Service Manual Manual

ManualsBrandsSkyTrak ManualsSpecial machinery8042

An Oshkosh Corporation Company

Service Manual

Models

6036, 6042, 8042,

10042 & 10054

6036

S/N 0160039338 & After including

0160024571 & 0160037911

6042

S/N 0160039075 & After

8042, 10042 & 10054

S/N 0160029593 & After

31200353

Revised

April 14, 2011

Summary of content (230 pages)

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Service Manual Models 6036, 6042, 8042, 10042 & 10054 6036 S/N 0160039338 & After including 0160024571 & 0160037911 6042 S/N 0160039075 & After 8042, 10042 & 10054 S/N 0160029593 & After 31200353 Revised April 14, 2011 An Oshkosh Corporation Company
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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. April 14, 2011 - C - Revised pages 1-3, 2-3 thru 2-9, 2-12 thru 2-18 thru 2-24, 3-31, 3-49, 4-9, 5-4, 6-3, 6-5 & 9-5 thru 9-11.
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EFFECTIVITY PAGE ii 6036, 6042, 8042, 10042, 10054 31200353
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SECTION CONTENTS Section Subject Section 1 Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 1.2 1.3 1.4 1.5 1.6 1.7 Page 1-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation & Safety Manual . . . . . . . .
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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 5-1 Axle, Drive Shaft and Wheel Component Terminology (6036 & 6042) . . . . . . . . . . . . . Axle, Drive Shaft and Wheel Component Terminology (8042, 10042 & 10054) . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Assemblies. . . . .
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Section Subject 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 Page 9-1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information . . . . . . . . . . . . . . .
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Section iv Subject Page 6036, 6042, 8042, 10042, 10054
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Section 1 Safety Practices Contents PARAGRAPH 1.1 1.2 1.3 1.4 1.5 1.6 1.7 TITLE Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . .
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Safety Practices 1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS 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. 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.
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Safety Practices 1.6 SAFETY INSTRUCTIONS 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.
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Safety Practices 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.
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Section 2 General Information and Specifications Contents PARAGRAPH 2.1 2.2 2.3 2.4 2.5 2.6 TITLE Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.2 Mertic Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . .
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General Information and Specifications 2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION 1 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.
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General Information and Specifications 2.2 TORQUE CHARTS 2.2.1 SAE Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Lubricated Torque (Dry) Tensile Clamp Load Stress Area Torque Torque (Loctite® 242TM or 271TM (Loctite® 262TM or VibraTM OR Vibra-TITE 111 or TITETM 131) 140) Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.
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General Information and Specifications 2.2.1 SAE Fastener Torque Chart (Continued) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Tensile Clamp Load Stress Area Torque (Dry or Loctite® 263) K= 0.20 Torque Torque (Loctite® 242TM or 271TM (Loctite® 262TM or VibraTITETM 131) OR Vibra-TITE TM 111 or 140) K=.18 K=0.15 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.
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General Information and Specifications 2.2.1 SAE Fastener Torque Chart (Continued) SOCKET HEAD CAP SCREWS Magni Coating (Ref 4150701)* Tensile Clamp Load Stress Area See Note 4 Torque (Dry) K = .17 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.16 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.
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General Information and Specifications 2.2.1 SAE Fastener Torque Chart (Continued) SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners (Ref 4150707)* Tensile Stress Area Clamp Load See Note 4 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.18 Torque (Dry) K = .20 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.
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General Information and Specifications 2.2.2 Mertic Fastener Torque Chart CLASS 8.8 METRIC BOLTS CLASS 8 METRIC NUTS SizePITCH Tensile Stress Area Sq mm Clamp Load Torque (Dry or Loctite® 263TM) Torque (Lub) KN [N.m] [N.m] Torque Torque (Loctite® TM TM (Loctite® 262 242 or 271TM OR VibraOR VibraTITETM 131) TITETM 111 or 140) [N.m] [N.m] 3 0.5 5.03 2.19 1.3 1.0 1.2 1.4 3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3 4 0.7 8.78 3.82 3.1 2.3 2.8 3.4 5 0.8 14.20 6.18 6.2 4.6 5.
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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* SizePITCH Tensile Stress Area Clamp Load Torque (Dry or Loctite® 263TM) K = 0.20 Sq mm KN [N.m] Torque (Lub OR Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140) K= 0.18 Torque (Loctite® 262TM OR Vibra-TITE TM 131) K=0.15 [N.m] [N.m] 3 0.5 5.03 3.13 3.5 0.6 6.78 4.22 4 0.7 8.78 5.47 5 0.8 14.20 8.
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General Information and Specifications 2.2.2 Mertic Fastener Torque Chart (Continued) Magni Coating (Ref 4150701)* CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE* Tensile Stress Area SizePITCH Sq mm Torque Torque (Lub OR Loctite® Torque (Loctite® 262TM TM TM (Dry or Loctite® Clamp Load 242 or 271 OR Vibra-TITE TM See Note 4 263TM) OR Vibra-TITE TM 131) K = .17 111 or 140) K = .15 K = .16 kN [N.m] [N.m] [N.m] 3 0.5 3.5 0.6 5.03 6.78 4 0.7 8.78 5 0.8 14.20 6 1 20.10 12.
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General Information and Specifications 2.2.3 Hydraulic Hose Torque Chart O-Ring Face Seal & JIC Torque Chart Size ORFS JIC Flats Method 4 13 lb-ft (18 Nm) 13 lb-ft (18 Nm) 1.5 to 1.75 6 23 lb-ft (31 Nm) 23 lb-ft (31 Nm) 1 to 1.5 8 40 lb-ft (54 Nm) 40 lb-ft (54 Nm) 1.5 to 1.75 10 60 lb-ft (81 Nm) 60 lb-ft (81 Nm) 1.5 to 1.75 12 74 lb-ft (100 Nm) 85 lb-ft (115 Nm) 1.0 to 1.5 16 115 lb-ft (156 Nm) 115 lb-ft (156 Nm) 0.75 to 1.0 20 170 lb-ft (230 Nm) 170 lb-ft (230 Nm) 0.
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General Information and Specifications 2.3 2.3.1 SPECIFICATIONS Travel Speeds 6036 & 6042 8042, 10042 & 10054 First Gear 3.5 mph (5,6 km/hr) 3.5 mph (5,6 km/hr) Second Gear 5.5 mph (9,7 km/hr) 6 mph (9,7 km/hr) Third Gear 13.5 mph (22 km/hr) 14 mph (23 km/hr) 20 mph (32 km/hr) 20 mph (32 km/hr) Fourth Gear 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.
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General Information and Specifications 2.3.3 Electrical System Battery Type, Rating 12 BCI, Negative (-) Ground, Maintenance Free Quantity 3.3 Liter - 1, 4.5 Liter - 2 Reserve Capacity 3.3 Liter - 700 Cold Cranking Amps @ 0° F (-18° C) 4.5 Liter - 900 Cold Cranking Amps @ 0° F (-18° C) Group/Series Group 31 Alternator (6036 & 6042) 12V, 120 Amps Alternator (8042, 10042 & 10054) 12V, 100 Amps 2.3.4 Engine Performance Specifications Description 6036 & 6042 Engine Make/Model Cummins QSB3.
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General Information and Specifications 8042, 10042 & 10054 Description (S/N 0160040220 & After including 0160039850, 0160040126, 0160040129 & 0160040171) Engine Make/Model Cummins QSB3.3 Displacement 274 in3 (4,5 liters) Low Idle 900 rpm High Idle 2400 rpm Horsepower 110 hp (82 Kw) @ 2400 rpm Peak Torque 306 lb-ft (415 Nm) @ 1600 rpm Fuel Delivery Fuel Injection Air Cleaner 2.3.
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General Information and Specifications b. 6042 Size Tire Type Minimum Ply/ Star Rating 13.0 x 24 G-2/L-2 Bias Ply Traction 12 Ply 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 G-2/L-2 Bias Ply Traction 12 Ply 15.5 x 25 G-3/L-3 Bias Ply Rock 12 Ply 15.
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General Information and Specifications c. 8042 Size Tire Type Minimum Ply/ Star Rating 15.5 x 25 G-2/L-2 Bias Ply Traction 12 Ply 15.5 x 25 G-3/L-3 Bias Ply Rock 12 Ply 15.5 R 25 G2/L-2 Radial 1 Star DuraForce 14 Ply Size Tire Type Minimum Ply/ Star Rating 17.50 x 25 G-2/L-2 Bias Ply Traction 12 Ply 17.50 x 25 G-3/L-3 Bias Ply Rock 12 Ply 17.
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General Information and Specifications 2.4 FLUID AND LUBRICANT CAPACITIES Engine Crankcase Oil Capacity with Filter Change Cummins QSB3.3 7.6 quart (7,2 liter) Cummins QSB4.5 11.0 quart (10,4 liter) Type of Oil 15W-40 CH Fuel Tank Capacity Type of Fuel 37 gallon (140 liter) #2 Diesel Cooling System System Capacity Cummins QSB3.3 6.3 gallon (23,8 liter) Cummins QSB4.5 5.
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General Information and Specifications Axles 8042 Before S/N 0160038967 including 0160038971 10042 Before S/N 0160038368 including 0160038375, 0160038378, 0160038379, 0160038381 & 0160038383 10054 Before S/N 0160038740 excluding 0160021270, 0160036713, 0160036715 & 0160036723 Differential Housing Capacity Front Axle 9.5 quart (9 liter) Rear Axle 10.6 quart (10 liter) Wheel End Capacity Front Axle 1.7 quart (1,6 liter) Rear Axle 1.
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General Information and Specifications 2.5 2.5.
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General Information and Specifications 2.5.2 50, 250 & 1st 500 Hour EVERY 50 Check Boom Wear Pads Check Washer Fluid Level (if equipped) Check Battery Lubrication Schedule EVERY 250 Change Engine Oil and Filter* Check Axle Oil Level Check Wheel End Oil Levels Change Air Filter Elements Check Boom Chain Lubrication Schedule 1st 500 Change Axle Oil Change Wheel End (S/N 0160037788 Oil (S/N 0160037788 & After) & After) OH4142 Note: Engine oil and filter service interval can be extended.
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General Information and Specifications 2.5.
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General Information and Specifications 2.5.4 2000 Hour EVERY 2000 Change Engine Coolant Engine Valve Lash Adjustment OH4601 Note: Valve Lash adjustment for QSB 3.3 engine ONLY. See Engine Manual for details.
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General Information and Specifications 2.6 LUBRICATION SCHEDULES a.
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General Information and Specifications b.
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General Information and Specifications c.
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General Information and Specifications d.
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General Information and Specifications e.
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Section 3 Boom Contents PARAGRAPH 3.1 3.2 3.3 3.4 3.5 3.6 3.7 TITLE Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom System - Three Section (6036, 6042, 8042 & 10042) . . . . . . . . . . . . . . . . . 3.3.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Assembly Maintenance . .
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Boom 3.8 3.9 3.10 3.11 3.12 3-2 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 . . . . . . . . . . . .
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Boom 3.1 BOOM SYSTEM COMPONENT TERMINOLOGY The following illustrations identify the components that are referred to throughout this section.
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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. 3.3 3.3.1 BOOM SYSTEM - THREE SECTION (6036, 6042, 8042 & 10042) Boom System Operation 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.
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Boom 3.4.2 Third Boom Section Removal 1. Remove any attachment from the quick attach assembly. Refer to Section 3.8.1, “Disconnecting from an Attachment.” 1 2 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.
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Boom 6 4 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. 5 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.
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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. 8 10 MH1021 3.
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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. MH1091 17. Remove the extend chain sheave (12). 3.4.4 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.
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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. 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. 9. Support the slave cylinder on the right side of the machine. Remove the rod end pins securing the cylinder in position.
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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.
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Boom 17. Install the Extend and Retract and Auxiliary (if equipped) tube assemblies to their appropriate bulkhead fittings. Secure with tube clamps. 3.4.6 Second Boom Section Installation 18. Uncap and connect the previously labeled Attachment Tilt and Auxiliary (if equipped) hydraulic hoses to their appropriate bulkhead fittings. 6 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.
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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.
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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.
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Boom 18. Insert the shoulder bolt from the top down and secure in place with a locknut. 15 14 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.
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Boom 3.5 3.5.1 BOOM SYSTEM - FOUR SECTION (10054) Boom System Operation 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.
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Boom 1 17 2 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. 19 MH1781 18. Remove the top and side wear pads on the inside of the third boom section.
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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.
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Boom 9 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.
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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.
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Boom 7. Remove the remaining wear pads, shims and hardware. Label and tag each set of wear pads being removed. 5. Remove the retract chain by pulling it out the rear of the boom. 8. Inspect all wear pads for wear. Refer to Section 3.9, “Boom Wear Pads.” 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.
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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.
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Boom 6 7 5 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.
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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.
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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.
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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. 3.6.8 Fourth Boom Section Installation 0 6.0 ) 19 8 cm (49 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.
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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.
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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. 2 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.
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Boom 3.7 3.7.1 BOOM EXTEND AND RETRACT CHAINS Boom Chain Inspection WARNING 6 MH1451 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.
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Boom Following are some examples of dynamic shock loading which can impose abnormal loads above the endurance limit of a leaf chain. Edge Wear • 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.
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Boom Cracked Plates Distorted or Battered Link 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. 85 It is important, however to determine the cause of the crack before installing a new chain so the condition does not repeat itself.
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Boom 3.7.3 f. Expose Chains for Inspection 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.
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Boom 3.7.5 Boom Chain Tension Check 3.7.6 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. 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. 2 3. Slowly, fully extend the boom and retract it about halfway.
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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.” 6 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.
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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 11 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.
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Boom 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 is not mounted in the last hole in the anchor plate. 14 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.
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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.
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Boom d. Component/Assembly Verification 3.7.8 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 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.
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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.
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Boom 3.7.9 Retract Chain 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. washer must be smaller than the diameter of the threads on the clevis.
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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.
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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.
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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. 2 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.
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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.
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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. 11. Coat the threads of the threaded clevis with multipurpose grease. 7 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.
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Boom 18. Install the boom rear cover. until all the tension on the retract chain is relieved. Shut the engine OFF. 19. Properly connect the battery. 20. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. Note: Record the location of the shoulder bolt to ensure correct installation. 11 d. Fourth Boom Section Retract Chain Removal and Replacement 1. Park the machine on level ground.
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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.
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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.
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Boom 3.8 QUICK ATTACH ASSEMBLY 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. Extend the boom out approximately 10 ft (3,05 m), ground the attachment and tilt the carriage backward. Shut the engine OFF. 4. Exit the machine using both hand holds.
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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 Wear Pad Inspection 1 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.
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Boom BOOM EXTEND AND RETRACT CHAINS 3.10 3.10.1 Boom Chain Inspection 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.
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Boom Distorted or Battered Link Plates Edge Wear 85 2 1 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.
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Boom Cracked Plates 3.10.3 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. • Stress Corrosion Cracking - The 10 outside link plates are particularly susceptible to stress corrosion cracking (10). 9 1.
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Boom 3.10.4 Chain Lubrication 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. 3.11 Forks should be cleaned and inspected prior to being attached to carriage.
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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 Remedy 1. Broken hydraulic hose(s) or tube(s) and/or connections leaking. 1. Locate break, replace hose(s) or tube(s), tighten connections. 2. Extend/retract hydraulic system not operating properly. 2. Refer to Section 8.4, “Hydraulic Circuits.” 3. Faulty extend/retract cylinder. 3. Repair cylinder.
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Boom Problem 6. Drooping chain, or jerky boom extend or retract functions. 7. Boom will not raise or lower. 8. Excessive Lift/Lower cylinder pivot pin noise and/or wear. 6036, 6042, 8042, 10042, 10054 Cause Remedy 1. Chain(s) tension not properly adjusted. 1. Adjust chain(s). 2. Chain(s) stretched or binding. 2. Replace chains as needed. Refer to Section 3.7, “Boom Extend and Retract Chains.” 3. Wear pads loose, contaminated, excessively worn or damaged. 3. Replace wear pad. Refer to Section 3.
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Boom Problem 9. Rapid boom pad wear. Cause Remedy 1. Incorrect wear pad gap. 1. Check wear pad gaps and correct as needed. Refer to Section 3.9, “Boom Wear Pads.” 2. Rapid cycle times with heavy loads. 2. Reduce cycle times. 3. Contaminated, corroded or rusted wear pad sliding surfaces. 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. Operating in extremely dusty/ abrasive conditions. 4.
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Section 4 Cab and Covers Contents PARAGRAPH 4.1 4.2 4.3 4.4 4.5 TITLE Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Cab and Covers 4.1 OPERATOR 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.
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Cab and Covers WARNING DO NOT service the machine without following all safety precautions as outlined in the “Safety Practices” section of this manual. 4.2 4.2.1 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 left, right and lower dash panels.
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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.
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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. 4 MH6210 5 5. Remove the lower dash panel. 6.
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Cab and Covers 4.3.4 Joystick Assemblies These removal and installation instructions apply to the boom control, attachment tilt/sway and auxiliary hydraulic joysticks. 4 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.
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Cab and Covers • Move the joystick handle to the left, activating the frame sway function. The boom should SWAY LEFT. Auxiliary Control Joystick 8 • Move the joystick handle to the right, the auxiliary attachment should LOWER/OPEN. 7 • 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. 4.3.5 6 Windshield Wiper Assembly Refer to Section 9.
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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.
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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. 19. Carefully begin to lift the cab. Stop and check that all wiring, hydraulic hoses and fasteners are disconnected and removed. 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. 20.
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Cab and Covers 2 1 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.
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Section 5 Axles, Drive Shafts, Wheels and Tires Contents PARAGRAPH 5.1 5.2 5.3 5.4 5.5 5.6 5. 5.8 5.9 TITLE 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.
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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.
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Axles, Drive Shafts, Wheels and Tires 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.
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Axles, Drive Shafts, Wheels and Tires 5.3 GENERAL INFORMATION 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.
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Axles, Drive Shafts, Wheels and Tires 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.
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Axles, Drive Shafts, Wheels and Tires 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.
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Axles, Drive Shafts, Wheels and Tires 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. 4 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. 4 18. Start the engine.
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Axles, Drive Shafts, Wheels and Tires 7 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.
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Axles, Drive Shafts, Wheels and Tires 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. 12.
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Axles, Drive Shafts, Wheels and Tires 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.
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Axles, Drive Shafts, Wheels and Tires 5.5 AXLE ASSEMBLY AND DRIVE SHAFT TROUBLESHOOTING Problem 1. Excessive axle noise while driving. 2. Intermittent noise when traveling. 3. Vibration or intermittent noise when traveling. 6036, 6042, 8042, 10042, 10054 Cause Remedy 1. Oil level too low. 1. Fill oil to correct level. Refer to Section 2.4, “Fluid and Lubricant Capacities.” 2. Axle and/or wheel end housings filled with incorrect oil or oil level low. 2.
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Axles, Drive Shafts, Wheels and Tires Problem 4. Oil leaking from axle (differential housing and/or axle housings). 5. Oil leaking from wheel end housing (planet carrier). 6. Oil leaking from steering cylinder. 5-12 Cause Remedy 1. Drain and/or inspection plugs loose and/or o-rings damaged or missing. 1. Replace o-rings as needed and tighten plugs to 96 lb-ft (130 Nm). 2. Hose fittings loose. 2. Tighten fittings. 3. Axle shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces.
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Axles, Drive Shafts, Wheels and Tires Problem 7. Axle overheating. 8. High steering effort required. 9. Slow steering response. 10. Excessive noise when brakes are engaged. 11. Brakes will not engage. 12. Brakes will not hold the machine or braking power reduced. 6036, 6042, 8042, 10042, 10054 Cause Remedy 1. Oil level too high. 1. Fill oil to correct level with Mobilfluid 424® ISO 46. Refer to Section 2.4, “Fluid and Lubricant Capacities.” 2.
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Axles, Drive Shafts, Wheels and Tires 5.6 DRIVE SHAFTS TO TRANSMISSION 5.6.1 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.
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Axles, Drive Shafts, Wheels and Tires 5.7 WHEELS AND TIRES 5 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.
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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. 3 5 1 7 10 TREAD “ARROWS” MUST POINT FORWARD 9 8 2 6 4 OY1220 4. Tighten lug nuts in an alternating pattern as indicated in figure. Torque to 430-470 lb-ft (583-637 Nm). 5. Remove machine from supports. 5.8 BRAKES 5.8.
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Axles, Drive Shafts, Wheels and Tires 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. 2 4.
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Axles, Drive Shafts, Wheels and Tires 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.
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Section 6 Transmission Contents PARAGRAPH 6.1 6.2 6.3 6.4 6.5 TITLE Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Specifications and Maintenance Information. . . . . . . . . . . . . . . . Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.1 Transmission Removal . . . . . . . . .
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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.
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Transmission WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. 6.2 TRANSMISSION SERIAL NUMBER entering during the replacement process. Avoid spraying water or cleaning solution onto or near the transmission shift solenoids and other electrical components. 6.4.
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Transmission 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-to- transmission and transmission-to-axle drive shafts. Refer to Section 5.6.3, “Drive Shaft Removal.” 12. Remove the hydraulic pump. Refer to Section 8.6.1, “Pump Replacement.” 2 4 16.
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Transmission 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. 3 4 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.
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Transmission 12. Uncap and connect the previously labeled transmission oil cooler inlet and out hoses at the transmission. 8 13. Install the hydraulic pump. Refer to Section 8.6.1, “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.
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Transmission 6.5 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.
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Transmission Problem 2. Low or no pump flow or pressure. 3. Low clutch pressure. 4. Lack of power. 6-8 Cause Remedy 1. Low oil level. 1. Fill transmission to correct level with Mobilfluid 424® ISO Grade 46. Refer to Section 2.4, “Fluid and Lubricant Capacities.” 2. Transmission filled with incorrect oil, or oil contaminated. 2. Drain transmission and fill to correct level with Mobilfluid 424® ISO Grade 46. Refer Section 2.4, “Fluid and Lubricant Capacities.” 3. Pump suction pipe screen clogged.
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Transmission Problem 5. Transmission overheating (oil above 120° C (248° F)). 6. Grinding or “clunking” noise from transmission. 6036, 6042, 8042, 10042, 10054 Cause Remedy 1. Low oil level. 1. Fill transmission to correct level with Mobilfluid 424® ISO Grade 46. Refer to Section 2.4, “Fluid and Lubricant Capacities.” 2. Clogged radiator. 2. Remove debris from the radiator. 3. Transmission filled with incorrect oil, or oil contaminated. 3.
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Transmission Problem 7. Oil leaking from transmission. 6-10 Cause Remedy 1. Oil leaking from vent (high oil level). 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. Drain plug loose and/or o-rings damaged or missing. 2. Replace o-rings as needed and tighten plug to 26 lb-ft (35 Nm). 3. Hose fittings loose. 3. Tighten fittings. 4.
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Section 7 Engine - Cummins QSB3.3T/QSB4.5T Contents PARAGRAPH 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 TITLE Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.2 Component Terminology - Cummins - QSB3.3T/QSB4.5T . . . . . . . . . . . . Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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.
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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.
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Engine - Cummins QSB3.3T/QSB4.5T 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. 7.3 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.
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Engine - Cummins QSB3.3T/QSB4.5T 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.
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Engine - Cummins QSB3.3T/QSB4.5T 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.
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Engine - Cummins QSB3.3T/QSB4.5T f. Fuel/Hydraulic Oil Tank Installation 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. 7.7.
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Engine - Cummins QSB3.3T/QSB4.5T 2. If previously removed, install the exhaust pipe (13). 3. Install the exhaust pipe (13) into the muffler (10). 6. Remove the clamps securing the hose (3) to the air cleaner assembly. 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.
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Engine - Cummins QSB3.3T/QSB4.5T 7.9 7.9.1 ENGINE REPLACEMENT Engine 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.
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Engine - Cummins QSB3.3T/QSB4.5T 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.
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Engine - Cummins QSB3.3T/QSB4.5T 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. 5.
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Engine - Cummins QSB3.3T/QSB4.5T 7.
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Section 8 Hydraulic System Contents PARAGRAPH 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 TITLE Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.1 Pressure Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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.
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Hydraulic System 8042, 10042 & 10054 LIFT/LOWER CYLINDERS SLAVE CYLINDERS ATTACHMENT TILT CYLINDER EXTEND/ RETRACT CYLINDER 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 OUTRIGGER CYLINDERS (10042 & 10054 ONLY) MAIN CONTROL VALVE STEERING CYLINDER (FRONT) STEERING CYLINDER (REAR) OUTRIGGER VALVE (10042 & 10054 ONLY) MH3441 6036, 6042, 8042, 10042, 1
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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.
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Hydraulic System 8.3.1 Pressure Checks and Adjustments 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.
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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 Gauge Fittings 2, 3, 4, 5 4000 psi gauge (280 bar gauge) Unit equipped with fittings from factory. 6, 7, 8, 10 1000 psi gauge (70 bar gauge) Unit equipped with fittings from factory.
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Hydraulic System c.
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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 2475 - 2525 rpm - Flow rate should be 28-32 GPM (1,8-2,0 liter/sec) Test Location 2 Adjust.
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Hydraulic System Test Location 8 Adjust. Location C Component Description Auxiliary Hydraulics 6036, 6042, 8042, 10042, 10054 Pressure Reading 3000 psi (207 bar) Pressure Test Procedures 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.
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Hydraulic System d. Pressure Specifications (6042) ATTACHMENT TILT CYLINDER FRONT AXLE FRAME SWAY CYLINDER FTR FTB AUXILIARY HYDRAULICS Ø .040 E FRONT STEERING CYLINDER Ø .047 R LS ATTACH TILT AUX T IN FRAME EXT/RET T Ø .089 BRAKE VALVE LFT/LWR MAIN CONTROL VALVE T P Ø .089 LS Ø .029 Ø .089 8 SHUTTLE VALVE UNLOADER VALVE Ø .
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Hydraulic System Test Location 1 Test Location 2 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 2475 - 2525 rpm - Flow rate should be 34-40 GPM (2,1-2,5 liter/sec) Valve Port VG Adjust.
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Hydraulic System Test Location 7 Adjust. Location D 8 N/A 8 N/A 9 8-12 Valve Port PBG G1 E Component Description Secondary Function Manifold Pressure Reading 500-600 psi (34-41 bar) Pressure Test Procedures 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. Brake Valve 400 psi (28 bar) With engine OFF, pump brake pedal twice.
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Hydraulic System e.
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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 2475 - 2525 rpm - Flow rate should be 48.
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Hydraulic System Test Location 8 Adjustment Location N/A Component Description Brake Valve (Service Brake Pressure) Pressure Reading minimum 550 psi (38 bar) 9 D Auxiliary Hydraulics 3000 psi (207 bar) 10 N/A Stabilizer Cylinder 75-150 psi (5,2-10,3 bar) 6036, 6042, 8042, 10042, 10054 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.
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8-16 A B C D E F G H 37.9 GPM 8 RATED SPEED 2500 RPM 41.7 GPM HIGH IDLE 2750 RPM 15.9 GPM LOW IDLE 1050 RPM 3.5 IN 3 4000 PSI HOIST CYLINDER - 5.00 X 2.75 X 39.65 4000 PSI 65 PSI PRESSURE PORT SHUTTLE IN LOAD SENSE OUT TANK 10um TANK 7 25 PSI 2750 PSI 3500 PSI BYPASS TO TANK 4000 PSI 250 PSI EXTEND CYLINDER - 4.50 X 3.00 X 102.
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6036, 6042, 8042, 10042, 10054 A B C D E F G H 8 8 37.9 GPM RATED SPEED 2500 RPM 41.7 GPM HIGH IDLE 2750 RPM 15.9 GPM LOW IDLE 1050 RPM 3.5 IN 3 4000 PSI HOIST CYLINDER - 5.00 X 2.75 X 44.36 4000 PSI HOIST CYLINDER - 5.00 X 2.75 X 44.36 65 PSI 7 PRESSURE PORT SHUTTLE IN LOAD SENSE OUT TANK 7 10um TANK 25 PSI BYPASS TO TANK 2750 PSI 3500 PSI 4000 PSI 250 PSI EXTEND CYLINDER - 4.50 X 3.00 X 102.
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8-18 A B C D E F G H 8 4000 PSI HOIST CYLINDER - 6.00 x 3.00 x 42.41 4000 PSI HOIST CYLINDER - 6.00 x 3.00 x 42.41 8 10um 7 25 PSI LOW IDLE 18.3 GPM HI IDLE 44.9 GPM RATED 41.6 GPM SHUTTLE IN 65 PSI TANK B A T 2A V 125 PCI HIGH HYD. OIL TEMP 3 3.84 IN/REV LOW IDLE-1100 RPM HIGH IDLE-2700 RPM RATED-2500 RPM HOIST 3000 PSI 4000 PSI EXTEND CYLINDER - 5.00 x 3.00 x 131.25 7 3 B 6 4A INLET A 11 2A G1 195 F 60~am 11 10~am 575 PSI STAND BY 3300 PSI 100 PSI 2B .
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6036, 6042, 8042, 10042, 10054 A B C D E F G H E B2 R.H. R 8 OUTRIGGER CYLINDER 5.00 X 3.00 X 13.31 A2 .156 OUTRIGGER VALVE E L.H. A1 B1 4000 PSI R LS HOIST CYLINDER - 6.00 x 3.00 x 42.41 4000 PSI HOIST CYLINDER - 6.00 x 3.00 x 42.41 8 LS P T 7 10um 25 PSI LOW IDLE 18.3 GPM HI IDLE 44.9 GPM RATED 41.6 GPM SHUTTLE IN 65 PSI TANK B 125 PCI A T 2A V 6 3 6 HIGH HYD. OIL TEMP 3 3.
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8-20 A B C D E F G H E B2 R.H. R 8 OUTRIGGER CYLINDER 5.00 X 3.00 X 13.31 A2 .156 OUTRIGGER VALVE E L.H. A1 B1 4000 PSI R LS HOIST CYLINDER - 6.00 x 3.00 x 42.41 4000 PSI HOIST CYLINDER - 6.00 x 3.00 x 42.41 8 LS P T 7 10um 25 PSI LOW IDLE 18.3 GPM HI IDLE 44.9 GPM RATED 41.6 GPM SHUTTLE IN 65 PSI TANK B 125 PSI A T T 6 P 1 FTR 4A 100 PSI 2B .03 11 2A G1 EXTEND B 195 F 60~am 11 G2 6 GPM MAX .
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Hydraulic System 8.5 HYDRAULIC RESERVOIR 5. Open the filler cap on the hydraulic oil reservoir. Remove the drain plug on the side of the hydraulic oil reservoir. 1 2 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.
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Hydraulic System 8.6 HYDRAULIC SYSTEM PUMP For internal service instructions contact your local authorized service distributor. 8.6.1 b. Pump Installation 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. Pump Replacement a. Pump Removal 1.
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Hydraulic System 8.7 VALVES AND MANIFOLDS 8.7.1 Main Control Valve The main control valve is mounted on the frame under the lower transmission cover. 3 The main control valve assembly consists of individual working sections with their own valve assemblies, each providing a specific hydraulic function. 4 a. Main Control Valve Removal 1.
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Hydraulic System Disassemble each Valve Section Assemble the Main Control Valve. 1. Carefully separate the load sense outlet section from the next section. 1. Place all three tie rods with the nuts through the end main control valve section. 2. Remove the o-rings from between the two sections. 2. Stand the end main control valve section on end. 3. Carefully separate each remaining sections, being careful not to lose the load sense shuttle ball. 4.
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Hydraulic System f. Main Control Valve Installation 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.
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Hydraulic System 8.7.3 Service Brake Valve 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.
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Hydraulic System 8.7.4 8.7.5 Brake Test Power Steering Valve 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. 3 1. Place the travel select lever in (N) NEUTRAL, engage the park brake, and start the engine.
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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. 4 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.
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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. 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. 7. Inspect for leaks and check the level of the hydraulic fluid in the reservoir. Shut the engine OFF. 3. Temporarily block up or support the raised boom.
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Hydraulic System 8.7.8 Outrigger Valve (10042 & 10054 only) 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. 3 Verify the correct operation of the outrigger valve solenoids before considering replacement of the valve. a. Outrigger Valve Removal 2 1.
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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.
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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.
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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.
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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.
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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 manufacturer’s axle literature.
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Hydraulic System 8.8.4 Cylinder Torque Specifications a. Lift/Lower Cylinder Model Nut Valve Locking Collar 6036, 6042 1750-2000 lb-ft (2373-2712 Nm) 30-35 lb-ft (41-47 Nm) 300-400 lb-ft (407-542 Nm) 8042, 10042, 10054 1735-1885 lb-ft (2352-2556 Nm) 30-35 lb-ft (41-47 Nm) 300-400 lb-ft (407-542 Nm) b.
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Hydraulic System f. Slave Cylinder Model Head Locknut Set Screw 6036 250-300 lb-ft (339-407 Nm) 675-750 lb-ft (915-1017 Nm) N/A 6042 300-350 lb-ft (407-475 Nm) 650-700 lb-ft (881-949 Nm) 3-4 lb-ft (4-5 Nm) 8042, 10042, 10054 300-400 lb-ft (407-542 Nm) 900-1050 lb-ft (1220-1424 Nm) N/A g.
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Hydraulic System This Page Intentionally Left Blank 8-38 6036, 6042, 8042, 10042, 10054
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Section 9 Electrical System Contents PARAGRAPH 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 TITLE Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1.1 General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . .
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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.
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Electrical System 9.2 SPECIFICATIONS Electrical system specifications are listed in Section 2, “General Information and Specifications.” 9.3 9.4 FUSES AND RELAYS 9.4.1 Engine Compartment SAFETY INFORMATION WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual.
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Electrical System 9.4.2 Cab Harness Fuses and Relays 6036, 6042, 8042 & 10042 10054 9 1 11 13 12 14 2 11 13 12 14 24 26 25 27 10 28 2 15 3 6 15 16 6 3 16 17 7 4 17 18 7 4 10 18 19 5 5 8 22 29 8 19 20 23 20 30 21 MAQ0350 21 No. Volt/ Amp 1 12 Volt 2 MAQ0340 Circuit No. Volt/ Amp Oil Temperature 21 40 Amp Road/Worklights (if equipped) 12 Volt Headlight Switch 22 7.5 Amp Outrigger 3 12 Volt Light Switch 23 7.
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6036, 6042, 8042, 10042, 10054 1 1 27C 1 1 27D_C 27C_C 7.5 22 27 AMPS 7.5 160 AMPS OPT1 7.
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9-6 152A1 152A2 sht1 22 1 INSTR_15F HR 4 INSTR_15F INSTR_15F 12 INSTR_15F 10 INSTR_15F 6 INSTR_15F 9 8 INSTR_15F 3 INSTR_15F 2 INSTR_15F 14 INSTR_15F 15 17 18_C 151 15 16_C 6 38 B5 6_C 16 15_C 151_C 18 17_C ENG_BULK2_15 A2 ENG_BULK1_15 B1 ENG_BULK2_15 B4 ENG_BULK2_15 A1 ENG_BULK1_15 C5 ENG_BULK1_15 C1 2G FUEL_SEND 2A TRANS_TEMP_SW 250 F sht 1 sht 1 HYD_OIL_TEMP_SW INT_GND 195 F ENG_WATER_TEMP_SW 210F ENG_OIL_PRESS_SW sht 1 sht 1 sht 1 10 PS
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6036, 6042, 8042, 10042, 10054 32_M -7 BSJ 6 BS_8F 7 8 5 5 7 1 6 6 6 BS_8F 8 7 2 9 7 2 +9 -7 30_W 6_W 9 +9 TW_10F 6C_W 6B_W 6A_W 6F_W 52_M 5 5 3 2 2 2 2 C H M 3 4 HEATER CIRCUIT BLOWER SWITCH B 1_H 4_H 3_H PARK A P C L H FRONT WIPER MOTOR 1B_W GROUND RUN TOP M WIPER MOTOR GRD M -7 7 1 +8 8 4 3 2 BS_8F BS_8F 3_BS 8_BS 3_M 3_F 8_M 51_M 2_BS 3A_BS BS_2F A CONNECTS TO FUSEBLOCK PIGTAIL WIRE 51 (SHEET 1) FW_8F 2 M B 2A_BS 2_W 1D_W
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9-8 B5 27D_C 27C_C 3B 3A 22 27 OPT2 160 AMPS OPT1 15 AMPS 3D 85 50_F 51_F sht 1 12 50 IR 51 86 30 12C_F 87 153A 3C 42-A 26 12A 87 A 113B 150 AMPS 12A_F 12B_F 19 113 113C 30 IGN_3M 2DD_C sht 1 1GN_5M 50 9 TR_12F 1 TR_12F B sht 1 RED 3 1 2 3 2 3 2 3 S6 S4 S5 VIOLET D2 D1 GREEN 12/8 12/7 BLUE 12/6 8 TR_12F 7 TR_12F 6 ZF DW3 TRANSMISSION SWITCH 4 1 4 1 4 E D E 4 3 1 ALT BN B 150_C 103_C 105_C 101_C 102A_C 104 111A 102
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6036, 6042, 8042, 10042, 10054 sht1 1 INSTR_15F 22 HR J12 TRANS TEMP J10 HYD OIL TEMP 6 17 18_C 151 15 A 16 A 6 38 B5 5 B1 18 17_C ENG_BULK2_15 A2 ENG_BULK1_15 A1 ENG BULK-15M 15 C5 2G FUEL_SEND 2A TRANS_TEMP_SW 250 F 16 sht 1 sht 1 INT_GND ENG BULK-15F HYD_OIL_TEMP_SW 15 16 sht 1 sht 1 sht 1 195 F 85 86 85 86 6_C 151_C ENG_BULK2_15 B4 ENG_BULK1_15 C1 2GG 38_C INSTR_15F ENG_BULK1_15 J2 BACKLIGHT J14 HI BEAM J15 TURN SIGNAL J7 PARK BRAKE J11 STAB TRA
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9-10 32_M 7 -7 9 BS_8F BSJ 6 7 8 5 5 7 1 6 BS_8F 8 7 2 +9 6C_W 6B_W -7 6 6 30_W 2 +9 9 6A_W 6_W 6F_W TW_10F 52_M 2_H 5 5 3 2 2 2 2 BS_8F TOP WIPER SWITCH 1 BS_8F C H M L 3 4 1 BLWR_5F 1_H 4_H 3_H C H FRONT WIPER MOTOR 1B_W GROUND RUN TOP M WIPER MOTOR GRD M 3_BS 3_M 3_F 8_M 51_M 8 7 1E_W -7 1 +8 3 4 1 2_BS 3A_BS BS_2F A FW_8F 2 M B BS_2F 2A_BS 2_W 1D_W GROUND FRONT/TOP WASHER PUMP POWER 5_H 1F_W M BLOWER MOTOR BM_4F
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6036, 6042, 8042, 10042, 10054 WLO_8F 7 7 2 2 3 5 5 6 6 2 1_WL1_WL MAQ0460A CONNECT TO WIRES 49 & 23 OF LOGIC/OUTRIGGER CIRCUIT 10054 MACHINES ONLY (SHEET 4) 2 8 8 1 1 WLOC_2M A 3D_WL A 2C_WL 4C_WL 4B_WL WLOC_2F 3C_WL 3B_WL P A P BWLO_2F WLO_RR_P P WLO_LR_P A BWLO_2M WLO_RF_P P WLO_LF_P 7 1 3 7 1 3 RO42_8F 7 1 3 LO42_8F 7 1 3 2B_O 61_O 62_O 2A_O 63_O 64_O WIRE0542 C BEC_3M_c0 B A WIRE0544 WIRE0545 WIRE0546 BOOM EXTEND SENSOR & HARNESS USED ON
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Electrical System 9.6 9.6.1 ENGINE START CIRCUIT 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. Starter 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.
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Electrical System 9.7 CHARGING CIRCUIT Note: Record how the alternator is installed to ensure correct installation later. 6. Label and disconnect the wire leads attached to the alternator. 2 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.
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Electrical System 9.8 WINDOW WIPER/WASHER WINDSHIELD WIPER MOTOR 9.8.1 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. Windshield Wiper Motor 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.
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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. 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.
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Electrical System 9.8.3 c. Installation and Testing Windshield Washer Reservoir 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.
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Electrical System 8. Pull the control panel out from the dash panel, and if removing variable speed fan control, remove the cab harness connector. 9.10 9. If removing the temperature control knob, disconnect the cable connector and remove control knob. 9.10.1 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.
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Electrical System 5. Start the engine. Allow it to reach operating temperature and observe the operator 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.
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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.
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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.
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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. 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. 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. 4. Properly disconnect the battery. 10.
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Electrical System 9.10.7 7. Loosen the inside locknut (17) on the sensor (18). Boom Extend Interlock Sensor (10054 only) 8. Slide the sensor out of the bracket and remove. 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.
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Electrical System 9.10.8 9.11 Outrigger Pressure Switches (10054 Only) DISPLAY MONITOR AND GAUGES 9.11.1 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.
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Electrical System 9.12 DASH SWITCHES c. Inspection and Replacement 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 To determine the proper operation of the ignition key switch, test the terminals on the back of the switch for continuity with an ohmmeter.
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Electrical System 9.12.2 c. Inspection and Replacement Dash Switches 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.
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Electrical System 9.13 TROUBLESHOOTING Example Fault Code Sequences 9.13.1 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.
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Electrical System 9.13.
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Electrical System Fault Code SPN Code FMI Code 245 647 4/4 253 98 1 Engine Oil Level 268 94 2 Injector Metering Rail 1 Pressure 269 1195 2 Antitheft Password Valid Indicator 271 1347 4 High Fuel Pressure Solenoid Valve Circuit - Low 272 1347 3 High Fuel Pressure Solenoid Valve Circuit - High 275 1347 7 Fuel Pumping Element Number 1 (Front) 9-28 Description Fan Control Circuit - Low 281 1347 7 284 1043 4/4 Fuel Pump Pressurizing Assembly 1 285 639 9 SAE J1939 Multip
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Electrical System Fault Code SPN Code FMI Code 429 97 4/4 Water-In-Fuel Indicator Sensor Circuit - Low Description 431 558 2/2 Accelerator Pedal or Lever Idle Validation Circuit - Erratic 432 558 13/13 433 102 2 434 627 2/2 Power Supply Lost with Ignition On - Erratic 435 100 2/2 Oil Pressure Switch Sensor Circuit - Erratic 436 105 2 441 138 1/18 Battery 1 Voltage - Low 442 138 0/16 Battery 1 Voltage - High 443 1043 4/4 Accelerator Pedal or Lever Position Sensor Supp
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Electrical System Fault Code SPN Code FMI Code 778 723 2 Engine Speed Sensor (Camshaft) Error - Erratic 779 703 11 Auxiliary Equipment Sensor Input #3 (OEM Switch) 784 1590 2 Loss of Communication with Adaptive Cruise Control 951 166 2 Cylinder Power Imbalance Between Cylinders 957 27 2 EGR Valve Position - Erratic 958 2795 2 VGT Position Sensor - Erratic 1117 627 2/2 1139 651 7 Injector Solenoid Driver Cylinder 1 - Not Responding 1141 652 7 Injector Solenoid Driver Cyl
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Electrical System Fault Code SPN Code FMI Code 1682 3362 11/31 Description 1683 3449 3 Catalyst Tank Heater Circuit - High 1684 3363 4 Catalyst Tank Heater Circuit - Low 1687 3050 0 1689 251 12/2 1692 3234 4 After treatment NOx Sensor - Low 1694 3234 2 After treatment NOx Sensor - Erratic Catalyst Reagent Dosing Unit Input Lines Catalyst Over Temperature Real-Time Clock Power Interrupt - Erratic 1697 3489 3 After treatment #1 Air Enable Actuator - High 1698 3489 4 Afte
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Electrical System Fault Code SPN Code FMI Code 2348 27 13/13 2349 2791 5/5 EGR Valve Control Circuit - Low 2351 2791 4/4 EGR Valve Control Circuit - Low 9-32 Description EGR Valve Failed Automatic Calibration Procedure 2352 2791 3/3 EGR Valve Control Circuit - High 2353 2971 6/6 Exhaust Gas Recirculation (EGR) Valve Control CIrcuit - High 2357 2791 7/7 Exhaust Gas Recirculation (EGR) Valve Control - Not Responding 2359 411 0/16 Exhaust Gas Recirculation (EGR) Differential Pre
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Section 10 Stabil-TRAK™ System and Boom Interlock System Contents PARAGRAPH 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 TITLE PAGE 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 . . . . . . . . . . . . . . . . . . . . . . . .
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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.
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Stabil-TRAK™ System and Boom Interlock System 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.
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Stabil-TRAK™ System and Boom Interlock System 10.3 STABIL-TRAK DESCRIPTION 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.
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Stabil-TRAK™ System and Boom Interlock System 10.4 STABIL-TRAK ELECTRICAL CIRCUIT OPERATION AND TROUBLESHOOTING (6042, 8042 & 10042) Note: Before using the 6042, 8042 and 10042 Stabil-TRAK 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.
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10-6 + REVERSE FORWARD 2F 1 2 107A Secondary Function Manifold Park Brake Solenoids SHIFTER ZF TRANSMISSION R N F 2E PB A 2HH 1 1 2 3 4 5 6 7 8 9 107B 45A2 GEAR GEAR GEAR GEAR B+ 3C REVERSE FORWARD B+ 7.
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Stabil-TRAK™ System and Boom Interlock System 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.” 10.5.1 Stabil-TRAK System Test Instructions • Test the Stabil-TRAK system with the machine on a level surface.
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Stabil-TRAK™ System and Boom Interlock System 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. FREE PIVOT MODE g. Check to be sure the Stabil-TRAK light is OFF. OH2500 Step 2 a. Start the engine. b. Turn the parking brake switch OFF. c.
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Stabil-TRAK™ System and Boom Interlock System 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°. LOCKED MODE e. Frame sway the machine no more than 5° to the right. Note: Observe that frame sway will be slower than normal during this test. f.
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Stabil-TRAK™ System and Boom Interlock System 10.6 STABIL-TRAK BOOM INTERLOCK ELECTRICAL CIRCUIT OPERATION AND TROUBLESHOOTING (10054) 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 properly.
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6036, 6042, 8042, 10042, 10054 30 REVERSE FORWARD 2K1 2K2 SHIFTER ZF TRANSMISSION R N F 2 51D Secondary Function Manifold Park PB A Brake Solenoids 51B Park Brake Interlock Relay Park Brake Light PB B 51C 51 51A 87 52 152A3 1 1 2HH 1 1 2 3 4 5 6 7 8 B+ B+ FORWARD REVERSE NEUTRAL GEAR GEAR GEAR GEAR 45A2 To Fuel Shutoff 34 3C 40A 26A 107B 9 Ignition Switch 152A 152A1 45B 152B 152A2 41B 87A 2B2 85 86 70A Park Brake Switch 42A 10A 45 113 104
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Stabil-TRAK™ System and Boom Interlock System 10.7 BOOM/OUTRIGGER INTERLOCK SYSTEM TEST (10054) Before performing the following Boom/Outrigger Interlock System Test, perform Section 10.5, “Stabil-TRAK 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.
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Stabil-TRAK™ System and Boom Interlock System Boom/Outrigger Interlock System Test Procedures BOOM EXTEND MODE 2 BOOM EXTEND MODE 1 Step 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.
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Stabil-TRAK™ System and Boom Interlock System 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.” Not OK Replace cartridge. Not OK Replace check valve(s). If OK Check solenoid cartridge in the Stabil-TRAK manifold. Refer to Section 10.3.
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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.