level Sensor Circuit - Low Catalyst Tank Level Sensor Circuit - High Catalyst Tank Level - Low - Moderately Severe Catalyst Tank Level - Low - Most Severe Exhaust Gas Temperature 2 Circuit - Low Exhaust Gas Temperature 2 Circuit - High Exhaust Gas Temperature 2 Circuit - Erratic Catalyst Tank Temperature - Low Catalyst Tank Temperature - High Catalyst Tank Temperature - Erratic Catalyst Dosing Control Unit
6036, 6042, 8042, 10042, 10054
Electrical System
Fault Code 1682 1683 1684 1687 1689 1692 1694 1697 1698 1699 1711 1712 1713 1716 1717 1718 1848 1849 1851 1892 1911 2183 2185 2186 2215 2216 2217 2249 2265 2266 2271 2272 2273 2274 2292 2293 2311 2321 2322 2345 2346 2347
SPN Code 3362 3449 3363 3050 251 3234 3234 3489 3489 1761 3361 3363 3363 411 3241 1322 105 3241 3249 84 157 1072
FMI Code 11/31 3 4 0 12/2 4 2 3 4 2 9 1/18 0/16 11 0/15 11/31 10 10 10 1/18 0 4 3/3 4/4
Description Catalyst Reagent Dosing Unit Input Lines Catalyst Tank Heater Circuit - High Catalyst Tank Heater Circuit - Low Catalyst Over Temperature Real-Time Clock Power Interrupt - Erratic Aftertreatment NOx Sensor - Low Aftertreatment NOx Sensor - Erratic Aftertreatment #1 Air Enable Actuator - High Aftertreatment #1 Air Enable Actuator - Low Catalyst Tank Level Sensor - Erratic Dosing Control Unit Datalink - Abnormal Update Rate Catalyst Tank Heater Circuit - Low Catalyst Tank Heater Circuit - High Auxiliary Temperature Sensor Input 1 Circuit Exhaust Gas Temperature 1 - High Engine Misfire for Multiple Cylinders Intake Manifold 1 Temperature - Abnormal Rate of Change Exhaust Gas Temperature 1 - Abnormal Rate of Change Exhaust Gas Temperature 2 - Abnormal Rate of Change Wheel-Based Vehicle Speed - Low Injector Metering Rail Number 1 Pressure - High Engine Brake Actuator Driver 1 Circuit - Low Sensor Supply Voltage 4 Circuit - High Sensor Supply Voltage 4 Circuit - Low Fuel Pump Delivery Pressure - Low Fuel Pump Delivery Pressure - High Engine Control Module Calibration Program Memory (RAM) - Corruption Injector Metering Rail 1 Pressure - Low Electric Lift Pump for Engine Fuel Supply Circuit - High Electric Lift Pump for Engine Fuel Supply Circuit - Low Exhaust Gas Recirculation (EGR) Valve Position Sensor Circuit - High Exhaust Gas Recirculation (EGR) Valve Position Circuit - Low EGR Valve Differential Pressure Sensor Circuit - Shorted High EGR VAlve Differential Pressure Sensor Circuit - Shorted Low Fuel Inlet Meter Device - High Fuel Inlet Meter Device Flow Demand Low Fueling Actuator Number 1 Circuit Error Engine Crankshaft Speed/Position - Erratic Backup Engine Speed/Position Sensor Number 2 - Erratic Turbocharger Speed - Invalid Rate of Change Detected Exhaust Gas Temperature - High Turbocharger Compressor Outlet Temperature - High 9-31
94 94 630 157 1075 1075 27 027 411 411
1 0 11/31 1 3 4 3/3 4/4 3/3 4/4 16 18
633 190 723 103 2789 611
11/31 2 2 10/10 1/15 0/15
6036, 6042, 8042, 10042, 10054
Electrical System
Fault Code 2348 2349 2351 2352 2353 2357 2359 2362 2363 2366 2367 2373 2374 2375 2376 2377 2381 2382 2383 2384 2385 2386 2387 2388 2554 2555 2557 2558 2771 2772 2773 2961 2962 2963 2964 2973 2976 9121 9122
SPN Code 27 2791 2791 2791 2971 2791 411 1072 1073 1072 1073 1209 1209 412 412 647 2795 2795 641 641 641 2975 2975 2795 1209 729 697 697 3234 3226 3226 412 412 110 105 102 3361 2791 641
FMI Code 13/13 5/5 4/4 3/3 6/6 7/7 0/16 4 4 3 3 3/3 4/4 3 4/4 3 4/4 4/4 5/5 4/4 3/3 6/6 7/7 13/13 2/2 4 3 4 9 0/15 0 0/15 0/16 0/15 0/15 2/2 2 0/15 0/15
Description EGR Valve Failed Automatic Calibration Procedure EGR Valve Control Circuit - Low EGR Valve Control Circuit - Low EGR Valve Control Circuit - High Exhaust Gas Recirculation (EGR) Valve Control CIrcuit - High Exhaust Gas Recirculation (EGR) Valve Control - Not Responding Exhaust Gas Recirculation (EGR) Differential Pressure Sensor - High Engine Brake Actuator Circuit #1 - Low Engine Brake Actuator Circuit #2 - Low Engine Brake Actuator Circuit #1 - High Engine Brake Actuator Circuit #2 - High Exhaust Gas Pressure Sensor Circuit - Shorted High Exhaust Gas Pressure Sensor Circuit - Shorted Low EGR Temperature Sensor Circuit - High Recirculation Exhaust Gas (EGR) Temperature Sensor Circuit - Low Fan Control Circuit - High Turbocharger Position Sensor Circuit - Shorted High Turbocharger Position Sensor Circuit - Shorted Low Variable Geometry Turbocharger Actuator Circuit - Low VGT Actuator Driver Circuit - Low VGT Actuator Driver Circuit - High Turbocharger Actuator Motor Circuit - High Turbocharger Actuator Motor - Not Responding Variable Geometry Turbocharger Actuator Position Failed Calibration Exhaust Pressure Sensor Circuit - Erratic Intake Air Heater #1 Circuit - Low Auxiliary PWM Driver #1 - High Auxiliary PWM Driver #1 - Low Aftertreatment Outlet NOx Sensor - Abnormal Update Rate Aftertreatment Outlet NOx Sensor - High - Least Severe Aftertreatment Outlet NOx Sensor - High - Most Severe Exhaust Gas Recirculation (EGR) Temperature - High - Least Severe Exhaust Gas Recirculation (EGR) Temperature - High - More Severe Engine Coolant Temperature High - Least Severe Intake Manifold Temperature High - Least Severe Intake Manifold Pressure Sensor Circuit - Erratic Dosing Control Unit Temperature - Erratic Exhaust Gas Recirculation (EGR) Valve Actuator Over Temperature Variable Geometry Turbocharger Actuator Over Temperature
9-32
6036, 6042, 8042, 10042, 10054
Section 10 Stabil-TRAK System and Boom Interlock System
Contents
PARAGRAPH 10.1 10.2 10.3 10.4 10.5 TITLE PAGE
10.6 10.7 10.8
Stabil-TRAK System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 Boom Extend Interlock System Component Terminology (10054 Only) . . . . . . 10-3 Stabil-TRAK Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 10.3.1 Stabil-TRAK Solenoid Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Stabil-TRAK Electrical Circuit Operation and Troubleshooting (6042, 8042 & 10042) 10-5 Stabil-TRAK System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 10.5.1 Stabil-TRAK System Test Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 10.5.2 Stabil-TRAK System Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 Stabil-TRAK Boom Interlock Electrical Circuit Operation and Troubleshooting (10054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 Boom/Outrigger Interlock System Test (10054) . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 10.7.1 System Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 Stabil-TRAK Hydraulic Circuit Operation and Troubleshooting . . . . . . . . . . . 10-14
6036, 6042, 8042, 10042, 10054
10-1
Stabil-TRAK System and Boom Interlock System
10.1
STABIL-TRAK SYSTEM COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the Stabil-TRAK system. The following illustration identifies the components that are referred to throughout this section.
STABIL-TRAK CYLINDER STABIL-TRAK MANIFOLD
FRAME SWAY CYLINDER
BOOM PROXIMITY SWITCH
MODEL 10054 SHOWN
MH2962
10-2
6036, 6042, 8042, 10042, 10054
10.2
BOOM EXTEND INTERLOCK SYSTEM COMPONENT TERMINOLOGY (10054 ONLY)
To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the boom extend interlock system. The following illustration identifies the components that are referred to throughout this section.
BOOM EXTEND SENSOR
OUTRIGGER CYLINDER PRESSURE SWITCH (2)
BOOM LOCKOUT VALVE

MH3002
6036, 6042, 8042, 10042, 10054
10-3
10.3
STABIL-TRAK DESCRIPTION
10.3.1
Stabil-TRAK Solenoid Valves
The patented rear axle lock or Stabil-TRAK system works to stabilize the machine under various conditions. The appropriate Operation & Safety manual contains basic Stabil-TRAK information; a copy of the Operation & Safety manual should always be available in the storage compartment located on the left inside wall of the cab, next to the seat support. The Stabil-TRAK lock system will be activated when the boom angle is greater than 40 and one or more of the following functions are activated: Engaging the Parking Brake Switch Placing the Travel Select Lever in (N) NEUTRAL Depressing and holding the Service Brake Model 10054 Only: Lowering both outriggers onto solid terrain, and extending the boom beyond a point between the E and F boom extend letters (approximately 40 ft(12 m)) With the boom lowered to an angle of less than 40, the rear axle lock system is not active and none of these functions will affect the Stabil-TRAK system.
There are five Stabil-TRAK solenoid valves installed in the Stabil-TRAK manifold, attached to the stabilizer cylinder above the left side of the rear axle. If a solenoid valve is suspected of malfunctioning, disconnect the coil wiring lead and test the coil for proper resistance (7-9 ohms) and for proper voltage from the harness (12 VDC). Replace the solenoid coil if open or shorted to ground. Also inspect the valve cartridge, o-rings, and the other hydraulic and electrical components in the circuit to accurately determine the cause of the problem. All solenoid coils are identical and can be interchanged for diagnostic purposes.
3 5 1 2 4
MT3132
Note: DO NOT interchange solenoid valves 4A (1), 4B (2), 12A (3) or 12B (4) with solenoid valve 3 (5). These valves will fit into the other locations, but are configured differently internally and will not operate properly if interchanged. Cartridge valves 4A (1), 4B (2), 12A (3) and 12B (4) are identical and can be interchanged for diagnostic proposes. Note: Make sure the 0.060 orifices are in place when installing solenoid valves 4A (1) and 4B (2). In general, if there is a problem with the Stabil-TRAK system beyond common electrical troubles, the involved electrical and hydraulic circuits should each be checked and the exact source of the problem diagnosed before any parts are replaced.
10-4
6036, 6042, 8042, 10042, 10054
10.4
STABIL-TRAK ELECTRICAL CIRCUIT OPERATION AND TROUBLESHOOTING (6042, 8042 & 10042)
Note: Before using the 6042, 8042 and 10042 StabilTRAK System Troubleshooting chart and diagrams, complete the Section 10.5, Stabil-TRAK System Test to determine what part of the system is not functioning properly. 6042, 8042 and 10042 Stabil-TRAK System Troubleshooting
FREE PIVOT MODE Machine Conditions Switch/ Relay Solenoid Solenoid 12A Solenoid 12B Solenoid 3 Solenoid 4A Solenoid 4B Boom Angle Sensor Boom Switch Relay Stabilizer Lock Relay Stabilizer Light Ignition Switch Park Brake Switch Service Brake Switch Secondary Function Manifold Park Brake Solenoids Park Brake Disengage Relay Neutral Start Relay Ignition On Boom Below 40 Boom Retracted PB & SB Released Trans. in Forward or Reverse E E DE DE DE C E DE OFF (DE) C O O E E DE SLOW PIVOT MODE Ignition On Boom Above 40 Boom Extended PB & SB Released Trans. in Forward or Reverse DE DE DE E E O DE DE OFF (DE) C O O E E DE LOCKED MODE Ignition On Boom Above 40 Boom Extended PB & SB Applied & Trans. in Neutral DE DE E DE DE O DE E ON (E) C C C DE DE E
Definitions: PB = Park Brake SB = Service Brake DE = De-energized E = Energized C = Closed O = Open
6036, 6042, 8042, 10042, 10054
10-5
+
40A 26A 3C Service Brake Switch
BRN BLK BLU
+
7.5A 10A 7.5A 24 7 Boom Angle Sensor 10 114B
C
86 30 30
10-6
10A 10A 46 To Horn
+
10A
Ignition Switch 39
34 157
A B
86 30
24A
42A 10 35
87A 87 85 87A 87
1 To Fuel Shutoff 45B

85 87A 87
Back-Up Alarm Relay 2T 47 35

40
85 86
Stabilizer Lock Relay 48 Boom Switch Relay
Park Brake Switch 153A To Back-Up Alarm 2AA 40A 28 114B 40 47 45 102B 153 47A
111 47
2BB 2CC 40B
31
41B 111 45A2

45
152B
41A 2HH 47B 40

SOL. 4B SOL. 3
152A1 45 111 Stabilizer Light

114
28
28
To Instrument Panel 107B 113A

86 30 86 30
41
107A 111A
SOL. 4A
28A
28B
SOL. 12A SOL. 12B
41
85 87A 87 87A 87 85
41B 114A 2T 2CC 2M 2N 113B

113
41A 2FF To Starter 114A 106
Park Brake Disengage Relay Neutral Start Relay 2K
PB B
PB A
Secondary Function Manifold Park Brake Solenoids 2HH 2EE 112A

112
2L
2P
2F
2E
2D
DIODE PACK DIODE PACK
112 113
9
B+ GEAR GEAR GEAR GEAR NEUTRAL REVERSE
104A
150A 105A 105 101 150

105
101A 103A
2DD 102A
153 150 103 105 101 112 102A

102
CONSOLE/ STABILIZER & ENGINE HARNESS CONNECTORS 105 101 150
RELAY LOCATIONS
FORWARD
7 6 5 4 3 2
FORWARD B+
Transmission
101 150
Outrigger Headlight Switch Relay
7.5
Lights 1
7.5
Optional Washer/Wiper
20
103 102 104 103 102 104
104 103 102
10
Stabilizer
Light Switch Relay Park Brake Disengage Relay
10
Steer Select Switch
REVERSE 104 113

1
SHIFTER ZF TRANSMISSION
10
Horn/Heater Stabilizer Lock Relay Neutral Start Relay
15
Instrument Panel
10
2J 104B 103B 102B 105B 101B 150B 2H
7 1 3 2 4 5 6 7
Y1 Y3 Y2
Y1 Y3 Y2
Light Swtch Relay
Upper Transmission Connectors ZF Transmission WG 98 Lower Y6 Y5 Y4 Transmission Connectors
Boom Switch Relay
Back-up Alarm Relay
7.5
Main
40
MH6390
6036, 6042, 8042, 10042, 10054
Y6 Y5 Y4
10.5
STABIL-TRAK SYSTEM TEST
Note: The operator must know that the Stabil-TRAK system is active and functioning properly. To test the function of the Stabil-TRAK system, read the Stabil-TRAK System Test instructions and follow Steps 1 through 9 of Section 10.5.2, Stabil-TRAK System Test Procedures.
If the Stabil-TRAK light goes OFF and the front left tire lowers to the ground consistently during Steps 4 through 7, the Stabil-TRAK system is not functioning properly and the test should be stopped immediately. If the StabilTRAK system is not functioning properly, follow the procedures in Section 10.8, Stabil-TRAK Hydraulic Circuit Operation and Troubleshooting, to repair the system.
10.5.1
Stabil-TRAK System Test Instructions
10.5.2
Stabil-TRAK System Test Procedures
Test the Stabil-TRAK system with the machine on a level surface. Remove any attachment from the quick attach before performing the test. DO NOT extend the boom at any time during the test. Perform the test with the boom fully retracted. DO NOT raise the boom above 60 for Steps 3-6. DO NOT raise the boom above 45 for Steps 7-9. Follow Steps 1 through 9 of the Stabil-TRAK system test procedure exactly as written. Note: If the Stabil-TRAK light goes OFF and the front left tire lowers to the ground at any time during Steps 4 through 7, the test was not performed properly or the Stabil-TRAK system is not functioning properly. Carefully repeat the steps starting with Step 1.
If Steps 1 through 9 prove positive, the Stabil-TRAK system is functioning properly, and the machine can be returned to service. If any of these steps indicate that the Stabil-TRAK system is not functioning properly, follow the procedures in Section 10.8, Stabil-TRAK Hydraulic Circuit Operation and Troubleshooting, to repair the system.
6036, 6042, 8042, 10042, 10054
10-7
Stabil-TRAK System Test Procedures Step 1 a. Enter the machine. b. Fasten the seat belt. c. Place the machine on a hard level surface. d. Have the boom fully retracted and horizontal. e. Place an 8 in (203 mm) wood or cement block in front of the front left tire. f. Turn the key to the RUN position. g. Check to be sure the Stabil-TRAK light is OFF. FREE PIVOT MODE
OH2500
Step 2 a. Start the engine. b. Turn the parking brake switch OFF. c. Move the range select lever to (1) FIRST gear. d. Move the travel select lever to the (F) FORWARD position. e. Drive the machine up on the block. f. Use the frame sway control to level the machine back to 0. Step 3 a. Depress the service brake pedal. b. Move the travel select lever to the (N) NEUTRAL position. c. Raise the boom to exactly 60. The Stabil-TRAK light should come ON when the boom angle is at about 40 and remain ON.
Service Brake Test
Step 4 a. Use your left foot to depress the service brake pedal. b. With the range select lever in (2) SECOND gear, move the travel select lever to the (R) REVERSE position. c. Ease your left foot partially off the service brake pedal, make sure that the Stabil-TRAK light remains ON. d. With your right foot, increase the engine rpm slightly, as necessary, just enough to back the machine off the block. While backing off the block, the front left tire should remain off the ground. Note: Perform Steps 5 thru 9 with the engine rpm at idle. Step 5 a. Keep the service brake pedal depressed. b. Move the travel select lever to the (N) NEUTRAL position. c. Take your foot off the service brake pedal. The Stabil-TRAK light should remain ON and the front left tire should remain off the ground. Step 6 a. With the travel select lever in the (N) NEUTRAL position, engage the parking brake switch. b. Move the travel select lever to the (F) FORWARD position. The Stabil-TRAK light should remain ON and the front left tire should remain off the ground.
LOCKED MODE 10-8

Park Brake Test Neutral Test
6036, 6042, 8042, 10042, 10054
Stabil-TRAK System Test Procedures Step 7 a. With the parking brake switch ON, move the travel select lever to the (N) NEUTRAL position. b. Lower the boom to exactly 45. c. Frame sway the machine no more than 5 to the left. d. Frame sway the machine back to 0. e. Frame sway the machine no more than 5 to the right. LOCKED MODE Note: Observe that frame sway will be slower than normal during this test. f. The Stabil-TRAK light should remain ON and the front left tire should remain off the ground. The front left tire should not raise or lower during frame sway. g. Frame sway back toward 0, leaving the machine swayed to the right approximately 1 to 2. Step 8 a. Depress the service brake pedal. b. Disengage the parking brake switch. c. With the range select lever in (1) FIRST gear, move the travel select lever to the (R) REVERSE position. d. Release the service brake pedal to deactivate the Stabil-TRAK system. e. The Stabil-TRAK light should go OFF. f. The front left tire should return to the ground while the machine travels in reverse.
SLOW PIVOT MODE
g. Depress the service brake pedal to stop the machine. Step 9 a. With the service brake pedal depressed and the boom angle at exactly 45, move the range select lever to (3) THIRD gear. b. Move the travel select lever to (F) FORWARD. c. Release the service brake pedal to deactivate the Stabil-TRAK system. The Stabil-TRAK light should go OFF. d. Slowly drive the machine forward against the block to stop the machine from moving forward. e. With the front left tire against the block, frame sway the machine no more than 5 to the left. f. Check that the front left tire remains on the ground. It is normal for the front left tire to raise slightly when swaying to the left, but the tire should immediately lower when the frame sway function is stopped.
SLOW PIVOT MODE
LOCKED MODE
g. Frame sway the machine back to 0 and pause briefly. h. Frame sway the machine no more than 5 to the right. i. Check that the front right tire remains on the ground. It is normal for the front right tire to raise slightly when swaying to the right, but the tire should immediately lower when the frame sway function is stopped. j. Frame sway the machine back to 0. k. Depress the service brake pedal. l. Shift the travel select lever to (N) NEUTRAL. m. Lower the boom. n. Engage the parking brake switch, shut the engine OFF and remove the key. o. Exit the machine using both handholds.
6036, 6042, 8042, 10042, 10054
10-9
10.6
STABIL-TRAK BOOM INTERLOCK ELECTRICAL CIRCUIT OPERATION AND TROUBLESHOOTING (10054)

properly. If an outrigger is raised or a pressure switch is defective, boom on the 10054 will not extend beyond the 42 Series extension limit.
Note: Before using the 10054 Stabil-TRAK System Troubleshooting chart and diagrams, complete Section 10.5, Stabil-TRAK System Test and Section 10.7, Boom/Outrigger Interlock System Test (10054), to determine what part of the system is not functioning
10054 Stabil-TRAK System Troubleshooting

BOOM EXTEND MODE 1 Machine Conditions Switch/ Relay Solenoid Solenoid 12A Solenoid 12B Solenoid 3 Solenoid 4A Solenoid 4B Boom Angle Sensor Boom Switch Relay Stabilizer Lock Relay Stabilizer Light Ignition Switch Park Brake Switch Park Brake Light Ignition On Boom Below 40 Boom Retracted PB Released Trans. Fwd. or Rev. Outriggers Raised E E DE DE DE C E DE OFF (DE) C O OFF (DE) BOOM EXTEND MODE 2 Ignition On Boom Below 40 Boom Extended To 42 Series Extension Limit PB Released Trans. Fwd. or Rev. Outriggers Raised E E DE DE DE C E DE OFF (DE) C O OFF (DE) BOOM EXTEND MODE 3 Ignition On Boom Below 40 Boom Extended Beyond 42 Series Extension Limit PB Applied By Interlock Sys. Trans. In Neutral By Interlock Sys. Outriggers Lowered DE DE E DE DE O DE E ON (E) C O ON (E)
BOOM EXTEND INTERLOCK SYSTEM TROUBLESHOOTING

Boom Extend Interlock Sensor Boom Extend Interlock Relay Boom Extend Lockout Relay Outrigger Pressure Switches Left Outrigger Lockout Relay Right Outrigger Lockout Relay Stabilizer Interlock Relay Stabilizer Lock-Up Relay Extend Circuit Solenoid Valve Secondary Function Manifold Park Brake Solenoids Park Brake Interlock Relay Park Brake Disengage Relay C E E O DE DE DE DE E E DE E O DE DE O E E DE DE E E DE E O DE DE C E E E E E DE E DE
Definitions: Boom Retracted = Less than 42 Series extension limit Boom Extended = Boom at 42 Series extension limit or greater. 10-10 PB = Park Brake DE = De-energized E = Energized
6036, 6042, 8042, 10042, 10054
Stabil-TRAK Components Affected By Boom Interlock System
+
40A 7.5A 7.5A 10A 10A
+ + BRN BLK BLK BRN BLU BLU
10A
7.5A
3B
3C
Ignition Switch 7 10 60A 56A

56 60 C
26A 24 39
7.5A 7.5A
-
C = Closed
3C 3A Left Outrigger Cylinder Pressure Switch 56 50C 57 Right Outrigger Cylinder Pressure Switch 3B
To Horn
Boom Angle Sensor
Boom Extend Interlock Sensor
24A 34
86 30
42A
A A B B C
1 49 2R
30
Park Brake Switch

85 87A 87 30 30
Back-Up Alarm Relay 7

86 85 87A 85 87A 87 86 30 87 86
Stabilizer Lock Relay 86 Boom Switch Relay 48 65A 58

56
60B 60E Left Outrigger Switch Right Outrigger Switch 64 62
To Fuel Shutoff
2BB 153A
85 87A 87
31
To Back-Up Alarm
152B 35 40B 35 47 2B2 67 50B 28 66

85 87A
Stabilizer Lock-Up Relay 23 2B3
6036, 6042, 8042, 10042, 10054

45A
87
41B
45B
68 Boom Extend Lockout Relay 55 50C
152A1
86 30
2C1
85 87A 87
152A2 70C 111

40
85 87A 87 86 30
50B 71 2CC 2AA 40A 65A 71
152A3
152A
Boom Extend Interlock Relay
71A 71B 58
86 30 86 30
1
102B 2C2 70B 114B
Stabilizer 2T Interlock Relay
70A
Park Brake Light
85
2HH
87A
87
Right Outrigger Lock Relay

85
52
1
28
28
87A
87
Left Outrigger Lock Relay 2A2 63 2A3 2A1
86
30
45A2
45 114
45 47
47
45
Stabilizer Light
85
87A
87
Park Brake Interlock Relay 153

111
61
28A 40
SOL. 12A
28B
51A
86 30
51B 113A 47A

SOL. 4A SOL. 4B
107B 47B
2B2
85 87A 87
51
SOL. 12B
51C 113B
113
Park Brake Disengage Relay 114A 40 2M 114A 2K

SOL. 3
2B3 2L 2P
64
62
PB B
51D Secondary Function Manifold Park PB A Brake Solenoids 2EE

112
2N
Extend Circuit Solenoid Valve
Left Outrigger DOWN Solenoid
Left Outrigger UP Solenoid
Right Outrigger DOWN Solenoid
Right Outrigger UP Solenoid
2H
2D
2E
2F
2G
O = Open
2K1
2K2
2D
DIODE PACK DIODE PACK
RELAY LOCATIONS
150A 105A
105
112 113
9
B+ GEAR GEAR GEAR GEAR NEUTRAL REVERSE
104A
101A 103A
2DD 102A
Headlight Switch Relay
101
Transmission
Open Fuse
153 150 103 105 101 112 102A

102
CONSOLE/ STABILIZER & ENGINE HARNESS CONNECTORS 105 101 150 105 101 150
7.5
Lights 1
7.5
Optional Washer/Wiper
FORWARD
7 6 5 4 3 2
FORWARD B+
Park Brake Interlock Relay
Stabilizer Interlock Relay
20
150
10
Stabilizer
Light Switch Relay Park Brake Disengage Relay
10
103
103
103 102 104
102 104
104
Steer Select Switch

102
Boom Extend Lockout Relay
Stabilizer Lock Up Relay
REVERSE 104 113

1
SHIFTER ZF TRANSMISSION
10
Horn/Heater Stabilizer Lock Relay Neutral Start Relay
15
Instrument Panel
Boom Extend Interlock Relay
10
Light Swtch Relay
7.5
2J 104B 103B 102B 105B 101B 150B 2H
7 1 3 2 4 5 6 7
Y1 Y3 Y2
Boom Switch Relay
Back-up Alarm Relay
7.5
Upper Transmission Connectors ZF Transmission WG 98 Lower Y6 Y5 Y4 Transmission Connectors
Y1 Y3 Y2
Main
Boom/Outrigger Interlock
40
7.5
Right Outrigger Lock Relay Boom/Outrigger Interlock Left Outrigger Lock Relay
Y6 Y5 Y4
MH6400
10-11
10.7
BOOM/OUTRIGGER INTERLOCK SYSTEM TEST (10054)
Before performing the following Boom/Outrigger Interlock System Test, perform Section 10.5, StabilTRAK System Test, to determine if the Stabil-TRAK system is working properly. If necessary, repair the Stabil-TRAK system before testing the boom/outrigger interlock system.
10.7.1
System Test Procedures
If Steps 1 through 5 prove positive, the Boom/Outrigger Interlock System is functioning properly, and the machine can be returned to service. If any of these steps indicate that the Boom/Outrigger Interlock system is not functioning properly, follow the procedures in Section 10.6, Stabil-TRAK Boom Interlock Electrical Circuit Operation and Troubleshooting (10054), to repair the system.
10-12
6036, 6042, 8042, 10042, 10054
Boom/Outrigger Interlock System Test Procedures Step 1 BOOM EXTEND MODE 1 a. Place the machine with no load on a hard, level surface such as blacktop or concrete. b. Fasten your seat belt. Step 2 a. With the outriggers in the raised position and the boom in a horizontal position, extend the boom. The boom should extend until the letter E appears and then should STOP. If the boom extends beyond the letter F, retract the boom fully and have the system repaired before using the machine again. b. Attempt to frame sway the machine to the right and left; it should frame sway normally. Step 3 a. Lower both outriggers to the ground. DO NOT lift the front wheels of the machine off the ground at this time. The Stabil-TRAK light should come ON when the outriggers are lowered. b. With the boom still in a horizontal position, extend the boom. c. Attempt to raise both outriggers; they should not rise. If the outriggers rise, STOP and retract the boom and have the system repaired before using the machine again. d. If the outriggers cannot be raised, attempt to lower the outriggers fully until both front wheels are off the ground; the outriggers should lower. Step 4 a. Place the travel select lever in the (F) FORWARD position and the gear select lever in the (1) FIRST gear position. BOOM EXTEND MODE 3 b. Attempt to accelerate the machine; the machine should not move. c. If the machine attempts to move, STOP and have the system repaired before using the machine. Note: Perform Steps 5 thru 9 with the engine rpm at idle. Step 5 a. Attempt to frame sway the machine to the right and left; it should frame sway, but at a slower speed than normal. b. The Stabil-TRAK light should remain ON. c. Return the machine to a level position. Step 6 a. Place the travel select lever in the (N) NEUTRAL position, move the neutral lock lever to the NEUTRAL LOCK position. b. Fully retract the boom. BOOM EXTEND MODE 1 c. Raise the outriggers. d. Engage the parking brake switch, shut the engine OFF and remove the key. e. Exit the machine using both handholds.
BOOM EXTEND MODE 2
6036, 6042, 8042, 10042, 10054
10-13
10.8
STABIL-TRAK HYDRAULIC CIRCUIT OPERATION AND TROUBLESHOOTING
The Stabil-TRAK hydraulic circuit can be tested using these basic guidelines. For more hydraulic information, refer to Section 8.4.2, Hydraulic Schematics.
Check electrical wiring.
Not OK
Refer to Section 9.5, Electrical System Schematics.
If OK
Check solenoid cartridge in the Stabil-TRAK manifold. Refer to Section 10.3.1, Stabil-TRAK Solenoid
Not OK
Replace cartridge.
If OK
Inspect check valves on the StabilTRAK cylinder. Refer to Section 10.3.1, Stabil-TRAK Solenoid Valves.
Not OK
Replace check valve(s).
10-14
6036, 6042, 8042, 10042, 10054
31200353
An Oshkosh Corporation Company
JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: +1-717-485-5161 Customer Support Toll Free: 1-877-554-5438 Fax: +1-717-485-6417
JLG Worldwide Locations

JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia Phone: +61 265 811 111 Fax: +61 265 810 122 JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil Phone: +55 193 295 0407 Fax: +55 193 295 1025 JLG Industries (UK) Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England Phone: +44 (0)161 654 1000 Fax: +44 (0)161 654 1001 JLG Industries (Italia) s.r.l. Via Po. 22 20010 Pregnana Milanese - MI Italy Phone: +39 029 359 5210 Fax: +39 029 359 5845 JLG France SAS Z.I. de Baulieu 47400 Fauillet France Phone: +33 (0)5 53 88 31 70 Fax: +33 (0)5 53 88 31 79
JLG Deutschland GmbH Max-Planck-Str. 21 D - 27721 Ritterhude-lhlpohl Germany Phone: +49 (0)421 69 350 20 Fax: +49 (0)421 69 350 45
JLG Equipment Services Ltd. Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N.T. Hong Kong Phone: +852 2639 5783 Fax: +852 2639 5797
JLG Europe B.V. Polaris Avenue 63 2132 JH Hoofddorp The Netherlands Phone: +31 (0)23 565 5665 Fax: +31 (0)23 557 2493
JLG Polska UI. Krolewska 00-060 Warsawa Poland Phone: +48 (0)914 320 245 Fax: +48 (0)914 358 200
JLG Industries (Scotland) Wright Business Centre 1 Lonmay Road Queenslie, Glasgow G33 4EL Scotland Phone: +44 (0)141 781 6700 Fax: +44 (0)141 773 1907
Plataformas Elevadoras JLG Iberica, S.L. Trapadella, 2 P.I. Castellbisbal Sur 08755Castellbisbal, Barcelona Spain Phone: +34 93 772 4 700 Fax: +34 93 771 1762
JLG Sverige AB Enkopingsvagen 150 Box 704 SE - 176 27 Jarfalla Sweden Phone: +46 (0)850 659 500 Fax: +46 (0)850 659 534
www.jlg.com

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Service Manual

Models 6036, 6042, 8042, 10042 & 10054

An Oshkosh Corporation Company

6036, 6042, 8042, 10042, 10054

6036, 6042, 8042, 10042, 10054

Section 1 Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2 General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 4 Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6036, 6042, 8042, 10042, 10054

Section 5 Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 7 Engine - Cummins QSB3.3T/QSB4.5T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 8 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6036, 6042, 8042, 10042, 10054

Section 9 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 10 Stabil-TRAK System and Boom Interlock System . . . . . . . . . . . . . . . . . . . . . . . . . .

6036, 6042, 8042, 10042, 10054

6036, 6042, 8042, 10042, 10054

Section 1 Safety Practices

6036, 6042, 8042, 10042, 10054

OPERATION & SAFETY MANUAL

DO NOT OPERATE TAGS

6036, 6042, 8042, 10042, 10054

1.6.1 1.5.1 Safety Alert System and Signal Words

6036, 6042, 8042, 10042, 10054

Safety Practices 1.6.3 General Hazards

6036, 6042, 8042, 10042, 10054

Section 2 General Information and Specifications

6036, 6042, 8042, 10042, 10054

General Information and Specifications

REPLACEMENT PARTS AND WARRANTY INFORMATION

6036, 6042, 8042, 10042, 10054

General Information and Specifications

Values for Zinc Yellow Chromate Fasteners

Torque Loctite 242 or 271 OR Vibra-TITE 111 or 140 K=.18

Torque Loctite 262 OR Vibra-TITE 131 K=0.15

6036, 6042, 8042, 10042, 10054

Values for Zinc Yellow Chromate Fasteners

Torque Loctite 242 or 271 OR Vibra-TITE 111 or 140 K=.18

Torque Loctite 262 OR Vibra-TITE 131 K=0.15

6036, 6042, 8042, 10042, 10054

SOCKET HEAD CAP SCREWS

Torque Loctite 242 or 271 OR Vibra-TITE 111 or 140 OR Precoat 85 K=0.16

Torque Loctite 262 OR Vibra-TITE 131 K=0.15

6036, 6042, 8042, 10042, 10054

SOCKET HEAD CAP SCREWS

6036, 6042, 8042, 10042, 10054

General Information and Specifications 2.2.2 Mertic Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners

Tensile Stress Area

Torque (Dry or Loctite 263TM)

6036, 6042, 8042, 10042, 10054

Values for Zinc Yellow Chromate Fasteners

Tensile Stress Area

Torque Dry or Loctite 263

Torque Loctite 262 OR Vibra-TITE 131