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1.
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3. MH6390 6036 6042 8042 10042 10054
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6. O BOOMANGLE BOOM EXTEND SENSOR INTERLOCK SENSOR FOUR SECTION BOOM SHOWN 10054 ONLY 9 2 6036 6042 8042 10042 10054 MAQ0360 Electrical System 9 2 SPECIFICATIONS Electrical system specifications are listed in Section 2 General Information and Specifications 9 3 SAFETY INFORMATION WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1 Safety Practices of this manual 6036 6042 8042 10042 10054 9 4 FUSES AND RELAYS 9 4 1 LI Engine Compartment d qr y The starter relay 1 one 250 amp fuse 2 and one 200 amp relay 3 for the cold start grid heater if equipped are located inside the engine compartment and are mounted on a bracket on the left side of the frame rail 120 9 3 Electrical System
7. X SLE ee x STZ X OFP IAO s 9 1 s MAQ0081A 8 17 6036 6042 8042 10042 10054 Hydraulic System c Model 8042 INVA 30 0538 diGL O OAH wg arg THM 1 dd sty War XOUEX MAQ0090A 6036 6042 8042 10042 10054 8 18 n Hydraulic System d Model 10042 SLEX SE LX SZ V SUBQNTAO Lal 157 005 X009 wu MAQ0100A 8 19 6036 6042 8042 10042 10054 Hydraulic System n e Model 10054 x 00 S ONAL 005 009 HIONAD w3obnuno i WEY X 009 19 wu MAQ0110A 6036 6042 8042 10042 10054 8 20 Hydraulic System n 85 HYDRAULIC RESERVOIR MH6180 The hydraulic reservoir 1 and the fuel tank are one unit They are located on the right side of the frame under a cover Occasionally fluid may seep leak or be more forcefully expelled from the filter head 2 when system pressure exceeds the rating of the filter he
8. 8042 10042 amp 10054 Electrical Schematic Continued Electrical System 8042 10042 amp 10054 9 5 2 lt sae 9 2 amis z d anm EL eg Sd ve save Lx wx HOLMS sy v v 1 LS TIVLOId we dur jaw HOLIMS DIVYA 9018384 OL SLOANI 30 IWNIWH3L 01 897 z 3 1 1 18919 Ter Tor LIVNIWHAL 9 LO3NNOO3 x90 t835nd Ea uu 1 133HS HOLIMS avis M v 01 5193 9 5 LOANNOOSIG o 5 TH az Ti ay wy Ww wa Tm Os TH ES HSHSVAVHSIdIA els ja a v j TH VE TH at sow EE Lx or prm Houms E s fe wild ew M3dlM OF LE 9 sor 2 ve we T aD T su doi Y am ue E n p plo E ran mmi Y ve wu wz 8 E C NS iu sJ MOL ak arua T s Wve wl LE _ MOL aru mz su VIO E Ts me 7 i HOLOSNNOO HNVd HOLIMS s 2 Cuz MLSNI OL LOBNI Wadi P amowo 1 9S s oi Mors T
9. Fault Code SPN Code FMI Code Description 1682 3362 11 31 Catalyst Reagent Dosing Unit Input Lines 1683 3449 3 Catalyst Tank Heater Circuit High 1684 3363 4 Catalyst Tank Heater Circuit Low 1687 3050 0 Catalyst Over Temperature 1689 251 12 2 Real Time Clock Power Interrupt Erratic 1692 3234 4 After treatment NOx Sensor Low 1694 3234 2 After treatment NOx Sensor Erratic 1697 3489 3 After treatment 1 Air Enable Actuator High 1698 3489 4 After treatment 1 Air Enable Actuator Low 1699 1761 2 Catalyst Tank Level Sensor Erratic 1711 3361 9 Dosing Control Unit Datalink Abnormal Update Rate 1712 3363 1 18 Catalyst Tank Heater Circuit Low 1713 3363 0 16 Catalyst Tank Heater Circuit High 1716 411 11 Auxiliary Temperature Sensor Input 1 Circuit 1717 3241 0 15 Exhaust Gas Temperature 1 High 1718 1322 11 31 Engine Misfire for Multiple Cylinders 1848 105 10 Intake Manifold 1 Temperature Abnormal Rate of Change 1849 3241 10 Exhaust Gas Temperature 1 Abnormal Rate of Change 1851 3249 10 Exhaust Gas Temperature 2 Abnormal Rate of Change 1892 84 1 18 Wheel Based Vehicle Speed Low 1911 157 0 Injector Metering Rail Number 1 Pressure High 2183 1072 4 Engine Brake Actuator Driver 1 Circuit Low 2185 3 3 Sensor Supply Voltage 4 Circuit High 2186 4 4 Sensor Supply Voltage 4 Circuit Low 2215 94 1 Fuel Pump Delivery Pressure Low 2216 94 0 Fuel Pump Deliver
10. 3 48 3 8 1 Disconnecting from an 3 48 3 8 2 Connecting to an 3 48 3 8 3 Quick Attach 3 48 3 8 4 Quick Attach 5 3 48 Boom Wear lt 3 49 3 9 1 Wear Pad 3 49 3 9 2 Wear Pad Installation and Lubrication 3 49 Boom Extend and lt 5 3 50 3 10 1 Boom Chain 3 50 3 10 2 Inspection 3 50 3 10 3 Expose Chains for 3 52 3 10 4 Chain Lubrication 3 53 SEE EE Da uat E ER M Sa Ere E 3 53 Troubleshooting 2 EEES 3 54 6036 6042 8042 10042 10054 Boom 3 1 BOOM SYSTEM COMPONENT TERMINOLOGY The following illustrations identify
11. 9 9 Gab Heater and Fan s cocer pete 9 10 Solenoids Sensors and 5 9 11 Display Monitor and Gauges 9 12 Dash Switches ree rm beoe nic Re bete ERE E XU MER 9 13 Troubleshooting gt Cede aca sait Section 10 Stabil TRAK System and Boom Interlock System 10 1 Stabil TRAK System Component Terminology 10 2 Boom Extend Interlock System Component Terminology 10054 Only 10 3 Stabil TRAK Description 10 4 Stabil TRAK Electrical Circuit Operation and Troubleshooting 6042 8042 amp 10042 10 5 Stabil TRAK System 5 10 6 Stabil TRAK Boom Interlock Electrical Circuit Operation and Troubleshooting 10054 10 7 Boom Outrigger Interlock System Test 10054 10 8 Stabil TRAK Hydraulic Circuit Operation and Troubleshooting 6036 6042 8042 10042 10054 9 1 9 2 9 3 9 3 9 3 9 5 9 12 9 13 9 14 9 16 9 17 9 23 9 24 9 26 10 1 10 2 10 3 10 4 10 5 10 7 10 10 10 12 10 14 Section Subject Page iv 6036 6042 8042 10042 10054 Section 1 Safety Practices Contents PARAGRAPH T
12. 4 3 4 3 Cab Component 2 20 6 0 cl err rr rrr ee eee 4 3 4 3 1 Steering Column and Steering 4 3 4 3 2 Service Brake 4 4 4 3 3 Throttle Pedal rayis ee Aca Ree de 4 5 4 3 4 Joystick 5 4 6 4 3 5 Windshield Wiper 4 7 4 3 6 Heater Defroster System If Equipped 4 7 4 4 Cab Removal all ie ee ence ee ee 4 8 4 5 Cab 4 9 6036 6042 8042 10042 10054 4 1 a Cab and Covers 415 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 HEATER AND A C CONTROLS OPTIONAL INSTRUMENT PANEL STEERING WHEEL TRANSMISSION 1 CONTROL LEVER ite KOS BOOM CONTROL SS e cc ue ae PARK Brake ASH gt SWITCH ATTACHMENT TILT SWAY CONTROL JOYSTICK AUXILIARY HYDRAULIC IGNITION CONTROL JOYSTICK SWITCH IF
13. 0 0552 Tighten or loosen the two extend chain adjustment locknuts 11 located at the rear of the boom Be sure each of the locknuts are adjusted equally so that each extend chain maintains the same tension Equal chain tension can be checked by the position of the yoke 12 on the first boom section The front of the yoke should be parallel with the front edge of the outer boom OA0513 If there is no adjustment left on the extend chains tighten the retract chain locknut 13 at the front on the underside of the boom Recheck chain tension Refer to Section 3 7 5 Boom Chain Tension Check 6036 6042 8042 10042 10054 Boom N J Z MA9451 5 Further chain adjustment can be achieved by loosening all three chain locknuts and moving the rear retract chain clevis 14 from the original mounting hole in the anchor plate to the next hole This is only acceptable when boom chain sag cannot be acquired and the chain elongation measurement is still less than 12 36 in 313 mm Follow the instructions in Section 3 7 7 b Component Assembly Verification 6 Recheck chain tension Refer to Section 3 7 5 Boom Chain Tension Check b Component Assembly Verification The third to second boom section separation should be checked when assembling new boom sections or chains or when the rear retract chain clevis has been moved forward on the ancho
14. 2 1 2 1 Replacement Parts and Warranty 2 2 2 2 verc pee Sou um Ad De ged edge oer 2 3 2 3 sese tata ce pet e elits melt baies Geel dandus enn eerie E 2 11 2 4 Fluid and Lubricant 2 16 2 5 Service and Maintenance 5 2 18 2 6 Lubrication Schedules 2 22 Section 3 BOOM c aA C DR A 3 1 3 1 Boom System Component 3 3 3 2 Safety Information x cel e ERROREM VR e RE eb bs 3 4 3 3 Boom System Three Section 6036 6042 8042 amp 10042 3 4 3 4 Boom Assembly 3 4 3 5 Boom System Four Section 10054 3 15 3 6 Boom Assembly 3 15 3 7 Boom Extend and Retract 5 3 28 3 8 Quick Attach Assembly 3 48 3 9 Boom Wear 3 49 3 10 Boom Extend and 5
15. 9 12 961 ewe eae 9 12 9 7 Charging Circuit A ee mom n 9 13 9 7 1 X 9 13 9 8 Window Wiper Washer Windshield Wiper Motor 9 14 9 8 1 Windshield Wiper 9 14 9 8 2 Skylight Wiper 9 15 9 8 3 Windshield Washer 9 16 9 9 Cab Heater and 9 16 9 9 1 Cab Heater lt 9 16 9 10 Solenoids Sensors and Senders 9 17 9 10 1 Coolant Temperature 9 17 9 10 2 Hydraulic Oil Temperature 9 18 9 10 3 Transmission Solenoid Valves 9 19 9 10 4 Transmission Temperature 9 19 9 10 5 Service Brake Switch 9 20 9 10 6 Angle Sensor 9 21 9 10 7 Extend Interlock Sensor 10054 9 22 9 10 8 Outrigger Pressure Switches 10054 9 23 9 11 Display Monitor and 9 23 9 11 1 Instrument
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17. 9 4 2 Cab Harness Fuses and Relays 6036 6042 8042 amp 10042 10054 roy TS UN SEN CIPUE GE 0 m xn 2 ME 26 11 d LM LT Ag 6 me M e 27 Ol 3 6 i t E nf es e ce f 3 ndo T 4 7 p n 10 n 28 4 m H 10 ien e 18 Po B j 1 1 139 une a 29 19 20 23 3 5 Ju 8 en 20 4 1 ep germ m cere 9 0350 21 MAQ0340 No Volt Circuit No Volt Circuit Amp Amp 1 12 Volt Oil Temperature 21 40 Amp Road Worklights if equipped 2 12 Volt Headlight Switch 22 7 5 Amp Outrigger 3 12 Volt Light Switch 23 7 5 Amp Outrigger 4 12 Volt Stabilizer Lock 24 12 Volt Park Brake Interlock 5 12 Volt Boom Switch 25 12 Volt Boom Extend Lockout 6 12 Volt Park Brake Disengage 26 12Volt Stabil TRAK Interlock 7 12 Volt Neutral Start 27 12 Volt Stabil TRAK Lock Up 8 12 Volt Back up 28 12 Volt Boom Extend Interlock 9 12 Volt Water Temperature 29 12 Volt Right Outrigger Lock 10 12 Volt Ignition 30 12 Volt Left Outrigger Lock 11 7 5 Amp Transmission 12 20 Amp Lights 13 15 Amp Horn Heater 14 10 Amp Wiper if equipped 15 10 Amp Stabilizer 16 10 Amp Steer Select 17 7 5 Amp Optional Cab Outrigger if equipped 18 10 Amp Park Brake 19 7 5 Amp Optional 20 40
18. 16 Inspect all wear pads for wear Refer to Section 3 9 Boom Wear Pads MH1091 17 Remove the extend chain sheave 12 3 4 4 First Boom Section Removal 1 Use a suitable overhead lifting device and sling attached to the ower cylinder remove slack from the sling MH1111 2 At the underside of the boom locate the retract chain locknut 13 Measure the amount of threads protruding beyond the locknut and record that measurement for reassembly of the chain Remove the locknut and flat washer 3 Remove the retract chain by pulling it out through the rear of the boom Place the retract chain on a clean surface 3 8 Label disconnect and cap the hydraulic hoses from the bulkhead fittings on the mounting plate 14 Remove the tubes from the bulkhead fittings At the rear right side of the boom label disconnect and cap the boom Extend Retract hoses from the bulkhead fittings on the mounting plate Cap the fittings to keep dirt and debris from entering the hydraulic system MH1151 Remove the tube clamps 15 and clamp covers to the Extend and Retract tubes under the boom At the rear right side of the boom label disconnect and cap the Extend and Retract tubes 16 from the bulkhead fittings Cap the fittings to keep dirt and debris from entering the hydraulic system 6036 6042 8042 10042 10054 Boom N J Z
19. MH1091 Install the double extend chain sheave 8 to the front of the second boom section With the sling still in place install the rod end of the Extend Retract cylinder pin and retaining ring Install the front bottom wear pads in the second boom section 3 4 7 Third Boom Section Installation MH1401 Stretch the Attachment Tilt and Auxiliary if equipped hoses out straight on a flat surface Measure from the male end of each hose back 196 in 498 cm and apply tape around each hose at that point The tape is for proper tensioning of the hoses during reassembly of the hose clamps Slide the elbow ends of the hoses down the third boom section and out the boom head Be careful not to cross the hoses as you pull them out Secure the hoses in place with hose clamps DO NOT tighten the hose clamps at this time MH1631 Install the hose clamp support bracket 9 and top left side wear pad to the third boom section Auxiliary hydraulics only Position the Attachment Tilt and Auxiliary hydraulic hoses with the edge of the tape at the hose clamps 10 Hold the hoses in this position and tighten the hose clamps 6036 6042 8042 10042 10054 Boom C E is 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 MH1651 6 Lay th
20. 7 en Dn A IN3S TOHINOO WaivaH La as wo Fu ep sansz b lt P wa ag mw ee T Y E ble g ON HO Hd sj L P Ann mo HIHO TE 5 xt SH THO LINDYID HOSN3S T3NVd LNSWNYLSNI si onng ena D mna D v XM Ou VA MS p b dez Mj ONAN jg med anum atone exa ist Ux p s we IS LLM ONA sand ona m w ost iv amog MS SS3ud 10 5N3 T NEETA apem 9 smog C sinner ona m 5 at 9 uH S sonner oy fe Ja M LIfYOHIO JO VE senes D 133 8 LH NAVOY 302 O1 S103NNOO c 133HS 1 D NN Ya Fah a0 YE SHIM OL SLOANNOD Pes 133Hs si 0 EE 99 LS n m 2 we Web 39r usu 21251 ane rec 662 uj s CO ak MAQ0160
21. Model Piston Head Set Screw Valves 6036 6042 440 500 lb ft 250 350 Ib ft 85 95 lb ft 30 35 Ib ft 597 678 Nm 339 474 Nm 115 129 Nm 41 47 Nm 8042 10042 10054 N A 250 350 Ib ft 85 95 lb ft 30 35 Ib ft 339 474 Nm 115 129 Nm 41 47 Nm h Side Tilt Carriage Cylinder If Equipped Head Locknut Valve 300 400 Ib ft 407 542 Nm 550 650 Ib ft 745 881 Nm 30 35 Ib ft 41 47 Nm i Outrigger Cylinder Model Head Locknut Valves 10042 10054 250 350 Ib ft 339 474 Nm 1650 1800 Ib ft 2237 2440 Nm 30 35 Ib ft 41 47 Nm 6036 6042 8042 10042 10054 8 37 Hydraulic System This Page Intentionally Left Blank 8 38 6036 6042 8042 10042 10054 Section 9 Electrical System Contents PARAGRAPH TITLE PAGE 9 1 Electrical Component 9 2 9 1 1 General 9 2 9 2 Eripe MA 9 3 9 3 Safety 9 3 9 4 Fuses and Relays 9 3 9 4 1 Engine Compartment 9 3 9 4 2 Cab Harness Fuses and 9 4 9 5 Electrical System Schematics 9 5 9 6 Engine Start
22. MA8391 The unloader valve 1 creates system pressure and distributes the hydraulic fluid for various machine functions via its load sense by to tank via the oil cooler and primary and secondary valve ports The unloader valve is secured to the frame toward the front of the machine near the main control valve a Unloader Valve Removal 1 Park the machine on a firm level surface level the machine fully retract the boom raise the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 6036 6042 8042 10042 10054 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 Temporarily block up or support the raised boom Open the rear door Allow the system fluids to cool Properly disconnect the battery oan 09 Label disconnect and cap the hydraulic hoses attached to the unloader valve Cap all fittings to prevent dirt and debris from entering the hydraulic system 7 Remove the hardware securing the unloader valve to the machine frame 8 Remove the unloader valve b Unloader Valve Disassembly DO NOT loosen disassemble or attempt to adjust any cartridges unless specifically instructed by the manufacturer Tampering with the cartridges will irrevocably alter pressure in the affected circuits c Unloader Valve Installation 1 Place the unloader valve in its original orien
23. 1451 ol iw pr Pee ud oraz E oT MES IM puer wal is Arom IM tae W wn erre eru 5ST 82 stows s Lx H j 088 J mowa T N 3H OW 4M O1 t 1338 we 848 OLIO3NNOO s urnon nex eras 4 8 01 OL LOINNOO row OT be OT als EE Wve we tae M 1 ems 1 133 H8 Ne Would ONLLO3NNOOSIG 1 981 SUM IM VE Mala 81 TIVL Id __HOUMS 72919 HOLO3NNOO IMS 8 OLIO3NNOO Hed TENYA HISNI OL LONI 9 11 6036 6042 8042 10042 10054 Electrical System 9 6 9 6 The a If th ENGINE START CIRCUIT 1 Starter MAQ0220 starter 1 is located on the left side of the engine Testing the Starter on the Engine e starter does not engage when the ignition key switch is turned check the following 1 The main fuse may be blown requiring replacement Check for the cause of the blown fuse There may be a defect in the ignition key switch ignition wiring or starter solenoid Check battery condition Clean the battery posts and the connectors at each end of the battery cables Check for broken wiring and damaged insulation on the wiring Replace all broken or damaged wiring
24. 5 9 23 9 12 DashSwitches suesc err ur 9 24 9 12 1 Ignition Key 9 24 9 12 2 Dash Switches 9 25 9 13 Troubleshooting 5 5 rrr A 9 26 9 13 1 Fault Detection 9 26 9 13 2 Flash Out of Fault Codes 9 26 9 13 3 Offboard 5 9 26 9 13 4 Engine Fault Codes 9 27 6036 6042 8042 10042 10054 9 1 Electrical System 9 1 ELECTRICAL COMPONENT TERMINOLOGY To understand the safety operation and service information presented in this section it is necessary that the operator mechanic be familiar with the name and location of the electrical components of the machine The following illustration identifies the components that are referred to throughout this section 9 1 1 General Overview COOLANT TEMPERATURE SWITCH DASH SWITCHES 23 VERE STARTER ARP MESS HEATER CONTROLS IGNITION TRANSMISSION TEMPERATURE SENDER TRANSMISSION SERVICE SOLENOID BRAKE VALVES SWITCH dg
25. 10 11 12 13 14 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 Support the slave cylinder on the right side of the machine Remove the rod end pins securing the cylinder in position Move the cylinder to a clean flat surface Repeat this procedure for the left side slave cylinder 18 MH1221 Remove the boom proximity sensor 18 from the right side boom pivot mounting plate Securely block up or support the right Lift Lower cylinder Remove the rod end pin Repeat this procedure for the left Lift Lower cylinder MH1241 Remove the boom pivot pins 19 to the frame While removing the pins note the location and quantity of shims between the outer boom and frame Using a sling or suitable support carefully lift the first boom section away from the machine Set the boom section down on a hard level surface Support the boom as required to allow removal of the Extend Retract cylinder from the underside of the boom Use a hoist and slings to support the Extend Retract cylinder At the base end of the cylinder remove a retaining ring from one side of the cylinder base end pin 6036 6042 8042 10042 10054 15 16 17 18 3 4 5 1 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
26. 19 Front Axle Install the front access panel 20 Close and secure the rear door Note The service brake circuit will need to be bled after axle installation Refer to Section 8 7 4 Brake Test 5 4 6 Axle Replacement 8042 10042 amp 10054 a Outrigger Removal 10042 amp 10054 only On Models 10042 and 10054 equipped with outriggers it is necessary to remove the outrigger assembly before removing the front axle 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the travel select lever in the NEUTRAL position engage the parking brake straighten all wheels and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated 3 Open the rear door Allow the system fluids to cool 4 Properly disconnect the battery 6036 6042 8042 10042 10054 5 MH3281 Label and disconnect the wiring harness connectors at both outrigger cylinder pressure switches 4 Remove the wire ties securing the wiring harness to the outrigger cylinders Tie a length of string to each pressure switch wiring connector and pull the harness out through the openings 5 at the rear of the outrigger housing Untie the strings from the wiring connectors and tape or otherwise secure the ends of the strings to the outrigger housing These strings will be used to pull the harness t
27. Check all connections at the starter solenoid key switch and wiring harness plugs Clean and tighten all connections If the starter still does not operate after these checks have been performed check the starting circuit Starter Circuit Checks Check wires and connections for looseness corrosion damage etc If a whirring noise is heard but the engine does not turn over the starter is spinning but not engaging the flywheel The starter drive or solenoid that pushes the drive forward to engage the flywheel may be defective Missing or damaged teeth on the flywheel can also prevent the starter from cranking the engine 9 12 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 For additional information on the starting circuit refer to Section 9 5 Electrical System Schematics Starter Removal Remove the starter only if it fails To remove the starter 1 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the rear and side engine covers Allow the system fluids to cool Properly disconnect the battery Remove the wires from the solenoid stud Remove the positive battery cable from the starte
28. MH6380 Note If the transmission is not shifting properly the transmission shift control switch travel select lever wiring harness or transmission shift solenoids 10 should be checked in order to determine which component is defective Specific information to determine which travel position and corresponding component is not responding can be found in the detailed transmission service instructions covering repair disassembly reassembly and adjustment information are provided in the ZF 4 WG 98 TC Repair Manual P N 5871 135 002 JLG P N 8990455 and can be obtained by calling your local Authorized Service Department The transmission should be checked serviced and repaired only by experienced service technicians who are aware of all safety instructions and particular component features Note Contact your local authorized Service Department if internal transmission repair is required during the warranty period 9 10 4 Transmission Temperature Sender a Transmission Temperature Sender Removal The transmission temperature sender 11 is threaded into the top of the transmission housing 1 Park the machine on a firm level surface level the machine fully retract the boom raise the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operat
29. 1 Ke HYDRAULIC OIL COOLER MH6170 6036 6042 8042 10042 10054 8 13 n Hydraulic System Test Hydraulic Pump Flow Test Location 1 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 9 GPM 3 liter sec Test Adjustment Component Pressure Pressure Test Procedures Location Location Description Reading 2 A Pump Standby 550 600 psi Loosen load sense line at location to bleed off Pressure 38 41 bar pressure and then retighten line With engine at idle and no hydraulic functions operated check pump standby pressure If pressure is incorrect adjust top screw on compensator 2 N A Pump Pressure 3300 psi With engine at idle turn steering wheel all the way in Compensator 228 bar one direction Hold over relief and check maximum pump pressure If pressure is incorrect consult factory 3 C Main Control System Relief With engine at FULL throttle use the boom control Valve 2900 3100 psi lever to fully retract the boom Hold over relief and 200 214 bar check pressure If pressure is incorrect adjust and replace cartridge 3 N A Attachment Tilt 2900 3100 psi CONSULT FACTORY Relief 200 214 bar FORWARD or REARWARD 4 N A Secondary Load Sense With engine at idle load sense i
30. 4 When an overhauled or repaired transmission is installed thoroughly clean the oil cooler lines to and from the transmission 5 Drain and flush the entire system 6 Disconnect and clean all transmission cooler hoses When possible remove transmission lines from the machine for cleaning 7 Thoroughly clean transmission filter screens and 6 6 Uncap and connect the previously labeled transmission oil cooler inlet and out hoses at the transmission Install the hydraulic pump Refer to Section 8 6 1 Pump Replacement Install the engine to transmission and transmission to axle drive shafts Refer to Section 5 6 5 Drive Shaft Installation Clean the transmission oil filter mounting surface Apply a thin film of clean Mobilfluid 4249 ISO Grade 46 to the new transmission filter gasket Install the new filter and torque to 20 25 Ib ft 27 34 Nm Transmission oil may be added through the dipstick tube Remove the dipstick and add Mobilfluid 4249 ISO Grade 46 Check the oil level by taking intermittent dipstick readings as outlined in the appropriate Operation amp Safety Manual DO NOT overfill Reinstall the dipstick when finished Install the transmission covers Properly connect the battery Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel cases and replace transmission filter elements 8 12 MH6300 Reassemble all components and fill the transmission
31. Boom C E i e 10 11 12 13 14 Inspect the capscrews for signs of wear or damage Replace with new capscrews if damaged or worn 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 MH6510 At the rear of the boom attach one end of a wire to the threaded clevis 18 on the right side extend chain with a threaded eye or a flat washer tack welded to a capscrew The outside diameter of the eye or flat washer must be smaller than the diameter of the threads on the clevis Have an assistant pull the chain from the front of the boom while guiding the wire into the boom from the rear Remove the wire from the clevis but not from inside the boom Coat the threads of the threaded clevis with multi purpose grease Lay the new extend chain on top of the first boom section with the threaded clevis toward the front of the boom Attach the wire to the threaded clevis of the new extend chain using a threaded eye or a flat washer tack welded to a capscrew The outside diameter of the eye or flat washer must be smaller than the diameter of the threads on the clevis 6036 6042 8042 10042 10054 15 16 17 18 19 20 21 22 23 2601 Pull the
32. di E eB a cu SPEM v 8 4337 4 a 5 8 2 g i uua rb Rb E EE 58 E _ 3 35 sj p al 8 PEE M Em 4 ied d 1 E 38 at E E Hi XA ON E bis at et 8 3 e 85 S al 1 9 F FE d 4 3 je ped 8 6036 6042 8042 10042 10054 MAQ0150B 9 5 Electrical System 6036 amp 6042 Electrical Schematic Continued 6036 amp 6042 9 5 1 wat WE AINO S2HOIDIHOM m Hem OF TIM eaz wrens O 4 gr wee 35000 stows PE Mg 1 133HS OLSIO3NNOO TM zaz nd CS DEJ snoronsom anon ons U Wve we Wiz 4 LEE We wal 1 5 weve IV1Old HOLO3NNOO QNO HLSNI OL 1O3NNOO 090 aman iria ty m m Ly 3 ges cu qoo OW VIHO 9 m s uvm y
33. 2 2 3 Hydraulic Hose Torque Chart O Ring Face Seal amp JIC Torque Chart Size ORFS JIC Flats Method a der SET dire 6 t Es tee 8 P NS a NS 1 510 1 75 10 he Nm 1 5 to 1 75 2 ionis 40 7 ib OE 24 n an Mn 0 75 to 1 0 32 N A 0 75 to 1 0 Note By definition the Flats Method will contain some variance Use the Flats Method only when accessibility with a torque wrench is not possible Torque Wrench 1 Identify the appropriate application and refer to the above chart for the correct torque value If equipped lubricate o ring with hydraulic oil Hand tighten the swivel nut until no lateral movement of the swivel nut can be detected Average hand torque is 3 Ib ft 4 Nm Use the double wrench method while tightening to avoid hose twist Torque wrench must be held at the center of the grip Apply constant force until it clicks After the connection has been properly tightened mark a straight line across the connecting parts indicating that the connection has been properly tightened 2 10 Flats Method 1 If equipped lubricate o ring with hydraulic oil Hand tighten the swivel nut until no lateral movement of the swivel nut can be detected Average hand torque is 3 Ib ft 4 Nm Mark a dot on one of the swivel nut flats and another dot in line on the hex of the adapter it s connecting to Use the double wrench method w
34. 8 0 mm One or two hardened washers are to be used on each wear pad bolt except where noted otherwise DO NOT use more than two hardened washers Use only one hardened washer if mounting bolts are recessed Wear Pad Bolt Torque 3 8 16 Bolt 31 Ib ft 42 Nm Torque wear pad bolts after shimming is completed Lubricate the face and pockets of each wear pad after being installed Boom Section Wear Pad Pathway Lubrication Clean and lightly grease all wear pad pathways with Mystik Tetrimoly grease Clean and lightly grease the hose carrier guide bar pathways with Mystik Tetrimoly grease 3 49 Boom CY 2 3 10 BOOM EXTEND AND RETRACT CHAINS 3 10 1 Boom Chain Inspection A WARNING Worn pins stretched or cracked links or corrosive environments can cause chain failure A chain failure could result in uncontrolled boom movement loss of load or machine instability Under normal operating conditions the boom chains will need to be inspected every 250 hours of operation The retract chains need to be exposed and inspected every 1000 hours of operation Environmental conditions and dynamic impulse shock loads can drastically affect normal operating conditions and require more frequent inspection intervals Environments in which material handling vehicles operate can vary widely from outdoor moisture to temperature to mildly corrosive or highly corrosive industrial atmospheres
35. 9 Install the fuel hydraulic oil tank cover 10 Properly connect the battery 11 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 12 Close and secure the rear door 7 6 3 1 Drain and flush the fuel tank if it was contaminated After Fuel System Service 2 Vent air from the fuel system in accordance with the instructions found in the appropriate Operator amp Safety Manual 3 Fill the fuel tank with fresh clean diesel fuel as required 7 7 ENGINE EXHAUST SYSTEM Rattles and noise vibrations in the exhaust system are usually caused by misalignment or parts When aligning the system leave all capscrews and nuts slightly loose until all parts are properly aligned then tighten all fasteners working from the front of the system to the rear When replacing the muffler also replace the tail pipe Before assembling components use exhaust system sealer at all slip joint connections When installing exhaust system components allow sufficient clearance between the components and other pipes hoses and wiring that could be adversely affected by excessive heat 6036 6042 8042 10042 10054 7 7 1 Exhaust System Removal 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the travel select lever in the N NEUTRAL position engage the parking brake and shut the engine OFF 2 Place a Do Not Operate Tag on bo
36. Change Hydraulic Filter OH4132 6036 6042 8042 10042 10054 General Information and Specifications Ay 2 5 2 50 250 amp 1st 500 Hour P a Check Boom Check Check Washer Lubrication Wear Pads Battery Fluid Level Schedule if equipped Change Engine Check Axle Check Wheel Change Air Check Boom Oil and Oil Level End Oil Levels Filter Elements Chain Filter Lubrication Schedule Change Axle Oil Change Wheel End S N 0160037788 Oil S N 0160037788 amp After amp After OH4142 Note Engine oil and filter service interval can be extended See Engine Manual for details 6036 6042 8042 10042 10054 2 19 General Information and Specifications 2 5 3 2 20 500 amp 1000 Hour Change Fuel Filter amp Strainer Transmission Oil amp Filter Check Boom Chain Tension Lubricate Boom Chain Check Wheel Lug Nut Torque Change Hydraulic Axle Oil Fluid amp Filters Check Boom Check Wear Pads Fan Belt Change Wheel End Oil Check Air Intake System Check Axle Brake Discs Lubrication Schedule OH4152 6036 6042 8042 10042 10054 General Information and Specifications A 2 5 4 2000 Hour Change Engine Engine Coolant Valve Lash Adjustment OH4601 Note Valve Lash adjustment for QSB 3 3 engine ONLY See Engine Manual for details 6036 6042 8042 10042 10054 2 21 Ay General Information and Specificati
37. Electrical System 8042 10042 amp 10054 Electrical Schematic Continued 8042 10042 amp 10054 9 5 2 9 9 arua UN WO3 008 aipin mi CM 4 THE 4 i ON HHO en As Hoa iHd Dy SEND Eg Umi u no D 5 dag BOSNSSTTANVE INSINITTHISNI 3 M Housisay Doni FINS BO sonno m E lt P ZHNO Db AN Mn UA 07 gt a da quas and ami us D EE mu MS RUM VINO srpnne ona m mats vans e imp E 1 T d Ei noums ane STAWALI QAHI NOLLVQIIVA Y son oa fan ia Sis E mw SHOIVOIONI m WO3 anum PUE ANNO9 Viddo M 14 om th d sue Lm E 1 syn woa 3 fd 4 dHL anum 57 D som 4
38. Main e gt 6036 6042 8042 10042 10054 Electrical System 9 5 ELECTRICAL SYSTEM SCHEMATICS The following Ladder Diagrams may be used to further investigate electrical circuits If a resolution cannot be found contact your local authorized service distributor 9 5 1 6036 amp 6042 Electrical Schematic 4 Yu T amp ChB aL fe ge te at te at 3 P0 cm cm d EE 7 kis 1j 4 4d Paa 111 dd SM 999 0 amp N 58 g E amp 5 E E IC E E ot EP F fir id ER aF ld MES FEE lul H yet wl i Biol i t si a 9 5 5 a INE 4 a 4 E m ME Xe E e chy rh 4 d Ts 1
39. T Installation and Testing Hold wiper motor up toward cab top and install the cab harness connectors With the help of an assistant insert the wiper motor through the roof hole and have the assistant thread the nut onto the wiper motor shaft Ensure that the motor housing is facing the front of the cab Install the wiper arm onto the wiper motor shaft Install the screws through the plastic motor cover and into the top locknut plate and tighten 5 Connect washer hose to top hose fitting 10 Properly connect the battery Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel the ignition key to the RUN position and turn skylight wiper switch to the ON position Ensure wiper stays on the window through a full stroke Turn the skylight wiper switch to the OFF position Engage the washer switch and ensure washer fluid is sprayed on the skylight window Turn the ignition key switch to the OFF position Close and secure the rear door 9 15 Electrical System 9 8 3 Windshield Washer Reservoir MA8351 The windshield washer motor and reservoir 7 is a unit and cannot be serviced separately a Removal 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Ta
40. a Outrigger Valve Removal 1 Park the machine on a firm level surface level the machine fully retract the boom raise the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Temporarily block up or support the raised boom Open the rear door Allow the system fluids to cool Properly disconnect the battery Remove the transmission covers E Label disconnect and cap the hydraulic hoses and the electrical plugs connected to the outrigger valve 8 Remove the two flange nuts and two carriage bolts securing the outrigger valve to the frame Remove the outrigger valve from the machine 9 Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools b Outrigger Valve Disassembly Cleaning Inspection and Assembly 1 Place the outrigger valve assembly on a suitable work surface 8 30 MH3881 2 Remove the solenoid valve assemblies 2 from the outrigger valve by removing the four capscrews 3 Discard the four o rings 3 Remove the shuttle cartridges 4 from the outrigger valve 4 Clean all components with a suitable cleaner before inspection 5 Inspect the solenoid cartridges for proper operation Check by shifting the spool to ensure that it is functioning properly Check th
41. correct level with Mobilfluid 4249 ISO Grade 46 Refer Section 2 4 Fluid and Lubricant Capacities Clean repair and or replace suction pipe Replace central shaft Repair or replace pump assembly 3 Low clutch pressure Incorrect oil level Main pressure valve stuck open Broken or worn coupling shaft or piston o rings Pressure reducing valve stuck open Fill transmission to correct level with Mobilfluid 4249 ISO Grade 46 Refer to Section 2 4 Fluid and Lubricant Capacities Clean the valve spool and housing Replace coupling and or o rings Clean the valve spool and housing 4 Lack of power Park or service brake dragging Low engine rpm causes converter stall Pump output pressure is low Clutch discs worn or damaged Transmission overheating Refer to Section 8 4 Hydraulic Circuits Adjust the engine rpm to specifications Refer to Transmission Service Manual Refer to Section 6 5 Transmission Troubleshooting Problem 2 Low or no pump flow or pressure Replace clutch discs Refer to Section 6 5 Transmission Troubleshooting Problem 5 Transmission overheating oil above 120 C 248 F 6 8 6036 6042 8042 10042 10054 Transmission Problem Cause Remedy 5 Transmission overheating oil above 120 C 248 F
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43. 14 to the threaded clevis with a threaded eye or a flat washer tack welded to a capscrew The outside diameter of the eye or flat 6036 6042 8042 10042 10054 washer must be smaller than the diameter of the threads on the clevis The wire or string will be used to pull the chain back through the boom during reassembly 8 Remove the locknut and flat washer holding the retract chain threaded clevis to the mounting tab Note Record the location of the shoulder bolt to ensure correct installation MH2551 9 Atthe rear of the boom locate the two retract chain anchor plates holding the retract chain to the third boom section just in front of the retract chain sheave Remove the locknut and shoulder bolt 15 holding the retract chain clevis to the anchor plates The two anchor plates can remain in place on the third boom section 10 From the rear of the boom pull the retract chain out of the rear of the boom 11 Inspect wear and condition of the booms chains clevis chain sheaves Extend Retract cylinder chain rods clevis anchors and all mounting hardware Replace a worn or damaged chain DO NOT attempt to make any repairs to the chain Note Chains and clevis are wear items and experience the same stress DO NOT attempt to repair a chain Replace a stretched or damaged chain with a new part Always replace both the chain and the clevis 12 Remove the string from the old chain and attach it to the new
44. 2 26 6036 6042 8042 10042 10054 C L J CY C Section 3 Boom Contents PARAGRAPH TITLE PAGE 3 1 Boom System Component 3 3 3 2 Safety 3 4 3 3 Boom System Three Section 6036 6042 8042 amp 10042 3 4 3 3 1 Boom System 3 4 3 4 Boom Assembly 3 4 3 4 2 Third Boom Section 3 5 3 4 8 Second Boom Section 3 6 3 4 4 First Boom Section 3 8 3 4 5 First Boom Section Installation 3 9 3 4 6 Second Boom Section Installation 3 11 3 4 7 Third Boom Section Installation 3 12 3 5 Boom System Four Section 10054 3 15 3 5 1 Boom System 3 15 3 6 Boom Assembly 3 15 3 6 1 Fourth Boom Section 3 15 3 6 2 Third Boom Section 3 18 3 6 3 Second Boom Section
45. 2 3 5 TES ordre Ee Eget t bb del dox ae deae pe bos A 2 13 2 4 Fluid and Lubricant Capacities 2 16 2 5 Service and Maintenance Schedules 2 18 2 5 1 10 amp USE DO eie ERR ERR ERGO ERR ERG 2 18 2 5 2 50 250 amp 1st 500 2 19 2 5 3 500 amp 1000 2 20 2 5 4 2000 HOUT i iue c beh e esee ond he Ge ack 2 21 2 6 Lubrication Schedules 2 22 6036 6042 8042 10042 10054 2 1 Ay General Information and Specifications 2 1 REPLACEMENT PARTS AND WARRANTY INFORMATION EX Before ordering parts or initiating service inquiries make note of the machine serial number The machine serial number plate 1 is located as indicated in the figure Note The replacement of any part on this machine with any other than JLG authorized replacement parts can adversely affect the performance durability or safety of the machine and will void the warranty JLG disclaims liability for any claims or damages whether regarding property damage personal injury or death arising out of the use of unauthorized replacement parts A warranty registration form must be filled out by the JLG distributor signed by the purchaser and returned to JLG when the machine is sold and or put into
46. 42 1120 4870 4090 3070 3680 4290 NO 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 MY3171 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED w m m 20 22 24 27 30 33 36 42 83 5 3 3 4 4 5 6036 6042 8042 10042 10054 General Information and Specifications 2 2 2 Mertic Fastener Torque Chart Continued Values for Zinc Yellow Chromate Fasteners Ref 4150707 CLASS 10 9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12 9 SOCKET HEAD SCREWS M5 Torque Torque Lub OR Loctite amp Torque Dry or Loctite 242 or 271 OR Loctite 262 OR 263 Vibra TITE 111 or Vibra TITE 131 K 0 15 Tensile Stress Area m 18 9 274 1160 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM MY3181 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR
47. 6036 6042 8042 10042 10054 8 9 Hydraulic System d Pressure Specifications 6042 gs ATTACHMENT TILT FRAME SWAY FRONT AXLE CYLINDER CYLINDER FTR FTB AUXILIARY HYDRAULICS M k II FRONT STEERING CYLINDER MAIN CONTROL VALVE oa LFT LWR EXT RET I SHUTTLE 1 VALVE UNLOADER VALVE LSG LS EXTEND RETRACT CYLINDER B a POWER STEERING STEER UNIT SELECT VALVE OPERATOR S CAB T P PS PBG PSG PPG PP PB SECONDARY FUNCTION MANIFOLD RIGHT PUMP LIFT LOWER CYLINDER LEFT LIFT LOWER CYLINDER STABILIZER CYLINDER FTR G1 BH LEFF SLAVE CYLINDER RIGHT SLAVE CYLINDER REAR STEERING CYLINDER REAR AXLE 27 HYDRAULIC OIL COOLER HYDRAULIC RESERVOIR MA9241 8 10 6036 6042 8042 10042 10054 n Hydraulic System Test Hydraulic Pump Flow Test Location 1 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 Test Valve Adjust Compo
48. 7 1 2 Component Terminology Cummins QSB3 3T QSB4 5T 7 3 7 2 Engine Serial 7 4 7 3 Specifications and Maintenance 7 4 7 4 Engine Cooling System 7 4 7 4 1 Radiator Pressure 7 4 7 4 2 Radiator Oil Cooler and Replacement 7 4 7 5 Engine Electrical 7 5 7 6 Fuel System heel ce RN ed e 7 5 7 6 1 Diesel Fuel ivo reb mt rk ED PEE s 7 5 7 6 2 Fuel Hydraulic Oil 7 5 7 6 3 After Fuel System 7 7 7 7 Engine Exhaust 7 7 7 7 1 Exhaust System 7 7 7 7 2 Exhaust System Installation 7 7 7 8 Air Cleaner 7 8 7 8 1 Air Cleaner Assembly Removal 7 8 7 8 2 Air Cleaner Assembly 5 7 8 7 9 Engine 7 9 7 9 1 Engine 7 9 7 9 2 Engine Insta
49. DO NOT apply an overload to the engine 7 2 6036 6042 8042 10042 10054 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 a J EONS 2 CONE EE E g Ves q D FUEL FILTER THERMOSTAT ALTERNATOR OIL FILTER 6036 6042 8042 10042 10054 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 SPECIFICATIONS AND MAINTENANCE INFORMATION For engine coolant and oil specifications and maintenance information refer to Section 2 General Information and Specifications Note Detailed Cummins engine service instructions covering disassembly inspection internal repair assembly adjustment and troubleshooting information are provided in the appropriate Cummins engine service manual 7 4 ENGINE COOLING SYSTEM 7 4 1 Radia
50. LHS OL orao L MAQ0460A 1 133HS oer WOU ONLLO3NNOOSIG son YOLVOIONI SIVEE XH Vd emou H3l4V 8291 IWLDId 7 HOLIMS OL 193NNOO ama YER anne ois HOLIMS ox z 1 133HS LHO L 13388 I SY OL 10 1014 STONY WOOS 8813 OL 812 US ad GVO 01 193NNOO XOHd STONY WOOS 309 O0 wor 133H8 ove amem ununi E 4 m dfi 1331 MS Sad H3OOIHLnO AKG 5 H3OOIHLDO amen ow Ter eso aren sean Res HG 5 Led z OT OS 8042 10042 amp 10054 Electrical Schematic Continued 8042 10042 amp 10054 9 5 2 ipio imi LINDU AINO SLHOTDIBOM 1 133HS AM WTOOMANO L
51. Low 148 0 Accelerator Pedal or Lever Position 1 Sensor Circuit High 151 110 0 0 Engine Coolant Temperature High Critical 153 105 3 3 Intake Manifold Air Temperature Sensor Circuit High 154 105 4 4 Intake Manifold Air Temperature Sensor Circuit Low 155 105 0 0 Intake Manifold 1 Temperature 187 1080 4 4 Sensor Supply Voltage Number 2 Circuit Low 195 111 3 3 Coolant Level Sensor Circuit High 196 111 4 4 Coolant Level Sensor Circuit Low 197 111 1 18 Coolant Level Low 221 108 3 3 Barometric Pressure Sensor Circuit High 222 108 4 4 Barometric Pressure Sensor Circuit Low 227 1080 3 8 Sensor Supply 2 Circuit High 234 190 0 0 Engine Crankshaft Speed Position 235 111 1 Coolant Level Low 237 644 2 External Speed Command Input Multiple Unit Synchronization 238 611 4 4 Sensor Supply 3 Circuit Low 241 84 2 2 Vehicle Speed Sensor Circuit 242 84 10 10 Vehicle Speed Sensor Circuit Tampering Has Been Detected 6036 6042 8042 10042 10054 9 27 Electrical System Fault Code SPN Code FMI Code Description 245 647 4 4 Fan Control Circuit Low 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
52. Low oil level Fill transmission to correct level with Mobilfluid 4249 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 Drain transmission and fill to oil or oil contaminated correct level with Mobilfluid 4249 ISO Grade 46 Refer to Section 2 4 Fluid and Lubricant Capacities 4 Excessive roading 4 Stop and idle the engine 5 Restriction in oil cooler hoses 5 Replace cooler hoses 6 Pump worn or damaged 6 Repair or replace pump assembly 7 Engine thermostat stuck 7 Replace engine thermostat 6 Grinding or clunking noise 1 Oil level too low 1 Fill oil to correct level Refer to from transmission Section 2 4 Fluid and Lubricant Capacities 2 Transmission filled with incorrect 2 Drain transmission and fill to oil correct level with Mobilfluid 4249 ISO Grade 46 Refer to Section 2 4 Fluid and Lubricant Capacities 3 Incorrect clutch engagement 3 Refer to Section 9 10 3 Transmission Solenoid Valves 4 Internal damage 4 Repair or replace parts as needed 5 Broken diaphragm flex plate 5 Replace diaphragm flex plate Refer to Section 6 4 1 Transmission Removal 6 Loose diaphragm flex plate 6 Tighten capscrews mounting capscrews 6036 6042 8042 10042 10054 6 9 Transmission Problem Cause Re
53. PB Released 42 Series Extension Limit 42 Series Extension Limit Relay gt Trans Fwd or Rev PB Released PB Applied By Interlock Sys Solenoid Outriggers Raised Trans Fwd or Rev Trans In Neutral By Interlock Sys Outriggers Raised Outriggers Lowered Solenoid 12A E DE Solenoid 12B DE Solenoid 3 DE DE E Solenoid 4A z 2 DE DE DE Solenoid 4B 2 DE DE DE Boom Angle Sensor 5 C C Boom Switch Relay ES E E DE Stabilizer Lock Relay DE DE E Stabilizer Light lt 2 Ignition Switch in Park Brake Switch 8 Park Brake Light i OFF DE OFF DE ON E BOOM EXTEND INTERLOCK SYSTEM TROUBLESHOOTING Boom Extend Interlock Sensor C Boom Extend Interlock Relay E DE DE Boom Extend Lockout Relay E DE DE Outrigger Pressure Switches Left Outrigger Lockout Relay DE E Right Outrigger Lockout Relay DE E Stabilizer Interlock Relay DE DE E Stabilizer Lock Up Relay DE DE E Extend Circuit Solenoid Valve E E E dE DE Park Brake Interlock Relay DE DE E Park Brake Disengage Relay E E DE Definitions Boom Retracted Less than 42 Series extension limit Boom Extended Boom at 42 Series extension limit or greater 10 10 PB Park Brake DE De energized E Energized 6036 6042 8042 10042 10054 Stabil TRAK System and Boom Interlock System Open Closed C
54. Prime the pump by filling the case drain port with fresh filtered hydraulic oil from a clean container before installing the case drain connector and hose Check all routing of hoses and tubing for sharp bends or interference with any rotating members tube and hose clamps must be tight Properly connect the battery Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel Close and secure the rear door Start the engine and run at approximately one third to one half throttle for about one minute without moving the machine or operating any hydraulic functions Inspect for leaks and check all fluid levels The hydraulic reservoir oil level must be to the middle of the sight gauge Pump Test Refer to Section 8 3 1 Pressure Checks and Adjustments 6036 6042 8042 10042 10054 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 The main control valve assembly consists of individual working sections with their own valve assemblies each providing a specific hydraulic function a Main Control Valve Removal 1 Park the machine on a firm level surface level the machine fully retract the boom raise the boom place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ign
55. Refer to Section 8 5 1 Hydraulic Oil Reservoir Draining 6 Properly disconnect the battery 7 Remove the transmission covers 8 Thoroughly clean the transmission and surrounding area including all hoses and fittings before proceeding OH2381 9 Place a suitable receptacle under the transmission drain plug 1 Remove the transmission drain plug and allow the transmission oil to drain into the receptacle 6 3 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 13 Label and disconnect the transmission temperature switch connector 2 and shift solenoid wiring harness connectors 3 14 Remove the capscrew securing the black wire 4 to the transmission housing and disconnect the wire DO NOT reinstall the capscrew at this time 15 Remove the capscrew securing the clamp 5 and wiring harness to the transmission housing and move the wiring harness safely out of the way DO NOT reinstall the capscrew at this time ES
56. a 1 Boom Extend Interlock Sensor Removal 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 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the rear door Allow the system fluids to cool Properly disconnect the battery 5 Make note of wire tie locations and clip wire ties where necessary 6 9 22 MH6121 Disconnect the boom interlock sensor electrical connector 16 7 Loosen the inside locknut 17 on the sensor 18 8 Slide the sensor out of the bracket and remove Boom Extend Interlock Sensor Installation Partially install inside locknut 17 onto the sensor 18 Make sure that there are four to six threads approximately 0 975 in 24 7mm and 1 0 in 25 4mm 19 between the outside locknut 20 and the end of the sensor Make sure that the wire harness is between the bracket and the sensor and slide the sensor into the bracket Connect the boom extend interlock sensor connector 16 to the boom extend harness connector Replace wire ties as necessary 6 Properly connect the battery Remove the Do Not Operate Tags from both the ignition key switch and the steering whe
57. coupler fitting or other component slowly and cautiously loosen the part involved A hissing sound or slow seepage of hydraulic fluid may occur in most cases After the hissing sound has ceased continue removing the part Any escaping oil should be directed into an appropriate container Cap or otherwise block off the part to prevent further fluid seepage Hydraulic system maintenance will at times require that the engine be operated Always follow safety precautions A major cause of hydraulic component failure is contamination Keeping the hydraulic fluid as clean as possible will help avoid downtime and repairs Sand grit and other contaminants can damage the finely machined surfaces within hydraulic components If operating in an exceptionally dirty environment change filters and inspect the fluid more often When servicing the system cap or plug hydraulic fittings hoses and tube assemblies Plug all cylinder ports valves and the hydraulic reservoir and pump openings until installation occurs Protect threads from contamination and damage 8 4 Some hydraulic functions are actuated by interfacing with electrical system components switches solenoids and sensors When the hydraulic system is not functioning properly check the electrical aspect of the malfunctioning circuit also 8 3 HYDRAULIC PRESSURE DIAGNOSIS JLG Parts Department has a kit available to use for hydraulic system maintenance and troubleshootin
58. instructions A WARNING NEVER weld or drill the boom unless approved in writing by the manufacturer The structural integrity of the boom will be impaired if subjected to any repair involving welding or drilling 6036 6042 8042 10042 10054 3 6 1 1 Remove any attachment from the quick attach assembly Refer to Section 3 8 1 Disconnecting from an Attachment Fourth Boom Section Removal Note replacing the fourth section boom remove the quick attach from the fourth section Refer to Section 3 8 3 Quick Attach Removal 2 Park the machine on a hard level surface level the machine fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 3 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 4 Open the rear door Allow the system fluids to cool 5 Move the Attachment Tilt joystick in both directions to relieve any trapped pressure in the Attachment Tilt system If the machine is equipped with Auxiliary controls move the Auxiliary hydraulic joystick in both directions to relieve any trapped pressure in the Auxiliary hydraulic system 6 Label disconnect and cap the hoses attached to the Attachment Tilt cylinder Cap all fittings to keep dirt and debris from entering the hydraulic system 7 If the machine is equipped with Auxi
59. on the second boom section 20 Remove the wire from the end of the clevis 21 Place the flat washer onto the threaded clevis Assemble a locknut onto the threaded clevis Turn the locknut only 2 or 3 turns onto the clevis to allow assembly of the other end of the retract chain 22 Atthe front of the boom disconnect the extend chain clevis from the anchor plates on the second boom section Remove the locknut holding the shoulder bolt to the anchor plates Pull the extend chain clevis from between the plates and lay over the front of the fourth boom section 23 Return to the operator compartment and start the engine and slowly retract the boom To avoid having the retract chain becoming entangled keep tension on the chain coming out the back of the boom Retract the boom as far as possible with the Extend Retract cylinder Turn the engine OFF 24 The fourth boom section will not retract completely and must be manually pushed in To avoid having the retract chain becoming entangled keep tension on the chain coming out the back of the boom while the fourth boom section is pushed in Note Care should be taken not to push the fourth boom section in too far If the fourth boom section is pushed in too far it could damage the hose reel at the back of the boom 25 Remove the wire from the anchor clevis at the rear of the boom Place the retract chain up and over the chain sheave in front of the hose reel assembly Place the clev
60. possible to see a section of the retract chain as the boom is slowly extended If there is ANY question that one or all the retract chains are damaged the boom should be removed and disassembled with the retract chains being inspected and replaced if necessary Note DO NOT attempt to repair a chain Replace a stretched or damaged chain with a new part Always replace both the chain and the clevis It is recommended that when any chain is replaced that all chains and clevis be replaced at the same time 6036 6042 8042 10042 10054 Boom C x 3 10 4 After inspection and before being returned to service chains must be lubricated with Mystik Tetrimoly Grease Chain Lubrication The lubricant must penetrate the chain joint to prevent wear Applying lubricant to the external surfaces will prevent rust but the chains should be articulated to make sure the lubricant penetrates to the working surfaces between the pins and links To prepare the chain for lubrication the chain plates should be brushed with a stiff brush or wire brush to clear the space between the plates so that lubricant can penetrate to the working surfaces Lubricant may be applied with a narrow paint brush or directly poured on but the chain should be well flooded with lubricant and the boom should be extended and retracted to be sure that the lubricant penetrates to the working surfaces All surplus lubricant should be wiped away
61. raise the machine using a suitable jack or hoist Place suitable supports beneath the frame and lower the machine onto the supports allowing enough room for axle installation Ensure that the machine will remain in place during axle installation 5 6 3 Using a suitable jack hoist or overhead crane and sling remove the axle from its support or holding stand Balance the axle and prevent it from tipping turning or falling while positioning it beneath the machine DO NOT raise or otherwise disturb the machine while installing the axle Keep the axle supported and balanced on the jack hoist or overhead crane and sling throughout the installation procedure 4 Install the capscrews securing the axle to the frame Torque to 600 680 Ib ft 813 922 Nm MT0822 Note new frame sway front or stabilizer rear cylinder bearings 3 have been installed in the axles or machine frame the fracture in the bearing race must be positioned at the 9 o clock position as shown below 5 Move the cylinder into position on the axle cylinder anchor Insert a cylinder mount pin through the cylinder and cylinder anchor Secure the cylinder mount pin with one capscrew and new locknut 6 Apply multi purpose grease through the self tapping lube fitting to lubricate the self align bearing and the cylinder mount pin 7 Install the drive shaft assemblies Refer to Section 5 6 5 Drive Shaft Installation 8 If reinstalling an axle pre
62. 1 Pressure High 451 157 3 Injector Metering Rail Number 1 Pressure Circuit High 452 157 4 Injector Metering Rail Number 1 Pressure Circuit Low 471 98 147 Engine Oil Level Low 488 105 0 16 Intake Manifold 1 Temperature High 497 1137 2 Multiple Unit Synchronization Switch Erratic 498 98 3 Engine Oil Level Sensor Circuit High 499 98 4 Engine Oil Level Sensor Circuit Low 523 611 2 Auxiliary Intermediate PTO Speed Switch Validation Erratic 527 702 3 Auxiliary Input Output 2 Circuit High 528 093 2 Auxiliary Alternate Torque Validation Switch Erratic 529 703 3 Auxiliary Input Output 3 Circuit High 545 1188 7 Turbocharger 1 Wastegate Control Not Responding 551 558 4 4 Accelerator Pedal or Lever Idle Validation Circuit Low 553 157 0 16 Injector Metering Rail 1 Pressure High 554 157 2 Injector Metering Rail 1 Pressure Erratic 559 157 1 18 Fuel Pump Delivery Pressure Low 584 677 3 3 Starter Relay Circuit High 585 677 4 4 Starter Relay Circuit Low 595 103 0 Turbocharger Number 1 Speed High 596 167 0 16 Electrical Charging System Voltage High 597 167 1 18 Electrical Charging System Voltage Low Moderately Severe 598 167 1 1 Electrical Charging System Voltage Low Most Severe 599 640 14 Auxiliary Commanded Dual Output Shutdown Special Instructions 649 1378 11 31 Change Lubricating Oil and Filter 687 103 18 Turbocharger Number 1 Speed Low 688 98 0 Engine Oil Level High 689 190 2 2 Engine Crankshaft Speed Position Erra
63. 10042 10054 MS T 3055 Rear 31200694 6036 6042 8042 10042 10054 Axles Drive Shafts Wheels and Tires hs 5 4 4 Axle Maintenance CLEANING Clean parts with machined or ground surfaces such as gears bearings and shafts with emulsion cleaners or petroleum based cleaners DO NOT steam clean internal components and the interior of the planetary hub and axle housing Water can cause corrosion of critical parts Rust contamination in the lubricant can cause gear and bearing failure Remove old gasket material from all surfaces DRYING Use clean lintless towels to dry components after cleaning DO NOT dry bearings by spinning them with compressed air this can damage mating surfaces due to lack of lubrication After drying lightly coat components with oil or a rust preventive chemical to help protect them from corrosion If storing components for a prolonged period wrap them in wax paper PERIODIC OPERATION REQUIREMENT Every two weeks drive the machine far enough to cause the drive train components to make several complete revolutions This will help ensure that internal components receive lubrication to minimize deterioration caused by environmental factors such as high humidity SUBMERSION If the machine has been exposed to water deep enough to cover the hubs disassemble the wheel ends and inspect for water damage and contamination If the carrier housing was submerged in water esp
64. 21 22 23 24 25 26 27 28 3 7 11 After the sheave is assembled apply a good grade of multi purpose grease to the grease fitting at the end of the pin Turn the sheave by hand to distribute the grease evenly Pull the extend chain up and around the sheave at the front of the third boom section Place the extend chain clevis between the mounting plates at the front of the third boom section Coat the saved shoulder bolt with anti seize compound and insert through the plates and clevis Secure the shoulder bolt in place with a locknut Tighten securely but the chain clevis should pivot freely At the rear of the boom tighten the locknut on the extend chain clevis until the amount of threads protruding beyond the locknut is the same as the measurement recorded during removal of the extend chain Check and adjust the extend chain tension Refer to Section 3 7 5 Boom Chain Tension Check Install the boom rear cover Properly connect the battery Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel Retract Chain Removal and Replacement 10054 c Third Boom Section Retract Chain Removal and Replacement Park the machine on level ground Place the transmission control lever NEUTRAL engage the parking brake switch level the boom and shut the engine OFF Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating tha
65. 307 TE ane 15 OL SLOANI 0 NETO d TT s Mod Inet aD ws f as x GH TW aoz a l1 X le lee h kb Ws N md wu sz a t 187002 9 DEJ my 1 LE Meum Me GE TH Bor jecur LE ME ear an aruba area es P pr T 8 z ww wo EEA mU D We D 1 133H8 3HIM IVLDId ws wi mas OL 8109 PAR Wow vi on Y IInOHIO E3IVSH Lj vi t 1 5 NUS 912 2 S3HIM BP Y smi Noa ies we Casa D Taro 2 cS wm ow ER pren f d 1 L33H8 SHIM 11018 n MOLON A We qu ipn pan EEA T Md in Wy LJ 01 SLO3NNOO Ly m e wwe Woz Wet Wu rim zx iol TIVLDId wor Bee ret ep re 1 133H8 SHIM M90183Sfi4 OL SLINI 6036 6042 8042 10042 10054 9 10 Electrical System KINO S3NIHOVW 99001 NO 5 SS3NHVH NaS one oaa ale a r 1 ANO S3NIHOVIN 73001 ae bil 007 30 le Mn S3HIM OL 193NNOO CEEI 002 OLSLO3NNOO
66. 4050 78000 1940 2630 1979 2025 1755 2379 1 5800 87700 2983 1640 2224 2300 3128 1974 2676 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 13 20 0 5000 0 1599 0 16 0 7500 0 3730 23800 407 1 2500 d 59600 1240 1681 1 8750 1 1550 64100 1460 1979 1491 1322 1792 8 ASSEMBLY USES HARDENED WASHER MY3141 6036 6042 8042 10042 10054 2 3 General Information and Specifications 2 2 1 SAE Fastener Torque Chart Continued Values for Zinc Yellow Chromate Fasteners Ref 4150707 SAE GRADE 8 HEX HD BOLTS amp GRADE 8 NUTS Bolt Dia Tensile Stress Area Clamp Load Torque Torque Loctite amp 242 or 271 Dry or Loctite 263 D OR Vibra TITE 111 or 0 20 140 18 Torque Loctite amp 262 or Vibra TITE 131 K 0 15 5 16 Ea 6 8 36 0 1640 0 01474 1320 43 10 60 68 1 4 143 164 5 6 38 0 3750 0 0775 7000 7 16 omm o o s me oe nm 40 0 1120 0 1120 0 00604 3 0 1900 0 01750 1580 0 2500 0 0318 2860 143 0 2500 0 0364 3280 164 43 2 0 3125 0 0524 4720 25 2 25 45 2 50 0 4375 0 1063 9550 70 2 0 4375 0 1187 10700 5 7 16 19 N m 35 35 70 95 110 0 5
67. 6 1 Transmission 6 1 TRANSMISSION ASSEMBLY COMPONENT TERMINOLOGY To understand the safety operation and maintenance information presented in this section it is necessary that the operator mechanic be familiar with the names and locations of the major assemblies of the transmission The following illustration identifies the components that are referred to throughout this section OIL FILL TUBE AND DIPSTICK VALVE BLOCK CONTROL CIRCUIT 1 OIL FILTER VALVE BLOCK CONTROL CIRCUIT 2 6 2 OUTLET COOLER HOSE RADIATOR MH6280 6036 6042 8042 10042 10054 Transmission A 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 o O 0 o 1 de o Q _ OH2381 The transmission serial number plate 1 is located on the pump side front of the transmission at the bottom right toward the machine frame Information on the serial number plate is required in correspondence regarding the transmission 6 3 TRANSMISSION SPECIFICATIONS AND MAINTENANCE INFORMATION For transmission oil specifications and maintenance information refer to Section 2 General Information and Specific
68. 6 DRIVE SHAFTS 5 6 1 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 Drive Shaft Inspection and Service Inspect areas where the drive shaft flange yokes and slip yokes mount to the drive shafts Attempt to turn each drive shaft in both directions Look for excessive looseness missing parts cracks or other damage Worn or damaged drive shafts and cross and bearing assemblies may cause an excessive amount of vibration or noise Note Any bolt removed from the drive shaft assembly MUST be replaced Do Not re torque 5 6 2 Refer to Section 2 6 Lubrication Schedules for information regarding the lubrication of the grease fittings on the drive shafts Drive Shaft Maintenance 5 6 3 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the transmission control lever NEUTRAL engage the park brake and shut the engine OFF Drive Shaft Removal 2 Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Properly disconnect the battery 5 Block the wheels 6 The drive shaft assembly is a balanced assembly Mark the yoke and axle transmis
69. 63 freely Tight 3 joints 3 resist flexing If the problem is caused by dirt or foreign substance packed in the joints clean and lubricate thoroughly before re installing the chain If the problem is caused by corrosion and rust or bent pins replace the chain 6036 6042 8042 10042 10054 Boom C x ind 3 7 3 Expose Chains for Inspection f Extend Chains 1 Park the machine on a firm level surface Place the transmission control lever in NEUTRAL engage the park brake switch and raise the boom to a horizontal level position 2 Fully extend the boom and shut the engine OFF The extend chains will be visible for inspection with the machine in this state While doing the chain inspection check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain If during the inspection any chain is found to be damaged or stretched the chain must be replaced It is recommended that when any chain is replaced that all the chains and clevises be replaced at the same time g Retract Chains The retract chains are only partially visible through the rear of the boom with all the sections retracted It is possible to see a section of the retract chain as the boom is slowly extended If there is ANY question that one or all the retract chains are damaged the boom should be removed and disassembled with the retract chains being inspected and repl
70. 8 0 Less than 8 0 Less than 8 0 Attachment Tilt Down 3 5 5 5 6 0 Less than 11 0 Less than 11 0 Less than 11 0 Frame Sway Left to Right with Boom Down 3 0 6 0 12 0 15 0 5 5 12 0 5 5 12 0 3 6 Frame Sway Left to Right 1 o WIL DBOIT ABOVE 40 23 0 3 03 23 0 33 0 23 0 33 0 23 0 33 0 and Emergency Brake Engaged Frame Sway Right to Left with Boom Down 4 0 8 0 12 0 15 0 4 0 8 0 4 0 8 0 4 0 8 0 Frame Sway Right to Left MU BONM ABOVE de 26 0 52 0 26 0 52 0 26 0 52 0 26 0 52 0 Engaged Outrigger Left or Right _ _ UP or DOWN 4 0 9 0 4 0 9 0 Outrigger Lett and 4 0 10 0 4 0 10 0 6036 6042 8042 10042 10054 Ay General Information and Specifications 2 3 3 Electrical System Battery Type Rating 12 BCI Negative Ground Maintenance Free Quantity 3 8 Liter 1 4 5 Liter 2 Reserve Capacity 3 8 Liter 700 Cold Cranking Amps 9 0 F 18 C 4 5 Liter 900 Cold Cranking Amps 0 18 C Group Series Group 31 Alternator 6036 amp 6042 12V 120 Amps Alternator 8042 10042 amp 10054 12V 100 Amps 2 3 4 Engine Performance Specifications Description 6036 amp 6042 Engine Make Model Cummins QSB3 3 Displacement 201 in 3 3 liters Low Idle 1100 rpm High Idle 2600 rpm Horsepower 99 hp 74 Kw 2600 rpm Peak Torque 306 Ib ft 415 Nm 1600 rpm Fuel Delivery Fuel Inj
71. 8 3 Steering 5 8 35 8 8 4 Cylinder Torque 5 8 36 6036 6042 8042 10042 10054 8 1 Hydraulic System 81 HYDRAULIC COMPONENT TERMINOLOGY To understand the safety operation and service information presented in this section it is necessary that the operator mechanic be familiar with the name and location of the hydraulic components of the machine The following illustration identifies the components that are referred to throughout this section 6036 amp 6042 LIFT LOWER CYLINDERS SLAVE CYLINDERS ATTACHMENT TILT CYLINDER EXTEND RETRACT CYLINDER HYDRAULIC FLUID RESERVOIR STEER SELECT FRAME SWAY 2 STABILIZER CYLINDER SQ CYLINDER 7 7 6042 ONLY ST ERING CYLINDER REAR SERVICE BRAKE SECONDARY VALVE FUNCTION MANIFOLD STEERING VALVE STEERING CYLINDER FRONT MA9251 8 2 6036 6042 8042 10042 10054 Hydraulic System 8042 10042 amp 10054 LIFT LOWER CYLINDERS SLAVE CYLINDERS EXTEND RETRACT ATTACHMENT TILT CYLINDER CYLINDER EXTEND LOCKOUT VALVE 10054 ONLY MAIN PUMP HYDRAULIC FLUID STEER SELECT i VALVE Ne FRAME SWAY CYLINDER STABILIZER CYLINDER SECONDARY FUNCTION MANIFOLD STEERING CYLINDER
72. Hold over relief and check pressure If 2900 3100 psi pressure is incorrect adjust or replace cartridge 200 214 bar 2 B Unloader Lift Lower Remove the carriage if attached With engine at full Valve Relief throttle use the boom control lever to lower boom fully 2900 3100 psi Hold over relief and check pressure If pressure is 200 214 bar incorrect adjust or replace cartridge 2 N A Attachment 3150 3250 psi CONSULT FACTORY Tilt Reliet 217 224 bar FORWARD or REARWARD 2 D Unloader Standby With engine at idle and no functions operated check Valve Pressure standby pressure If pressure is incorrect adjust or replace 250 300 psi differential pressure sense cartridge on the unloader 17 21 bar valve 3 N A Unloader Load Sense With engine at idle load sense at 0 psi With engine at Valve 0 3000 psi FULL throttle use the boom control lever to fully retract the 0 207 bar boom Hold over relief Pressure should be 2750 3000 psi 190 207 bar 4 E Secondary Steering Relief With engine at FULL throttle turn the steering wheel all the Function 2400 2600 psi way in one direction and hold while checking pressure If Manifold 165 179 bar pressure is incorrect adjust or replace the pressure reducing cartridge 5 F Secondary Park Brake With engine at idle park brake released and no functions Function minimum operated pressure should be 400 psi 28 bar minimum Manifold 400 psi 28 With engine at idle park brak
73. Overheating Cold running Incorrect tappet adjustment Sticking valves Incorrect high pressure pipes Worn cylinder bores Pitted valves and seats Broken worn or sticking piston ring s Worn valve stems and guides Restricted air cleaner Worn or damaged bearings Insufficient oil in sump Inaccurate gauge Oil pump worn Pressure relief valve sticking open Pressure relief valve sticking closed Broken relief valve spring Faulty suction pipe Restricted oil filter Piston seizure pick up Incorrect piston height Damaged fan Faulty engine mounting Incorrectly aligned flywheel housing or incorrectly aligned flywheel Faulty thermostat Restriction in water jacket Loose fan belt Restricted radiator Faulty water pump Restricted breather pipe Damaged valve stem oil deflectors if fitted Coolant level too low Blocked sump strainer Broken valve spring Exhauster or vacuum pipe leak Turbo impeller damaged or dirty Turbo lubricating oil seal leak Induction system leaks 6036 6042 8042 10042 10054 Section 8 Hydraulic System Contents PARAGRAPH TITLE PAGE 8 1 Hydraulic Component 8 2 8 2 Safety 8 4 8 3 Hydraulic Pressure 8 4 8 3 1 Pressure Checks
74. Remove the boom rear cover fi MH1752 5 At the rear of the boom locate the extend chain locknuts 7 Record the amount of threads extending beyond both the locknuts These measurements will be the starting point for adjustment of the extend chains after installation 6 Remove and replace the extend chains one at a time Remove the right side locknut and flat washer holding the clevis to the anchor plate SH1811 7 Atthe front of the boom remove the capscrew 8 and locknut holding the right side extend chain clevis to the yoke plates Replace the capscrew if damaged or worn 3 37 Boom 10 MH6510 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 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 Inspect wear and condition of the booms chains clevis chain sheaves Extend Retract cylinder chain rods clevis anchors and all mounting hardware Replace any worn or damaged parts DO NOT attempt to make any repairs to the chain Note Chains and clevis are wear items and experience the same stress DO NOT attempt
75. THESE TORQUE VALUES DO NOT APPLY CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER 151 6036 6042 8042 10042 10054 General Information and Specifications 2 2 1 SAE Fastener Torque Chart Continued Bolt Dia Tensile Clamp Load Torque SOCKET HEAD CAP SCREWS Magni Coating Ref 4150701 Torque Loctite amp 242 or 271 TM Stress Area See Note 4 Dry 17 OR Vibra TITE 111 or 140 OR Precoat 85 Kz0 16 Torque Loctite amp 2627 or Vibra TITE 131 0 3125 0 0580 3 8 16 0 3750 0 0775 __ m Sem t MiB Nm me DL LJ L 1 L e o S e 1 L e 14 114 13 16 131 15 N m FT LB N m FT LB 5 16 18 0 3125 0 0524 25 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS NO 5000059 REV J 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS MY3161 6036 6042 8042 10042 10054 REQUIRED General Inform
76. and tire assemblies Refer to Section 5 7 2 Installing Wheel and Tire Assembly onto Machine Carefully remove the jack hoist or overhead crane and sling supporting the axle Carefully raise the machine using a suitable jack or hoist Remove the supports from beneath the frame and lower the machine to the ground Remove the blocks from the front and rear of both tires on the other axle Note ALWAYS use new o rings when servicing the machine 15 16 17 18 19 20 21 22 23 Install new o rings into the fittings Lubricate the o rings with clean hydraulic oil Uncap and connect the steering and brake lines at their axle fittings Models 10042 and 10054 Front Axle Only Install outrigger assembly Refer to Section 5 4 6 b Outrigger Installation Check the hydraulic reservoir oil level Properly connect the battery Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel Start the engine Turn the steering wheel several times lock to lock operate the frame tilt function several times in both directions and check the function of the brakes Check for hydraulic leaks and tighten or repair as necessary Install the fender assembly if equipped Close and secure the rear door The service brake circuit will need to be bled after axle installation Refer to Section 8 7 4 Brake Test 6036 6042 8042 10042 10054 Axles Drive Shafts W
77. approved recycling facility 8 Label disconnect and cap the steering and brake lines at the axle Cap all fittings to prevent dirt and debris from entering the hydraulic system Wipe up any spilled oil 9 Block the front and rear of both tires on the axle that is not being removed Ensure that the machine will remain in place during axle removal before proceeding 10 Raise the machine using a suitable jack or hoist Place suitable supports under both sides of the frame and lower the machine onto the supports Ensure that the machine will remain in place during axle removal 11 Support the axle that is being removed with a suitable jack hoist or overhead crane and sling DO NOT raise the axle or the machine 6036 6042 8042 10042 10054 12 Remove both wheel and tire assemblies from the axle that is being removed Refer to Section 5 7 1 Removing Wheel and Tire Assembly from Machine Note The wheel and tire assemblies must be re installed later with the directional tread pattern arrows facing in the direction of forward travel 13 Remove the drive shaft assembly Refer to Section 5 6 3 Drive Shaft Removal MH6270 14 Remove the capscrew and locknut securing the lower position cylinder mount pin 2 to the cylinder Tap the cylinder mount pin out and move the cylinder to prevent it from interfering with axle removal 15 Remove the capscrew and locknut securing the axle pivot pin 3 to the
78. bell housing Use the cleaner to clean the threaded holes around the flange of the bell housing 7 10 2 1 Use cleaner to clean the backside of the coupler where it comes in contact with the flywheel Isolation Coupler Installation Note The new coupler is heavy and requires two people one on each side to install 2 Place the new coupler into the indentation of the flywheel and use new hardware to secure the coupler to the flywheel 3 Insert one capscrew into the access hole on the rear right side of the bell housing and through the flywheel and coupler Assemble a new locknut onto the capscrew DO NOT fully tighten at this time 4 Turn the flywheel 180 and insert another capscrew and assemble with another new locknut DO NOT fully tighten until all capscrews and locknuts are in place 6036 6042 8042 10042 10054 5 After all capscrews are in place check to be sure the coupler is resting squarely in the indentation of the flywheel Torque all the capscrews to 37 lb ft 48 Nm 6 Install the small access cover plate to the right side of the engine and tighten the hardware securely Note Before assembling the drive shaft to the coupling be sure the access cover plate is placed on the engine side of the frame member that mounts the rear axle to the frame Note Apply Loctite 242 threadlock compound to all of the capscrews used during assembly 7 Install the access cover plate over the drive shaft a
79. cable to the back of the control Insert the control shaft through the panel ensuring that the knob is in the VERTICAL position Install the locknut on the shaft and tighten Connect the cab harness connector to the variable speed fan control Install the screws and backing locknuts securing the control panel to the dash panel 7 Install the setscrew securing the knob to the control 11 12 13 Install the right side control panel Properly connect the battery Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel Turn the ignition key to the ON position and check the fan speeds If further repair is needed refer to Section 9 5 Electrical System Schematics Start the machine and allow engine to warm to operating temperature Check heat control at different levels Close and secure the rear door 6036 6042 8042 10042 10054 9 10 SOLENOIDS SENSORS AND SENDERS 9 10 1 Coolant Temperature Switch a Coolant Temperature Switch Removal Park the machine on a firm level surface level the machine fully retract the boom raise the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF Place a Do Not Operate Tag on both the ignition key Switch and the steering wheel stating that the machine should not be operated Open the rear door Allow the system fluids to cool Temporarily block up or sup
80. clevis 13 Coat the threads of the threaded clevis with multi purpose grease 3 39 ote Boom 14 15 16 17 18 19 20 21 22 23 24 25 26 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 Have an assistant guide the threaded end of the clevis through the hole in the tab Remove the string or wire from the end of the clevis Reassemble the flat washer and locknut onto the threaded clevis Tighten the locknut until the threaded end of the clevis is flush with the top of the locknut At the rear of the boom place the retract chain up and over the chain sheave Place the clevis between the two anchor plates If re installing a used chain insert the saved shoulder bolt in the same position in the plates and clevis recorded during removal If installing a new chain line up the hole in the clevis with the second hole from the rear of the anchor plates Insert the shoulder bolt saved during removal of the old chain Secure the shoulder bolt in place with a locknut Tighten the locknut securely Tighten the locknut on the retract chain clevis until the amount of threads pro
81. engine OFF 6036 6042 8042 10042 10054 b Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the rear door Allow the system fluids to cool Properly disconnect the battery Unplug the engine boom angle sensor connector from the wiring harness connector Loosen and remove the sensor locknut Remove the sensor from the outside of boom frame Disassembly DO NOT disassemble the sensor The sensor is not serviceable Replace the sensor if found to be defective 1 Boom Angle Sensor Installation Install boom angle sensor through outside of boom frame Install locknut onto sensor MH6310 Measure the clearance between the sensor and frame and adjust sensor distance 15 to 0 120 3 05 mm and tighten locknut 4 Properly connect the battery Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel Close and secure the rear door 9 21 Electrical System 9 10 7 Boom Extend Interlock Sensor 10054 only 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
82. frame Note Hecord the number and location of shims 4 to ensure correct installation 16 Remove the pivot pin and shims 17 Remove the axles from the machine using the jack hoist or overhead crane and sling supporting the axle DO NOT raise or otherwise disturb the machine while removing the axle Balance the axle and prevent it from tipping turning or falling while 5 9 ES 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 Place suitable supports beneath the frame and lower the machine onto the supports allowing enough room for axle installation Ensure that the machine will remain in place during axle installation 3 Using a suitable jack hoist or overhead crane and sling remove the axle from its support or holding stand Balance the axle and prevent it from tipping turning or falling while positioning it beneath the machine DO NOT raise or otherwise disturb the machine while installing the axle Keep the axle supported and balanced on the jack hoist or overhead crane and sling throughout the installation procedure 4 Position the axle under t
83. left Lift Lower MH1151 cylinder 14 Install the Extend and Retract tubes 3 to the inside bulkhead fitting and the Extend Retract cylinder 15 Install the Extend and Retract tube clamp halves 4 16 Uncap and connect the hydraulic hoses and attach 3 10 to their appropriate cylinder locations 6036 6042 8042 10042 10054 Boom N OUO VU 17 18 19 20 21 Install the Extend and Retract and Auxiliary if equipped tube assemblies to their appropriate bulkhead fittings Secure with tube clamps Uncap and connect the previously labeled Attachment Tilt and Auxiliary if equipped hydraulic hoses to their appropriate bulkhead fittings QY MH1461 Inside the rear of the boom slide the threaded clevis end 5 of the retract chain down the right side of the boom Guide the threaded part of the clevis out through the hole in the tab on the bottom of the boom Pull threaded part of clevis all the way through tab Coat the entire threaded portion of the clevis with multi purpose grease Install a flat washer and locknut onto the clevis Thread the nut onto the clevis until the threads are flush with the top of the nut Install the bottom wear pads to the first boom section with the previously used hardware 6036 6042 8042 10042 10054 3 4 6 Second Boom Section Installation MH1481 At the rear of the second boom section assemble the retract chain sheave 6 to th
84. legible re stamp if required 6 Compare fork tips 11 when mounted on a carriage Maximum difference in height of fork tips is 3 percent of the length of the blade 13 3 53 Es 3 12 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that occur during operation of the boom Problem Cause Remedy 1 Boom will not extend or retract Broken hydraulic hose s or tube s and or connections leaking Extend retract hydraulic system not operating properly Faulty extend retract cylinder Broken chains or anchors Locate break replace hose s or tube s tighten connections Refer to Section 8 4 Hydraulic Circuits Repair cylinder Refer to Section 8 8 1 General Cylinder Instructions Replace chains as needed 2 Boom shifts to right or left when extending Boom side wear pads improperly shimmed or worn Shim wear pads to correct gap Replace wear pads as needed Refer to Section 3 9 Boom Wear Pads 3 Excessive pivot pin noise and or wear Insufficient lubrication Worn bearing s Lubricate at regular intervals Refer to Section 2 6 Lubrication Schedules Replace worn pins as needed Replace bearing s and lubricate at regular intervals Refer to Section 2 6 Lubrication Schedules 4 Excessive Compensation
85. manual Note To help ensure optimum performance the drive shaft assemblies are specially balanced as a unit at the factory When servicing any flange yoke slip yoke or drive shaft tube order a complete assembly if components are bent or damaged Refer to the appropriate parts manual for ordering information Before performing any inspection maintenance or service operation thoroughly clean the unit The axles and drive shafts should be checked and repaired only by experienced service technicians who are aware of all safety instructions and particular component features Use suitable products to thoroughly clean all disassembled mechanical parts to help prevent personal injury to the worker and prevent damage to the parts Carefully inspect the integrity of all moving parts bearings yokes tubes gears shafts etc and fasteners nuts bolts washers etc as they are subject to major stress and wear Always replace any damaged worn cracked seized or otherwise improper parts that could affect the safe and proper functioning of the machine axles and drive shafts 5 4 AXLE ASSEMBLIES 5 4 1 The front axle serial number plate is located ona mounting pad on the inboard portion of the right beam trumpet The rear axle serial number plate is located ona mounting pad on the inboard portion of the left trumpet Information on the serial number plate is required in correspondence regarding the axle Axle Serial Number
86. off the block While backing off the block the front left tire should remain off the ground Note Perform Steps 5 thru 9 with the engine rpm at idle Step 5 Keep the service brake pedal depressed Move the travel select lever to the N NEUTRAL position Take your foot off the service brake pedal The Stabil TRAK light should remain ON and the front left tire should remain off the ground With the travel select lever in the N NEUTRAL position engage the parking brake switch Move the travel select lever to the F FORWARD position The Stabil TRAK light should remain ON and the front left tire should remain off the ground 10 8 6036 6042 8042 10042 10054 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 e Frame sway the machine more than 5 to the right e Note Observe that frame sway will be slower than normal during this test 9 f The Stabil TRAK light should remain ON and the front left tire should remain off the ground The a front left tire should not rais
87. panel in the cab 7 Install the transmission covers 4 3 5 Windshield Wiper Assembly Refer to Section 9 8 Window Wiper Washer Windshield Wiper Motor for removal and installation information 4 3 6 Heater Defroster System If Equipped a Heater Assembly Removal 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the travel select lever the NEUTRAL position engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the rear door Allow the system fluids to cool 4 Properly disconnect the battery 5 Place a suitable container beneath the radiator drain plug or petcock Slowly turn the radiator cap to the first stop and allow any pressure to escape Remove the radiator cap 6 Place a funnel at the base of the radiator to channel the drained coolant into the container Loosen the drain plug or petcock and allow the coolant to drain 7 Transfer the coolant to a container with a cover and label as Used Antifreeze Dispose of the used coolant at an approved recycling facility 8 Close the radiator drain plug or petcock 9 Remove the heater access panel 10 Label disconnect and cap the heater hoses Pull the hoses through the grommets 6036 6042 8042 10042 10054 MA8371 Note The capscrew 6 at the l
88. psi 4 5 bar Pneumatic 55 psi 3 8 bar 13 0 x 24 G 3 L 3 Bias Ply Rock 12 Ply Foam Approx 542 Ib 246 kg 65 psi 4 5 bar Pneumatic 55 psi 3 8 bar 13 0 R 24 G 2 L 2 Radial 1 Star Foam Approx 542 Ib 246 kg 75 psi 5 2 bar Pneumatic 55 psi 3 8 bar 15 5 x 25 G 2 L 2 Bias Traction 12 Ply Foam Approx 600 Ib 272 kg 58 psi 3 9 bar Pneumatic 55 psi 3 8 bar 15 5 x 25 G 3 L 3 Bias Ply Rock 12 Ply Foam Approx 600 Ib 272 kg 58 psi 3 9 bar Pneumatic 58 psi 3 9 bar 15 5 R25 G 2 L 2 Radial 1 Star Foam Approx 600 Ib 272 kg 73 psi 5 0 bar Pneumatic 76 psi 5 2 bar 370 75x28 DuraForce 14 Ply Foam Approx 464 Ib 210 kg 73 psi 5 0 bar 6036 6042 8042 10042 10054 2 13 General Information and Specifications b 6042 Size Tire Type Minimum Ply Fill Type Pressure Star Rating Pneumatic 70 psi 4 8 bar 13 0 x 24 G 2 L 2 Bias Traction 12 Ply Foam Approx 542 Ib 246 kg 65 psi 4 5 bar Pneumatic 70 psi 4 8 bar 13 0 x 24 G 3 L 3 Bias Ply Rock 12 Ply Foam Approx 542 Ib 246 kg 65 psi 4 5 bar Pneumatic 70 psi 4 8 bar 13 0 R 24 G 2 L 2 Radial 1 Star Foam Approx 542 Ib 246 kg 65 psi 4 5 bar Pneumatic 65 psi 4 5 bar 15 5 25 G 2 L 2 Bias Traction 12 Ply Foam Approx 600 Ib 272 kg 58 psi 3 9 bar Pneumatic 65 psi 4 5 bar 15 5 x 25 G 3 L 3 Bias Ply Rock 1
89. remains on the ground It is normal for the front right tire to raise 2 slightly when swaying to the right but the tire should immediately lower when the frame sway function is stopped 9 j Frame sway the machine back to 0 o k Depress the service brake pedal Shift the travel select lever to NEUTRAL m Lower the boom n Engage the parking brake switch shut the engine OFF and remove the key o Exit the machine using both handholds 6036 6042 8042 10042 10054 10 9 d 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 T RAK System Test and Section 10 7 Boom Outrigger Interlock System Test 10054 to determine what part of the system is not functioning properly If an outrigger is raised or a pressure switch is defective boom on the 10054 will not extend beyond the 42 Series extension limit 10054 Stabil TRAK System Troubleshooting Boom Retracted BOOM EXTEND MODE 1 BOOM EXTEND MODE 2 BOOM EXTEND MODE 3 PH Ignition On Ignition On Machine SRL SUN Boom Below 40 Boom Below 40 Conditions Boom Extended To Boom Extended Beyond Switch T
90. retract the boom completely and turn the engine OFF 3 32 3 7 6 Boom Chain Tension Adjustment 6036 6042 8042 amp 10042 Note Always perform Section 3 7 5 Boom Chain Ten sion Check before adjusting the boom chain tension OHO0241 1 Adjust the two boom extend chains 2 38 mm tighten the two extend chain adjustment locknuts 3 If the chain sag measurement is more than 2 5 in 64 mm loosen the two extend chain adjustment locknuts 2 Tighten or loosen the two extend chain adjustment locknuts located at the rear of the boom Be sure each of the locknuts are adjusted equally so that each extend chain maintains the same tension Equal chain tension can be checked by the position of the yoke 4 on the outer boom The front of the yoke should be parallel with the front edge of the outer boom 6036 6042 8042 10042 10054 Boom I 0513 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 MA9451 5 Further chain adjustment can be achieved by loosening all three chain locknuts and moving the rear retract chain clevis 6 from the original mounting hole in the anchor plate
91. shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the rear door Allow the system fluids to cool 4 Properly disconnect the battery 5 Drain oil from the hydraulic tank reservoir into a clean container for reuse 6 Label and disconnect the temperature switch wiring connector from the harness connector 7 Unthread the switch from the hydraulic reservoir b Disassembly DO NOT disassemble the switch The switch is not serviceable Replace switch if found to be defective 9 18 7671 Hydraulic Oil Temperature Switch Installation Thread the switch into its fitting on the hydraulic reservoir Tighten securely 2 Fill hydraulic oil reservoir with hydraulic oil 3 Connect the switch wiring connector to the harness connector 4 Properly connect the battery 5 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel Start the engine check for hydraulic fluid leaking at the hydraulic oil temperature switch and allow the hydraulic fluid to reach operating temperature Cycle the boom several times and check whether the hydraulic oil temperature warning indicator illuminates on the operator display panel 6036 6042 8042 10042 10054 Electrical System 9 10 3 Transmission Solenoid Valves
92. side of the boom remove the hardware f securing the rear of the hose carrier guide in place 36 Carefully slide the hose channel assembly out of the rear of the boom 3 6 2 Third Boom Section Removal 1 Atthe front of the second boom section remove the top and side wear pads Label and tag each set of wear pads being removed MH1911 32 Loosen but DO NOT remove the hardware holding the front of the hose carrier guide and the top wear pad 10 to each side of the boom 33 Tilt the back of the hose carrier guide up Label all hoses and their orientations Pull the hoses from the channels inside the boom Lay the hoses out behind the boom 34 After the hoses are removed remove the hose carrier guide by pulling the guide out the rear of the boom MH1991 2 Remove the shoulder bolt 12 holding the yoke plates to the mount at the front of the first boom section 3 Remove the extend chain sheave pin and sheave on the third boom section 3 18 6036 6042 8042 10042 10054 Boom C E i e 10 Remove the locknuts 13 holding the threaded clevis of the extend chains to the anchor bracket on the rear of the third boom section Pull both extend chains out from the front of the boom At the rear of the third boom section remove the retract chain sheave Remove the shoulder bolt Let the retract chain hang out the rear of the boo
93. slack in the fourth boom section extend chain Shut the engine OFF 3 16 16 17 18 19 MH1791 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 Remove the extend chain sheave Remove the top and side wear pads on the inside of the third boom section Label and tag each set of wear pads being removed MH1501 e At the rear of the boom remove the hose reel assembly 3 This requires removal of the bottom and side wear pads Reinstall the wear pads for second boom section removal 6036 6042 8042 10042 10054 Boom N M VU MH2841 20 Inside the third boom section remove the hose clamps and hose clamp support bracket 4 21 Return to the cab start the engine and fully retract the boom slowly Shut the engine OFF Note Record the location of the shoulder bolt to ensure correct installation 22 At the rear of the boom remove the shoulder bolt 5 to the fourth boom section retract chain 6 Let the chain hang out the rear of the boom MH1861 6036 6042 8042 10042 10054 MH4071 23 24 25 Remove the two capscrews and lockwashers holding the hose carrier support 7 and the lower wear pad to the third boom section Pull the hose carr
94. switch and the steering wheel stating that the machine should not be operated Temporarily block up or support the raised boom Open the rear door Allow the system fluids to cool Properly disconnect the battery Remove the transmission covers Label disconnect and the hydraulic hoses and the electrical plugs connected to the extend lockout valve 8 Remove the nut and bolt securing the extend lockout valve to the frame Remove the valve from the machine 9 Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools b Extend Lockout Valve Disassembly Cleaning Inspection and Assembly MH3792 1 Secure the extend lockout valve assembly in a suitable bench vise if possible Remove the solenoid nut coil and cartridge 6 from the valve Remove the pressure sense valve 7 from the valve 2 Clean all components with a suitable cleaner before inspection 3 Inspect the solenoid cartridge for proper operation Check by shifting the spool to ensure that it is 8 31 Hydraulic System n 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 ultra smooth polished finish or are damaged in any way replace the extend lockout valve Often dirty hydr
95. system The following illustration identifies the components that are referred to throughout this section L BOOM EXTEND SENSOR OUTRIGGER CYLINDER PRESSURE SWITCH 2 UN N BOOM LOCKOUT VALVE MH3002 6036 6042 8042 10042 10054 10 3 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 amp Safety manual contains basic Stabil TRAK information a copy of the Operation amp Safety manual should always be available in the storage compartment located on the left inside wall of the cab next to the seat support The Stabil TRAK lock system will be activated when the boom angle is greater than 40 and one or more of the following functions are activated Engaging the Parking Brake Switch Placing the Travel Select Lever in NEUTRAL Depressing and holding the Service Brake Model 10054 Only Lowering both outriggers onto solid terrain and extending the boom beyond a point between the E and F boom extend letters approximately 40 ft 12 m With the boom lowered to an angle of less than 40 the rear axle lock system is not active and none of these functions will affect the Stabil TRAK system 10 4 10 3 1 Stabil TRAK Solenoid Valves There are five Stabil TRAK solenoid v
96. that are in good condition connected properly and are tightened to the proper torque Capture fluid in an appropriate container and dispose of in accordance with prevailing environmental regulations RADIATOR CAP The cooling system is under pressure and escaping coolant can cause severe burns and eye injury To prevent personal injury NEVER remove the radiator cap while the cooling system is hot Wear safety glasses Turn the radiator cap to the first stop and allow pressure to escape before removing the cap completely Failure to follow the safety practices could result in death or serious injury FLUID FLAMABILTITY DO NOT service the fuel or hydraulic systems near an open flame sparks or smoking materials NEVER drain or store fluids in an open container Engine fuel and hydraulic fluid are flammable and can cause a fire and or explosion DO NOT mix gasoline or alcohol with diesel fuel The mixture can cause an explosion PRESSURE TESTING When conducting any test only use test equipment that is correctly calibrated and in good condition Use the correct equipment in the proper manner and make changes or repairs as indicated by the test procedure to achieve the desired result LEAVING MACHINE Lower the forks or attachment to the ground before leaving the machine TIRES Always keep tires inflated to the proper pressure to help prevent tipover DO NOT over inflate tires NEVER use mismatched tire types sizes or ply ra
97. the components that are referred to throughout this section THREE SECTION BOOM 6036 6042 8042 amp 10042 BOOM RETRACT SECOND BOOM FIRST BOOM THIRD BOOM BOOM EXTEND CHAIN SECTION SECTION CN CHAINS N BOOM PROXIMITY EXTEND RETRACT SENSOR CYLINDER SN 67 SLAVE ATTACHMENT CYLINDER TILT CYLINDER LIFT LOWER CYLINDER 0 QUICK ATTACH FOUR SECTION BOOM 10054 SECOND amp THIRD THIRD BOOM BOOM SECTION SECOND BOOM FIRST BOOM SECTION FOURTH BOOM SECTION EXTEND CHAIN EXTEND CHAINS FOURTH BOOM SECTION RETRACT CHAIN FOURTH BOOM SECTION SECOND amp THIRD BOOM SECTION RETRACT CHAIN SECTION OL BOOM PROXIMITY SENSOR S NN EXTEND RETRACT 6 ES CYLINDER ATTACHMENT TILT CYLINDER LIFT LOWER CYLINDER oP QUICK ATTACH 6036 6042 8042 10042 10054 BOOM PROXIMITY SENSOR SLAVE CYLINDER MH4351 3 3 Boom CY 3 2 SAFETY INFORMATION A WARNING DO NOT service the machine without following all safety precautions as outlined in the Practices section of this manual Safety 3 3 BOOM SYSTEM THREE SECTION 6036 6042 8042 amp 10042 3 3 1 The three section boom assembly consists of first second and third boom section
98. the hydraulic fluid reservoir Refer to Section 8 5 2 Hydraulic Oil Reservoir Filling 6036 6042 8042 10042 10054 7 Start the engine and run at approximately one third to one half throttle for about one minute without moving the machine or operating any hydraulic functions 8 Inspect for leaks and check the level of the hydraulic fluid in the reservoir Shut the engine OFF Note Check for leaks and repair as required before continuing Add hydraulic fluid to the reservoir as needed 9 Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools 10 Install the transmission covers 11 Close and secure the rear door g Main Control Valve Test Conduct a pressure check of the hydraulic system in its entirety Adjust pressure s as required Refer to Section 8 3 1 Pressure Checks and Adjustments 8 7 2 The secondary function manifold is a directional control valve Hydraulic oil from the pump flows into the secondary function manifold where the pressure is reduced before the oil is directed to the power steering unit or the park brake Secondary Function Manifold The secondary function manifold is a machined block with the ports for two pressure reducing valves a pressure relief valve two park brake solenoid valves one normally open and one normally closed a check valve and diagnostic test nipples The secondary function manifold is secured on the left side of the fra
99. to the next hole This is only acceptable when boom chain sag cannot be acquired and the chain elongation measurement is still less than 12 36 in 313 mm Follow the instructions in Section 3 7 6 a Component Assembly Verification 6 Recheck chain tension Refer to Section 3 7 5 Boom Chain Tension Check 6036 6042 8042 10042 10054 a Component Assembly Verification L L 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 OH1091 Measure the separation 9 between the third and second boom section top plates The distance should be at least 8 5 in 216 mm and not greater than 11 in 279 mm with the boom fully retracted and the chains properly tensioned A distance of less than 8 5 in 216 mm could result in interference and cause damage to boom components If the distance is less than 8 5 in 216 mm or greater than 11 in 279 mm 1 Verify that the retract chain clevis 6 is not mounted in the last hole in the anchor plate 2 Make sure that the chain system is properly tensioned Refer to Section 3 7 5 Boom Chain Tension Check 3 To increase the separation distance Loosen the retract chain locknut B on th
100. with clean fresh Mobilfluid 4249 ISO Grade 46 through the dipstick tube opening 8 Check the level by taking intermittent dipstick readings as outlined in the appropriate Operation amp Safety Manual DO NOT overfill Reinstall the dipstick when finished Run the engine for two minutes at idle to help prime the torque converter and the transmission oil lines Recheck the level of the fluid in the transmission with the engine running at idle Add Mobilfluid 4249 ISO Grade 46 as necessary to bring the fluid level up until it reaches the FULL mark on the dipstick Recheck the oil level when it reaches operating temperature 180 200 F 83 94 C Recheck all drain plugs lines connections etc for leaks and tighten where necessary 6036 6042 8042 10042 10054 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 Cause Remedy 1 Transmission will not engage 1 Oil level too high or low or will not shift properly 2 Transmission control lever not func
101. 000 0 1419 12750 In 0 5625 PI 40 48 2 0 2 6 24 20 8 18 16 4 14 0 18 0 105 235 25 45 0 3750 0 0878 7900 50 70 80 105 129 148 HEB 15 17 N m FT LB N m 25 35 55 50 70 95 6o 80 130 0 0 5 5 50 0 0 0 6 9 25 25 50 50 70 80 110 155 2 0 5000 0 1599 14400 12 0 1820 16400 155 210 140 190 115 0 5625 0 2030 18250 170 230 155 210 130 175 0 6250 0 2260 20350 210 285 190 260 160 220 0 6250 0 2560 23000 240 325 215 290 180 245 0 7500 0 3340 30100 375 510 4 1 1 1 5 7 0 4620 41600 0 8750 0 8750 0 5090 45800 0 4 8 2 8 3 4 8 1 910 340 78 600 1 8 1000 0 6060 51500 1170 770 1045 645 875 118 460 280 380 0 7500 0 3730 33600 315 430 455 620 500 680 11 8 1 1250 0 7630 68700 1290 1755 1160 1580 965 1310 12 1 2500 1 0730 96600 2015 2740 1810 2460 1510 2055 13750 13150 118100 2705 3680 2435 3310 2030 2760 112 1 5000 1 5800 142200 3555 4835 3200 4350 2665 3625 16 9 i 14 8 7 12 11250 0 8560 77000 1445 1965 1300 1770 1085 1475 7 2 6 2 6 5000059 REV J NOTES 1
102. 0038740 excluding 0160021270 0160036713 0160036715 amp 0160036723 Differential Housing Capacity 8042 S N 0160038967 amp After excluding 0160038971 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 3 quart 1 2 liter Type of Fluid Mobilfluid 4249 Tractor Hydraulic Fluid 6036 amp 6042 10042 S N 0160038368 amp After excluding 0160038375 0160038378 0160038379 0160038381 amp 0160038383 10054 S N 0160038740 amp After including 0160021270 0160036713 0160036715 amp 0160036723 Differential Housing Capacity 12 5 quart 11 8 liter Wheel End Capacity Front Axle 2 1 quart 2 0 liter Rear Axle 2 2 quart 2 1 liter Type of Fluid Mobilfluid 4249 Tractor Hydraulic Fluid 6036 6042 8042 10042 10054 Ay General Information and Specifications 2 5 SERVICE AND MAINTENANCE SCHEDULES 2 5 1 10 amp 1st 50 Hour bat Check Fuel Drain Fuel Air Filter Check Engine Level Water Seprator Restriction Oil Level Indicator Check Tire Check Check Engine Additional Condition amp Transmission Coolant Level Checks Pressure Oil Level Change Axle Oil Change Wheel Change Engine Change Before End Oil Before Oil amp Filter Transmission S N 0160037788 S N 0160037788 Filter Check Wheel Check Boom Lug Nut Chain Tension Torque 2 18 e Check Hydraulic Oil Level
103. 071 4 Further chain adjustment can be achieved by loosening both chain locknuts and moving the rear retract chain clevis 3 from the original mounting hole in the anchor plate to the next hole This is only acceptable when boom chain sag cannot be acquired and the chain elongation measurement is still less than 12 36 in 313 mm Follow the instructions in Section 3 7 7 d Component Assembly Verification 5 Recheck chain tension Refer to Section 3 7 5 Boom Chain Tension Check 6036 6042 8042 10042 10054 Boom C E d Component Assembly Verification The fourth to third boom section separation should be checked when assembling new boom sections or chains or when the rear retract chain clevis has been moved forward on the anchor plate NE DCSE Nes 9 NE o d E SSE OCC OCC OC N 2C 2C 2C 2C 9 6 96 9X6 9 9o OH2871 Measure the separation between the third 4 and fourth 5 boom section top plates The distance 6 should be at least 13 75 in 349 mm and not greater than 14 25 in 362 mm with the boom fully retracted and the chains properly tensioned A distance of less than 13 75 in 349 mm could result in interference and cause damage to boom components If the
104. 1 Record the amount of threads extending beyond the locknut This measurement will be the starting point for adjustment of the extend chain after installation Remove the locknut and flat washer holding the extend chain clevis to the anchor plate on the boom 3 42 N MH1791 At the front of the boom disconnect the extend chain clevis from the anchor plates on the second boom section Remove the locknut holding the shoulder bolt 2 to the anchor plates Pull the extend chain clevis from between the plates and lay over the front of the fourth boom section 3 Remove the locknut and capscrew holding the extend chain sheave to the front of the third boom section Inspect the sheave pin for corrosion or damage If the pin is damaged it should be replaced Minor corrosion can be repaired with fine emery cloth Save the chain sheave pin and capscrew MH6510 At the rear of the boom attach one end of a wire to the threaded clevis 4 on the extend chain with a threaded eye or a flat washer tack welded to a capscrew The outside diameter of the eye or flat washer must be smaller than the diameter of the threads on the clevis Have an assistant pull the chain from the front of the boom while guiding the wire into the boom from the rear Remove the wire from the clevis but not from inside the boom 6036 6042 8042 10042 10054 Boom C E 12 13 14 15 1
105. 2 10054 300 400 Ib ft 390 460 Ib ft 150 160 Ib ft 9 11 Ib ft 407 542 Nm 529 624 Nm 1203 217 Nm 12 15 Nm c Tilt Cylinder Model Head Piston Locknut Locking Valve Set Screw Collar 6036 6042 300 400 Ib ft 200 300 Ib ft N A N A 30 35 Ib ft 30 35 Ib ft 407 542 Nm 271 407 Nm 41 47 Nm 41 48 Nm 8042 10042 N A N A 1735 1885 Ib ft 300 400 Ib ft 30 35 lb ft N A 10054 2352 2556 Nm 407 542 Nm 41 47 Nm d Sway Cylinder Head Locknut Valve 300 400 Ib ft 407 542 Nm 1100 1250 Ib ft 1491 1695 Nm 35 40 lb ft 47 54 Nm e Stabil TRAK Cylinder Model Locknut Check Valve Guide Set Screw Pressure Solenoid Reducing Coil PO Check Valve 6042 1175 1400 Ib ft 20 25 lb ft 300 350 Ib ft 3 4 lb ft 35 40 16 25 30 Ib ft 1593 1898 Nm 27 34 407 475 4 5 Nm 47 54 Nm 34 41 Nm 8042 10042 N A 20 25 Ib ft 300 350 Ib ft 3 4 Ib ft 35 40 Ib ft 25 30 Ib ft 10054 27 34 Nm 407 475 Nm 4 5 Nm 47 54 Nm 34 41 Nm 8 36 6036 6042 8042 10042 10054 Hydraulic System i f Slave Cylinder Model Head Locknut Set Screw 6036 250 300 Ib ft 339 407 Nm 675 750 Ib ft 915 1017 Nm N A 6042 300 350 Ib 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 Ib ft 1220 1424 Nm N A g Swing Carriage Cylinder If Equipped
106. 2 33 61 63 8 9 10 12 13 14 16 18 19 20 25 26 28 29 30 32 11 13 14 16 18 19 20 22 23 24 25 27 28 29 31 32 33 63 11 13 14 16 18 19 20 22 24 25 27 28 29 31 32 33 61 63 4 16 18 19 20 25 27 31 33 34 35 45 56 62 4 36 37 38 39 40 42 43 44 58 9 14 16 18 19 22 26 28 29 31 33 35 36 45 46 59 7 8 9 10 11 12 13 14 16 20 21 23 26 28 29 30 33 35 45 59 13 14 20 23 25 26 29 30 33 45 47 48 49 4 38 41 11 13 14 16 18 19 24 25 45 50 51 52 53 54 57 25 11 19 25 28 29 31 32 33 34 46 59 10 31 33 34 45 55 60 11 12 1 Battery charge low 2 Bad electrical connection 3 Faulty starter motor 4 Incorrect grade of lubricating oil 5 Low cranking speed 6 Fuel tank empty 7 Faulty stop control operation 8 Fuel inlet restricted 9 Faulty fuel lift pump Clogged fuel filter 11 Restricted air cleaner Air in fuel system Faulty fuel injection pump Faulty fuel injectors or incorrect type Incorrect use of cold start equipment Faulty cold start equipment Broken fuel injection pump drive 18 Incorrect fuel pump timing Incorrect valve timing 20 Poor compression 15 16 17 7 12 Key to Possible Causes Blocked fuel tank vent Incorrect grade of fuel Sticking throttle or restricted movement Exhaust pipe restriction Leaking cylinder head gasket
107. 2 Ply Foam Approx 600 Ib 272 kg 58 psi 3 9 bar Pneumatic 65 psi 4 5 bar 15 5 25 G 2 L 2 Radial 1 Star Foam Approx 600 Ib 272 kg 58 psi 3 9 bar Pneumatic 76 psi 5 2 bar 370 75x28 DuraForce 14 Foam Approx 464 Ib 210 kg 73 psi 5 0 bar 6036 6042 8042 10042 10054 General Information and Specifications c 8042 Size Tire Type Minimum Ply Fill Type Pressure Star Rating Pneumatic 70 psi 4 8 bar 15 5 x 25 G 2 L 2 Bias Ply Traction 12 Ply Foam Approx 600 Ib 272 kg 58 psi 3 9 bar Pneumatic 70 psi 4 8 bar 15 5 x 25 G 3 L 3 Bias Ply Rock 12 Ply Foam Approx 600 Ib 272 kg 58 psi 3 9 bar Pneumatic 70 psi 4 8 bar 15 5 R 25 G2 L 2 Radial 1 Star Foam Approx 600 Ib 272 kg 73 psi 5 0 bar Pneumatic 76 psi 5 2 bar 370 75x28 DuraForce 14 Ply Foam Approx 464 Ib 210 kg 73 psi 5 0 bar d 10042 amp 10054 Size Tire Type Minimum Ply Fill Type Pressure Star Rating Pneumatic 60 psi 4 1 bar 17 50 x 25 G 2 L 2 Bias Traction 12 Ply Foam Approx 785 Ib 356 kg 51 psi 3 5 bar Pneumatic 60 psi 4 1 bar 17 50 x 25 G 3 L 3 Bias Ply Rock 12 Ply Foam Approx 785 Ib 356 kg 51 psi 3 5 bar Pneumatic 73 psi 5 0 bar 17 50 x 25 G 2 L 2 Radial 1 Star Foam Approx 785 Ib 356 kg 73 psi 5 0 bar Pneumatic 76 psi 5 2 bar 370 75x28 DuraForce 14 Ply Foam Approx 464 Ib
108. 210 kg 73 psi 5 0 bar 6036 6042 8042 10042 10054 2 15 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 37 gallon 140 liter Type of Fuel 2 Diesel Cooling System System Capacity Cummins QSB3 3 6 3 gallon 23 8 liter Cummins QSB4 5 5 0 gallon 18 9 liter Overflow Bottle Capacity 3 quart 2 8 liter Type of Fluid 50 50 ethylene glycol amp water Hydraulic System System Capacity 6036 amp 6042 57 gallon 216 liter 8042 10042 amp 10054 58 gallon 218 liter 64 gallon 242 liter Reservoir Capacity to Full Mark 32 gallon 122 liter Type of Fluid Mobilfluid 4249 Tractor Hydraulic Fluid Transmission Capacity with Filter Change 4 8 gallon 13 6 liter Filter 1 5 quart 1 4 liter Type of Fluid Mobilfluid 4249 Tractor Hydraulic Fluid 2 16 6036 6042 8042 10042 10054 General Information and Specifications A Axles 8042 Before S N 0160038967 including 0160038971 10042 Before S N 0160038368 including 0160038375 0160038378 0160038379 0160038381 amp 0160038383 10054 Before S N 016
109. 3 19 3 6 4 First Boom Section 3 20 3 6 5 First Boom Section 3 21 3 6 6 Second Boom Section Installation 3 23 3 6 7 Third Boom 5 3 24 3 6 8 Fourth Boom Section Installation 3 25 3 7 Boom Extend and Retract Chains 3 28 3 7 1 Boom Chain 3 28 3 7 2 Inspection Guidelines 3 29 3 7 3 Expose Chains for 5 3 31 3 7 4 Chain Lubrication 3 31 3 7 5 Boom Chain Tension 3 32 3 7 6 Boom Chain Tension Adjustment 6036 6042 8042 amp 10042 3 32 3 7 7 Boom Chain Tension Adjustment 10054 3 34 3 7 8 Extend Chains Removal and Replacement 6036 6042 8042 amp 10042 3 37 3 7 9 Retract Chain Removal and Replacement 6036 6042 8042 amp 10042 3 39 3 7 10 Extend Chains Removal and Replacement 10054 3 40 3 7 11 Retract Chain Removal and Replacement 10054 3 43 6036 6042 8042 10042 10054 3 1 Boom 3 2 3 8 3 9 3 10 3 11 3 12 Quick Attach Assembly
110. 3 50 3 11 FOKS 3 53 3 12 Troubleshooting 39er veda gees een xn mus Yaa ed 3 54 Section 4 Gab and COVBES saos a dorsa 4 1 4 1 Operator Cab and Covers Component Terminology 4 2 4 2 Operator ea a et 4 3 4 3 Cab 5 4 3 4 4 Cabs REMOVAL 4 8 4 5 nstallation 2 we eet Ed ES 4 9 6036 6042 8042 10042 10054 Section Subject Page Section 5 Axles Drive Shafts Wheels and 5 1 5 1 Axle Drive Shaft and Wheel Component Terminology 6036 amp 6042 5 2 5 2 Axle Drive Shaft and Wheel Component Terminology 8042 10042 amp 10054 5 3 5 3 General 5 4 5 4 Axle 5 5 4 5 5 Axle Assembly and Drive Shaft 5 11 5 6 ce esee aces Sepe 5 14 5 7 Wheels and Tires sss aver eme eek DEI RUE 5 15 5 8 Biakes vict Sale RR D Mach PO BAADER BC Elk 5 16 5 9 Towing a Disabled 5 18 Sect
111. 36 6042 8042 10042 10054 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 28 Remove any external transmission components as required including the transmission temperature Switch and inlet and outlet cooler hose fittings Cover all transmission openings 29 Remove the transmission oil filter and dispose of properly Clean the filter mounting surface Cover or cap the oil filter mount 6 4 2 Transmission Inspection and Internal Repair If replacing the entire transmission transfer the transmission temperature switch to the replacement transmission The gear shift solenoids are included with new transmission 6 4 3 Transmission Installation WARNING NEVER lift a transmission alone enlist the help of at least one assistant or use a suitable hoist or overhead crane and sling with the minimum lifting capacity of 1000 Ib 454 kg 1 Install two rubber mounts and the rear transmission mount 1 in the machine frame Secure the mount with the previously used hardware 2 Use a hoist or overhead crane and sling attached to the lifting eye at the top of the transmission Raise and position the transmission within the chassis 3 Attach the transmission to the rear mounting bracket with the previously used hardw
112. 6 17 18 19 20 Coat the threads of the threaded clevis with multi purpose grease Lay the new extend chain on top of the fourth boom section with the threaded clevis toward the front of the boom 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 MH5731 Pull the extend chain forward and place in between the chain sheave mounts Guide the wire and the threaded clevis into the boom by placing the threaded clevis between the third boom section 5 and the top of the fourth boom section 6 Have an assistant guide the extend chain into the front of the boom while pulling the wire and threaded clevis into the hole in the anchor plate Place the flat washer onto the threaded end of the threaded clevis and assemble the locknut Thread the locknut onto the threaded clevis until the threads are flush with the top of the nut Remove the wire from the clevis After the chain is replaced inside the boom assemble the sheave to the mount at the front of the third boom section Place the extend chain sheave between the mounts at the front of the third boom section Insert the sheave pin through the mounts and the sheave Secure in place with the capscrew saved and a locknut Tighten securely 6036 6042 8042 10042 10054
113. 60 220 625 56 240 325 215 290 180 245 0 6250 0 2560 0 7500 0 3340 30100 375 280 0 7500 0 3730 33600 570 380 515 430 1290 1815 2015 2385 2705 3165 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD 1 REQUIRED ADDITIONAL TESTING IS REQUIRED 3555 ojoo oI Sl als 5000059 REV J MY3400 2 6 6036 6042 8042 10042 10054 General Information and Specifications 2 2 2 Mertic Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners Ref 4150707 CLASS 8 8 METRIC BOLTS CLASS 8 METRIC NUTS Torque Torque Loctite amp Tensile puse Lub OR Vibra OR Vibra TITE 131 TITE 111 or 140 mm 35 4 oz ez 31 23 5 os 1420 62 46 6 1 2000 av n 79 8 125 36 60 159 w 12 1 75 84 30 36 7 88 66 79 97 14 2 115 50 0 140 105 126 154 16 2 157 68 3 219 164 197 241 18 2 5 19 2 301 226 271 331 106 5 1320 244 0 1460 1100 1320 1530 302 0 1990 1490 1790 2090 817 355 5 2560 1920 2300 2690
114. AAS way oo bo Ly gy WIS ON rome a 3x TLS 7 lau i dod euis LJ se n ln si onng bd 1 m Og 901 d ud sond Ona ew siping ona caw EN ag ooz 74 F ue ae rS zal 3 vede LJ Ta o d mis ose ist 1 7 0802 a M o sonona S3NIHOVW 99001 NO oe 2 7 QUE 13 3H8 SE anm 5001 OL SE 3 SFYIM 10 i KINO S3NIHOVM 270012708 HOS 281 SWIM adn D bnnd on 19 5 or Ou we x so ez 92 D won ou Lx Herm 1 5 oe c133Hs 1 ww wel 30 OL SLONI w VEL gu az ON usi 6 2 vie ares p HOMS uvassng 9313S 132HS 338 4334 pi soma ora 1 n SW g 3 uvassng xogasn Sod ee n zo 8042 10042 8 10054 Electrical Schematic Electrical System 9 5 2 MAQ0430A 6036 6042 8042 10042 10054 9 8
115. AK system With the boom above 40 the transmission shifter in either forward or reverse and the service brake depressed the Stabil TRAK system engages If the Service Brake Switch is suspect in the proper operation of the Stabil TRAK system refer to Section 10 5 Stabil TRAK System Test a Service Brake Switch Removal 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the rear door Allow the system fluids to cool 4 Properly disconnect the battery 5 Label and disconnect the electrical connectors attached to the service brake switch 6 Loosen locknut and remove switch dust cover 13 Remove switch body 9 20 b Service Brake Switch Installation 1 Ensure that there is only one thread showing above the locknut on the shaft of the switch body 2 Insert switch body through the top of the service brake switch bracket 3 Thread the switch dust cover onto the switch body until finger tight against the service brake switch bracket 4 Use a wrench and fully tighten the locknut against the service brake switch bracket There should now be approximately two or three threads showing above the locknut 5 Thread the b
116. AUTION DO NOT exceed 575 psi 40 bar when pressurizing the park brake Applying too much pressure may damage the brake seals 8 Clear the area of all unnecessary personnel 9 Remove the blocks from the wheels Tow the machine to a secure location 10 Remove the hydraulic pressurizing unit Note Without engine power service brake power is reduced Only the rear service brakes will function when the brake pedal is depressed Steering is not possible and the machine will only travel in the direction that the wheels were last turned Tow or push the machine at a very slow speed 6036 6042 8042 10042 10054 Section 6 Transmission Contents PARAGRAPH TITLE PAGE 6 1 Transmission Assembly Component Terminology 6 2 6 2 Transmission Serial 6 3 6 3 Transmission Specifications and Maintenance Information 6 3 6 4 Transmission 6 3 6 4 1 Transmission 6 3 6 4 2 Transmission Inspection and Internal 6 5 6 4 3 Transmission 8 6 5 6 4 4 After Transmission Service or 6 6 6 5 Transmission Troubleshooting 6 7 6036 6042 8042 10042 10054
117. B 6036 6042 8042 10042 10054 9 6 Electrical System 9 7 6036 amp 6042 Electrical Schematic Continued 6036 amp 6042 9 5 1 390915 8 NOOV38 Es sac 4 9 vous z 4 E quus gt tA il D P Ue UR t TE d m we us HOLMS DIVAA seis wa zs jar ER a TEES Gi Man NOUA ESP LOSNNOOSIG l Ta wey wy wW NL LAT Wivd SNONV Ad SsaNuvH LINDYID H3HSVWH3dIM lalis J TH VE Pa AP ee anus ET s 2 n UE 401 aun Mat ww 73792 d BUM inam oL Hir 137822 p mar IL rr nx 00 TH vee wu DE 59 au EE nt m Mz MS ax J Waz MOL M 89 E o zs AT Wve ww Wee MOL anus HE wal ijdem mel 3 HOLO3NNOO HNvd d k HOLIMS s 2 EE HLSNI
118. CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED 2 8 6036 6042 8042 10042 10054 General Information and Specifications 2 2 2 Mertic Fastener Torque Chart Continued Magni Coating Ref 4150701 CLASS 12 9 SOCKET HEAD CAP SCREWS M6 AND ABOVE Torque Torque Torque Lub OR Loctite m Clamp Load Dry or Loctite 242 or 271 Loctite 262 See Note 4 263 OR Vibra TITE OR Vibra TITE K 17 111 or 140 n 16 Tensile SizePI CH Stress Area Sq mm 5 03 6 78 8 78 5 os 2 6 1 200 s is ma 7 8 125 3660 228 31 20 160 22 2 5 303 189 0 705 665 24 3 790 33 3 5 694 1120 6980 4985 4690 1120 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 8 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED MY3191 6036 6042 8042 10042 10054 General Information and Specifications
119. Check wear pad gaps and correct as needed Refer to Section 3 9 Boom Wear Pads Reduce cycle times Remove contamination and or corrosion from wear pad sliding surfaces and lubricate If the surfaces cannot be reconditioned replace the boom section s Clean equipment frequently 10 Auxiliary hydraulics will not operate Auxiliary hydraulic system not operating properly Refer to Section 8 Hydraulic System 11 Excessive chain wear Improper chain adjustment Chain sheave s not properly lubricated Chain sheave s not rotating freely Improper chain lubrication Adjust to correct tension Refer to Section 3 7 1 Chain Inspection Replace chains as needed Lubricate chain sheave Refer to Section 2 5 Service and Maintenance Schedules Lubricate chain sheave Refer to Section 2 5 Service and Maintenance Schedules Repair or replace chain sheave s as needed Lubricate at regular intervals Refer to Section 2 5 Service and Maintenance Schedules Replace chains as needed 3 56 6036 6042 8042 10042 10054 Section 4 Cab and Covers Contents PARAGRAPH TITLE PAGE 4 1 Operator Cab and Covers Component Terminology 4 2 4 2 Operator Cab E ee ee ae 4 3 4 2 1 Cab Salely by edo au pue uei dades eru 4 3 4 2 2 Serial Number
120. Checks and Adjustments 4 3 2 Service Brake Pedal a Brake Valve Removal Refer to Section 8 7 3 Service Brake Valve for removal information b Brake Valve Installation Refer to Section 8 7 3 Service Brake Valve for installation information c Service Brake Pedal Removal 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the travel select lever in the NEUTRAL position engage the parking brake and turn the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated 3 Open the rear door Allow the system fluids to cool 4 Properly disconnect the battery 6036 6042 8042 10042 10054 Cab and Covers a MH6210 5 Remove the lower dash panel Remove the two capscrews four flat washers two pivots and two nuts securing the service brake pedal to the cab Remove the service brake pedal from the cab Service Brake Pedal Installation Position the service brake pedal in its mounting location within the cab Insert the two brake pedal pivots into mounting locations on the service brake pedal Install the service brake pedal with the previously used hardware sure the brake pedal has the correct range of motion Secure pivot pin with bolt and lockwasher Adjust the service brake as needed Refer to Sect
121. EQUIPPED MH6230 e j ACCELERATOR PEDAL 4 2 6036 6042 8042 10042 10054 Cab and Covers as 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 A WARNING 3 Open the rear door Allow the system fluids to cool DO NOT service the machine without following all 4 safety precautions as outlined in the Safety Practices section of this manual Properly disconnect the battery 5 Remove the left right and lower dash panels 4 2 OPERATOR 1 4 2 1 Cab Safety A WARNING The protection offered by this ROPS FOPS will be impaired if subjected to any modification or structural damage at which time replacement is necessary ROPS FOPS must be properly installed using fasteners of correct size and grade and torqued to their specified value A WARNING DO NOT weld grind drill repair or modify the cab in any way Any modification or damage to cab structural components requires cab replacement Refer to Section 2 5 in the Operation amp Safety Manual To help ensure optimum safety protection and performance replace the cab if it is damaged Refer to the appropriate parts manual for ordering information MY0120 4 2 2 Serial Number Decal i 6 Remove the steering wheel 1 disconnect and The cab serial number decal is located on the left side of remove t
122. F Note Record the location of the shoulder bolt to ensure correct installation 9 10 11 12 2671 At the rear of the boom locate the two retract chain anchor plates 11 The two anchor plates can remain in place on the fourth boom section Pull the retract chain clevis toward the rear of the boom through the middle of the two center hoses on the chain reel and over the top of the chain reel Let the clevis end of the retract chain hang out the rear of the boom Use a piece of wire that is approximately 6 feet 1 8 m long and tie it to the clevis end of the retract chain This wire will be used to guide the chain back into the boom when the boom is extended to expose the other end for removal Havean assistant start the engine and slowly extend the boom Guide the retract chain with the wire attached into the back of the boom Extend the boom until the retract chain adjustment nut on the lower left side of the second boom section can be accessed and removed Turn the engine OFF Remove the locknut and flat washer holding the threaded clevis on the retract chain to the tab in the second boom section MH6510 3 45 Boom 13 Attach a wire to the end of t
123. H0912 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 MH0921 At the front of the second boom section pull both extend chains 5 out from between the second and third boom sections The extend chains can remain anchored between the yoke plates on the first boom section Loop both chains over the top of the chain sheave and lay the chains on top of the boom MH2551 Note Hecord the location of the shoulder bolt 6 to ensure correct installation 16 At the rear of the boom locate the retract chain 7 on the right side of the boom In front of the retract chain sheave locate the shoulder bolt which holds the retract chain to the anchor plates on the third boom section Remove the locknut from the shoulder bolt Allow the retract chain to hang out the rear of the boom Note replacing the third boom section with a new boom section the quick attach assembly and the Attachment Tilt cylinder should be removed at this time Refer to Section 3 8 3 Quick Attach Removal If the third boom section is not to be replaced the quick attach assembly and Attachment Tilt cylinder can remain in place 17 Using a sling or suitable support pull the third boom section straight out of the second boom section Reposi
124. IT OPERATION AND TROUBLESHOOTING 6042 8042 amp 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 6042 8042 and 10042 Stabil TRAK System Troubleshooting FREE PIVOT SLOW PIVOT LOCKED MODE MODE MODE Machine Ignition On Ignition On Ignition On Conditions Boom Below 40 Boom Above 40 Boom Above 40 Switch i Boom Retracted Boom Extended Boom Extended Relay PB amp SB Released PB amp SB Released PB amp SB Applied Solenoid Trans in Forward or Reverse Trans in Forward or Reverse amp Trans in Neutral Solenoid 12A E DE DE Solenoid 12B E DE DE Solenoid 3 DE DE E Solenoid 4A DE E DE Solenoid 4B DE DE Boom Angle Sensor Boom Switch Relay E DE DE Stabilizer Lock Relay DE DE E Stabilizer Light OFF DE OFF DE ON E Ignition Switch C C Park Brake Switch Service Brake Switch DE Park Brake Disengage Relay E E DE Neutral Start Relay DE DE E Definitions PB Park Brake SB Service Brake DE De energized E Energized C Closed O Open 6036 6042 8042 10042 10054 10 5 Stabil TRAK System and Boom Interlock System
125. ITLE PAGE 1 1 Introduction 1 2 ke Rad EXTARE EG EIE E mE 1 2 1 2 Disclaimet re ERE 1 2 1 3 Operation amp Safety Manual 1 2 1 4 Do Not Operate 1 2 1 5 Safety 1 2 1 5 1 Safety Alert System and Signal 1 2 1 6 Safety Instructions 2 ee ee EX RIS ee 1 3 1 6 1 Personal 1 3 1 6 2 Equipment Hazards cure gH RR ER 1 3 1 6 3 General 5 1 8 1 6 4 Operational 1 4 1 7 Safety Decals uei RR eee Sewage ee 1 4 6036 6042 8042 10042 10054 1 1 Safety Practices 1 1 INTRODUCTION This service manual provides general directions for accomplishing service and repair procedures Following the procedures in this manual will help assure safety and equipment reliability Read understand and follow the information in this manual and obey all locally approved safety practices procedures rules codes regulations and laws These instructions cannot cover all details or variations in the equipment procedures or processes described nor provide directions for meeting eve
126. OL LO3NI NOU z 133 9st T 1 ama NE LEL CM HISNI OL 5193 7 TEAST WROWS RENT esl 737002 ww E 1 E wur RA A wwe B y GNO avo amp 187002 9 DEJ xU 7 NIA AE 1 1 ONG avo Waz x xU C E ans T 00 z wv 9702 na va D t jon peus TU d 09 tJ waz wj LT n a aariddns SIN3NOdWOO EV H3 1V3H 2 3 HOLMS FRI nU us tel od h Houme er LE n MES WWE m UE pr C wn mer HT tle w ww CEA 190 un p E wor Ue QUEM wm 6036 6042 8042 10042 10054
127. Plate Supply information from the axle serial number plate when communicating about an axle assembly or axle components 5 4 2 General axle specifications are found in Section 2 4 Fluid and Lubricant Capacities Axle Specifications 5 4 5 4 3 Detailed axle service instructions covering the axle differential brakes and wheel end safety repair disassembly reassembly adjustment and troubleshooting information are provided in the appropriate Axle Repair Manual 8042 Before S N 0160038967 including 0160038971 amp 0160038984 10042 Before S N 0160038368 including 0160038375 0160038378 0160038379 0160038381 amp 0160038383 10054 Before S N 0160038740 excluding 0160021270 0160036713 0160036715 0160036721 amp Axle Internal Service 0160036723 Machine ZF Model Axle P N 8042 10042 amp MS T 3060 Front 8990430 10054 8042 MS T 3045 Rear 8990419 10042 10054 MS T 3055 Rear 8990419 6036 amp 6042 8042 S N 0160038967 amp After excluding 0160038971 amp 0160038984 10042 S N 0160038368 amp After excluding 0160038375 0160038378 0160038379 0160038381 amp 0160038383 10054 S N 0160038740 amp After including 0160021270 0160036713 0160036715 0160036721 amp 0160036723 Machine ZF Model Axle P N 6036 6042 MS T 3045 Both 31200694 8042 10042 amp MS T 3060 Front 31200695 10054 8042 MS T 3045 Rear 31200694
128. SERVICE REAR BRAKE STEERING VALVE VALVE MAIN OUTRIGGER CONTROL VALVE 10042 amp VALVE 10054 ONLY STEERING CYLINDER FRONT OUTRIGGER CYLINDERS 10042 amp 10054 ONLY MH3441 6036 6042 8042 10042 10054 8 3 Hydraulic System 8 2 SAFETY INFORMATION A WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1 Safety Practices of this manual Petroleum based hydraulic fluids are used in this machine The temperature of hydraulic fluid increases during the operation of various hydraulic functions A heated petroleum based hydraulic fluid presents a fire hazard especially when an ignition source is present Hydraulic fluid has a flash point that ranges from 300 600 F 150 318 and an auto ignition temperature of 500 750 F 262 402 C Accordingly periodically inspect all hydraulic system components hoses tubes lines fittings etc Carefully examine any deterioration and determine whether any further use of the component would constitute a hazard If in doubt replace the component Operate the hydraulic controls after the engine has stopped to relieve trapped pressure Note Residual pressure may remain in hydraulic cylinders hoses valve bodies components etc If the hyaraulic lines going to or coming from a component are taut slowly and cautiously relieve bleed off pressure Whenever you disconnect a hyaraulic line
129. SKYTHAK Service Manual Models 6036 6042 8042 10042 amp 10054 6036 S N 0160039338 amp After including 0160024571 amp 0160037911 6042 S N 0160039075 amp After 8042 10042 amp 10054 S N 0160029593 amp After 31200353 Revised April 14 2011 JL An Oshkosh Corporation Company EFFECTIVITY PAGE February 23 2007 A Original Issue Of Manual November 2 2010 B Revised pages 1 4 2 3 thru 2 18 9 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 amp 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 amp 9 5 thru 9 11 31200353 6036 6042 8042 10042 10054 EFFECTIVITY PAGE 6036 6042 8042 10042 10054 31200353 SECTION CONTENTS Section Subject Page Section 1 Safety Practices auos LEID xe uos en XR RUNDE 1 1 1 1 1 2 1 2 Disclalmoet iz sese EP 1 2 1 3 Operation amp Safety 1 2 1 4 Do Not Operate TagS cbe xvin eerie E Mr e Rex UE ecu dis uve 1 2 1 5 Safety Information rore ecu CE DENM ERE ie tee eee EAE E MA 1 2 1 6 Safety Instructions x pue pb ge kde gane De pens dubi qas s ue 1 3 1 7 Safety Decals fn hae oe aetna ee ee bb d vt d Mero MA 1 4 Section 2 General Information and Specifications
130. Sequences Fault Code 244 Pause N N P P P P 0 e 1 Blink 2 Blinks 4Blinks 4Blinks 1 Blink Fault Code 112 N N 3 P P P P Ts 4x 1 Blink 1 Blink 1 Blink 2 Blinks 1 Blink MU5441 Stop Lamp 3 The stop lamp provides critical operator messages These messages require immediate and decisive operator response The stop lamp is also used to diagnose flash out fault codes Warning Lamp 4 The warning lamp provides important operator messages These messages require timely operator attention The warning lamp is also used to delineate diagnostic fault codes 9 13 3 Offboard Diagnostics INSITE M is the Windows based PC service programming diagnostic tool for the Cummins engine It is used to help troubleshoot and repair the engine with extended fault diagnostics and processing power INSITE allows the user to view active and inactive faults and clear the inactive faults It provides a monitor function that allows the service technician to monitor measured parameters actuator status and some calculated values It also provides the technician with the capability to turn on certain drivers such as the grid heaters and lift pump as well as running diagnostic tests such as single cylinder cutout 6036 6042 8042 10042 10054 Electrical System 9 13 4 Engine Fault C
131. Tighten securely Using a sling position the Extend Retract cylinder to its original orientation under the boom Coat the base end of the cylinder with anti seize compound Insert the base end cylinder pin through both mounting ears and the base end of the Extend Retract cylinder Secure the pin in place with a retaining ring on each side of the pin Lift the rod end of the Extend Retract cylinder enough to insert the threaded stud on the rubber bumper into the hole in the Extend Retract cylinder retainer Secure the rubber bumper in place with a locknut Tighten securely Lower the rod end of the Extend Retract cylinder and allow it to rest on the rubber bumper 3 9 sae Boom 6 Using a suitable hoist and slings lift the boom 11 Use a hoist or suitable support to position the right assembly and position the boom on the frame Align side Slave cylinder to its original orientation onto the the mounting plates on the frame between the lower cylinder mount Coat the entire Slave cylinder mounting hubs on each side of the boom assembly pin with anti seize compound Insert the pin through Lower the boom assembly until the holes in the the rod end of the cylinder and the self aligning boom assembly and the mounting plates align bearing Secure with lockbolt Repeat procedure for 7 On the end of the boom pivot pin closest to th
132. Valve Circuit High 275 1347 7 Fuel Pumping Element Number 1 Front 281 1347 7 Fuel Pump Pressurizing Assembly 1 284 1043 4 4 Engine Speed Position Sensor Crankshaft Supply Voltage Circuit 285 639 9 SAE J1939 Multiplexing PGN Timeout Error 286 639 13 SAE J1939 Multiplexing Configuration Error 287 91 19 SAE J1939 Multiplexing Accelerator Pedal or Lever Sensor System Error 288 974 19 SAE J1939 Multiplexing Remote Accelerator Pedal or Lever Data 291 625 9 Proprietary Datalink Error 292 441 14 Auxiliary Temperature Sensor Input 1 Special Instructions 293 441 3 Auxiliary Temperature Sensor Input 1 High 294 441 4 Auxiliary Temperature Sensor Input 1 Low 295 108 2 Barometric Pressure Erratic 296 1388 14 Auxiliary Pressure Sensor Input 1 Special Instructions 297 1388 3 Auxiliary Pressure Sensor Input 1 Circuit High 298 1388 4 Auxiliary Pressure Sensor Input 1 Circuit Low 319 251 2 2 Real Time Clock Power Interrupt 322 651 5 Injector Solenoid Driver Cylinder 1 Circuit Low 323 651 5 Injector Solenoid Driver Cylinder 5 Circuit Low 324 653 5 Injector Solenoid Driver Cylinder 3 Circuit Low 325 656 5 Injector Solenoid Driver Cylinder 6 Circuit Low 331 652 5 Injector Solenoid Driver Cylinder 2 Circuit Low 332 654 5 Injector Solenoid Driver Cylinder 4 Circuit Low 334 110 2 Engine Coolant Temperature 341 630 2 2 Engine Control Module Data Lost 342 630 13 Electronic Calibration Code Incompatibility 343 629 12 2 Engine Control Module Warni
133. a and tools 10 Install the transmission covers 11 Close and secure the rear door 8 32 d Extend Lockout Valve Test Conduct a test of the extend lockout valve 1 Park the machine on a firm level surface 2 With the boom fully retracted and lowered lower the outriggers 3 Extend the boom to 54 ft The boom should extend fully and should not stop at 42 ft 8 8 HYDRAULIC CYLINDERS 8 8 1 General Cylinder Instructions a Cylinder Removal 1 Remove any attachment from the machine Park the machine on a firm level surface and fully retract the boom Allow sufficient work space around the hydraulic cylinder being removed Support the boom if the lift lower cylinder is being removed Place the travel select lever in N NEUTRAL engage the park brake shut the engine OFF and chock wheels 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the rear door Allow the system fluids to cool 4 Label disconnect and cap or plug hydraulic hoses in relation to the cylinder 5 Attach a suitable sling to an appropriate lifting device and to the cylinder Make sure the device used can actually support the cylinder 6 Remove the lock bolt and or any retaining clips securing the cylinder pins Remove the cylinder pins 7 Remove the cylinder 8 Wipe up any hydraulic fluid spillage in on near and around the machine work are
134. a and tools 6036 6042 8042 10042 10054 Hydraulic System n b Cylinder Disassembly 1 Clean the cylinder with a suitable cleaner before disassembly Remove all dirt debris and grease from the cylinder MH6520 2 Clamp the barrel end of the cylinder in a soft jawed vise or other acceptable holding equipment if possible A WARNING Significant pressure may be trapped inside the cylinder Exercise caution when removing a counterbalance valve or a pilot operated check valve from a cylinder Note Avoid using excessive force when clamping the cylinder in a vise Apply only enough force to hold the cylinder securely Excessive force can damage the cylinder tube 3 If applicable remove the counterbalance valve from the side of the cylinder barrel Note DO NOT tamper with or attempt to adjust the counterbalance valve cartridge If adjustment or replacement is necessary replace the counterbalance valve with a new part 4 Extend the rod as required to allow access to the base of the cylinder Note Protect the finish of the rod at all times Damage to the surface of the rod can cause seal failure 5 Using a pin spanner wrench unscrew the head gland from the tube A considerable amount of force will be needed to remove the head gland Carefully slide the head gland down along the rod toward the rod eye away from the cylinder barrel 6036 6042 8042 10042 10054 Note When slidi
135. aced if necessary Note DO NOT attempt to repair a chain Replace a stretched or damaged chain with a new part Always replace both the chain and the clevis It is recommended that when any chain is replaced that all chains and clevis be replaced at the same time 6036 6042 8042 10042 10054 3 7 4 After inspection and before being returned to service chains must be lubricated with Mystik Tetrimoly Grease Chain Lubrication The lubricant must penetrate the chain joint to prevent wear Applying lubricant to the external surfaces will prevent rust but the chains should be articulated to make sure the lubricant penetrates to the working surfaces between the pins and links To prepare the chain for lubrication the chain plates should be brushed with a stiff brush or wire brush to clear the space between the plates so that lubricant can penetrate to the working surfaces Lubricant may be applied with a narrow paint brush or directly poured on but the chain should be well flooded with lubricant and the boom should be extended and retracted to be sure that the lubricant penetrates to the working surfaces All surplus lubricant should be wiped away from the external surfaces DO NOT use a solvent for this wiping operation Regular application of lubricant is necessary to make sure that all working surfaces are adequately lubricated In extremely dusty conditions it may be necessary to lubricate the chains more often Refer
136. achment the boom head Reassemble the shims between the quick attach and the boom head 3 8 2 Connecting to an Attachment NP Tm 2 Coat the quick attach head pin with an anti seize 1 Perform this procedure on a hard level surface only compound Insert the quick attach head pin through Position the machine directly behind the attachment the quick attach and boom head Secure with the to be mounted previous capscrew and locknut 2 Tilt the quick attach backward 3 Align the quick attach with the Attachment Tilt 3 Extend the boom approximately 10 ft 3 05 m and drive the machine forward until the attachment pivot pins are below and between the two hooks on the attachment 3 48 cylinder rod end and insert the Attachment Tilt cylinder pin Align the Attachment Tilt cylinder pin and screw in the locking bolt Torque as required 6036 6042 8042 10042 10054 Boom e a i 3 9 BOOM WEAR PADS 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 amp 10042 machines and 47 wear pads on the 10054 machines 3 9 1 Wear Pad Inspection 1 1 xS a Ma2070 Inspect all wear pads for wear If the angle indicators 1 on the ends of the wear pads are visible the wear pads can be reused If the pads show uneven wear front to back they should be replaced Replace pads as a set if
137. ad or breather If the return filter becomes plugged return hydraulic oil will bypass the filter when pressure reaches 25 psi 1 7 bar and return to the reservoir unfiltered Carefully examine fluid seepage or leaks from the hydraulic reservoir to determine the exact cause Clean the reservoir and note where any seepage occurs Leaks from a cracked or damaged reservoir require that the reservoir be removed from the machine flushed completely with water and repaired by a certified welder using approved techniques If these conditions cannot be met the reservoir must be replaced in its entirety 8 5 1 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 Hydraulic Oil Reservoir Draining 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the rear door Allow the system fluids to cool 4 Properly disconnect the battery 6036 6042 8042 10042 10054 5 Open the filler cap on the hydraulic oil reservoir Remove the drain plug on the side of the hydraulic oil reservoir 6 Transfer the used hydraulic oil into a suitable covered container and label as Used Oil Dispose of used oil at an approved recycling facility Clean and reinstall the drain plug 7 Wipe up any hydraulic fluid s
138. al components from the old tank and retain for use on the replacement tank Note Have a dry chemical Class B fire extinguisher near the work area A WARNING NEVER drain or store fuel in an open container due to the possibility of explosion or fire Discard the fuel in an approved manner 5 Remove the fuel hydraulic oil tank top cover 6 Remove the two frame top covers from above the frame 7 5 Engine Cummins QSB3 3T QSB4 5T MAQ0330 7 Remove fuel tank drain plug 5 and drain fuel into an approved and suitable container Dispose of fuel properly 8 Drain the hydraulic oil tank 6 Refer to Section 8 5 1 Hydraulic Oil Reservoir Draining 9 Label disconnect and cap the fuel and hydraulic lines from the tank 10 Label and disconnect the electrical components from the fuel hydraulic oil tank 11 Position and connect a suitable chain support to tank lifting point 7 and take up slack in the chain 12 While supporting the tank remove nuts and lockwashers securing the tank to the machine frame Pull tank away from the tank carriage bolts and remove tank b Disassembly The fuel hydraulic oil tank is a one piece unit and cannot be disassembled The fuel level indicator and hydraulic filters can be removed and reused on the new replacement tank Dispose of the old tank according to local regulations concernin
139. ally check for leaks with the engine running Check the coolant level in the overflow bottle and fill or drain as necessary 6 Close and secure the side and rear engine doors 7 5 ENGINE ELECTRICAL SYSTEM The engine electrical system including the starter alternator and primary wiring is described in Section 9 Electrical System 7 6 FUEL SYSTEM 7 6 1 Fuel represents a major portion of machine operating costs and therefore must be used efficiently ALWAYS use a premium brand of high quality clean diesel fuel Low cost inferior fuel can lead to poor performance and expensive engine repair Diesel Fuel Note Use only diesel fuel designed for diesel engines Some heating fuels contain harmful chemicals that can seriously affect engine efficiency and performance Note Due to the precise tolerances of diesel injection systems keep the fuel clean and free of dirt and water Dirt and water in the fuel system can cause severe damage to both the injection pump and the injection nozzles Use ASTM 2 diesel fuel with a minimum Cetane rating of 40 2 diesel fuel gives the best economy and performance under most operating conditions Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to help prevent misfiring and excessive smoking Inform the owner operator of the machine to use 2 diesel fuel unless ambient temperatures are below 32 F 0 C When tempera
140. alve is installed in the machine Air in the system will not allow the brakes to apply properly There are four brake bleeder locations on the axles Work with an assistant to perform this procedure 1 Place the travel select lever in N NEUTRAL engage the park brake and start the engine MH6220 Remove the plastic cap from the brake bleeder 2 Attach one end of a length of transparent tubing over the brake bleeder Place the other end of this tubing in a suitable transparent container that is partially filled with hydraulic oil The end of the tubing must be below the oil level in the container DO NOT open the brake bleeder without holding the tubing firmly on the bleeder There is pressure at the brakes Carefully open the bleeder with a wrench Have the assistant depress the brake pedal Close the brake bleeder when air bubbles no longer appear in the oil Release the brake pedal Remove the tubing from the brake bleeder Repeat Steps 2 and 3 for the remaining brake bleeders Conduct a pressure and function check of the service brake Refer to Section 8 4 1 Hydraulic Pressures 6036 6042 8042 10042 10054 8 7 5 Power Steering Valve The power steering valve 3 is located at the base of the steering wheel shaft concealed by the lower dash cover The valve is not serviceable and must be replaced in its entirety if defective For detailed information refer to Section 4 3 1 Steering Column
141. alves installed in the Stabil TRAK manifold attached to the stabilizer cylinder above the left side of the rear axle If a solenoid valve is suspected of malfunctioning disconnect the coil wiring lead and test the coil for proper resistance 7 9 ohms and for proper voltage from the harness 12 VDC Replace the solenoid coil if open or shorted to ground Also inspect the valve cartridge o rings and the other hydraulic and electrical components in the circuit to accurately determine the cause of the problem All solenoid coils are identical and can be interchanged for diagnostic purposes MT3132 Note DO NOT interchange solenoid valves 4A 1 4B 2 12A 3 or 12B 4 with solenoid valve 3 5 These valves will fit into the other locations but are configured differently internally and will not operate properly if interchanged Cartridge valves 4A 1 4B 2 12A 3 and 12B 4 are identical and can be interchanged for diagnostic proposes Note Make sure the 0 060 orifices are in place when installing solenoid valves 4A 1 and 4B 2 In general if there is a problem with the Stabil TRAK system beyond common electrical troubles the involved electrical and hydraulic circuits should each be checked and the exact source of the problem diagnosed before any parts are replaced 6036 6042 8042 10042 10054 Stabil TRAK System and Boom Interlock System 10 4 STABIL TRAK ELECTRICAL CIRCU
142. and 5 8 5 8 4 Hydraulic 8 5 8 4 1 Hydraulic Pressures 8 6 8 4 2 Hydraulic 5 8 16 8 5 Hydraulic Reservoir 8 21 8 5 1 Hydraulic Oil Reservoir 8 21 8 5 2 Hydraulic Oil Reservoir 8 21 8 5 3 Hydraulic Oil Reservoir Replacement 8 21 8 6 Hydraulic System 8 22 8 6 1 Pump 8 22 8 7 Valves and Manifolds 8 23 8 7 1 Main Control Valve 8 23 8 7 2 Secondary Function 8 25 8 7 3 Service Brake Valve 8 26 8 7 4 Brake Test ug apes UT odas 8 27 8 7 5 Power Steering Valve 8 27 8 7 6 Steer Select 8 28 8 7 7 Unloader Valve 6036 amp 6042 only 8 29 8 7 9 Extend Lockout Valve 10054 8 31 8 8 Hydraulic 5 8 32 8 8 1 General Cylinder 5 8 32 8 8 2 Cylinder Pressure 8 34 8
143. and Steering Valve 8 27 Hydraulic System MH6190 The machine can be used in the front wheel four wheel or crab steering mode The steer select valve 4 controls the direction of hydraulic fluid flow to the steering cylinders mounted on each axle The steer select valve is attached to a manifold mounted to a mounting plate inside the frame near the fuel tank Verify the correct operation of the steer select valve solenoids before considering replacement of the valve The housing of the steer select valve is not serviceable and must be replaced if defective a Steer Select Manifold and Valve Removal 1 Park the machine on a firm level surface level the machine fully retract the boom raise the boom place the transmission control lever in 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 Temporarily block up or support the raised boom Open the rear door Allow the system fluids to cool Properly disconnect the battery Remove the transmission covers c C Label disconnect and cap the hydraulic hoses and the electrical plugs connected to the steering select valve 8 Remove the bolts holding the steer select valve to the mounting plate on the frame 9 Remove the steer select manifold with the attached steer select valve from th
144. are Torque to 148 Ib ft 200 Nm 4 Install the two front rubber mounts and the front transmission mounting bracket 9 on the transmission with the previously used hardware Torque to 148 Ib ft 200 Nm 5 Attach the front mounting bracket to the frame with the previously used hardware 6 Remove the hoist or overhead crane and sling 6036 6042 8042 10042 10054 S id LS A Ee A OIA MH3411 Note The lifting ring 3 must be repositioned to allow the covers to be installed 7 Remove the two capscrews securing the lifting ring to the transmission housing Save the capscrews for later use 8 Remove the capscrew and secure the lifting ring in the storage position 4 on the transmission housing as shown MH3391 9 Connect the transmission temperature switch connector 5 and shift solenoid wiring harness connectors 6 10 Attach the black wire 7 to the transmission housing with a capscrew removed in step 7 11 Secure the wiring harness to the transmission housing using the clip and a capscrew removed in step 7 6 5 Transmission 12 13 14 15 16 17 18 19 20 21 Close and secure the rear door 6 4 4 After Transmission Service or Replacement In general 1 Check the transmission oil level and add oil as required 2 Install a new transmission filter 3 Check the torque on the drive shaft yoke capscrews
145. assemblies with double top boom extend chains and a single retract chain Boom extension and retraction is accomplished via hydraulic power and chain movement Boom System Operation As the Extend Retract hydraulic cylinder which is anchored at the rear of the second boom section and the rear of the first boom section begins to extend it forces the second boom section out of the first boom section The second and third boom sections are connected by extend and retract chains These chains are routed around sheaves on the second boom section As the second boom section is forced out the extend chain pulls the third boom section out of the second boom section As hydraulic pressure is applied to the retract port on the Extend Retract cylinder the second boom section is pulled back into the first boom section and retract chain pulls the third boom section back into the second section This mechanical linkage formed by the chains and supporting hardware extends and retracts the second and third boom sections at the same rate The first boom section does not extend or retract but lifts and lowers via action of the lift lower cylinder 3 4 BOOM ASSEMBLY MAINTENANCE These instructions must be completed in sequence The third boom section must be removed before removing the second boom section The third and second boom section must be removed at one time before removing the first boom section Before beginning conduct a visua
146. at the spring is intact Inspect the cartridge interior for contamination 6 Inspect internal passageways of the outrigger valve for wear damage etc If inner surfaces of the valve DO NOT display an ultra smooth polished finish or components are damaged in any way replace the valve or appropriate part Often dirty hydraulic fluid causes failure of internal seals and damage to the polished surfaces within the secondary function manifold Note ALWAYS replace seals o rings gaskets etc with new parts to help ensure proper sealing and operation Lubricate seals and o rings with clean hydraulic oil 7 Install the shuttle cartridges into the outrigger valve Torque to 35 Ib ft 48 Nm 8 Attach the solenoid assemblies to the outrigger valve using four new oiled o rings and the previously used capscrews 6036 6042 8042 10042 10054 Hydraulic System n c Outrigger Valve Installation 1 Insert the previously used bolts through the bottom of the outrigger valve and loosely attach the flange nuts to the carriage bolts 2 Position the outrigger valve so that the heads of the carriage bolts go through the slots in the frame Tighten the flange nuts 3 Connect all the previously labeled hydraulic hoses fittings solenoid wire terminal leads etc to the outrigger valve 4 Check the routing of all hoses and wiring for sharp bends or interference with any rotating members and install tie wraps an
147. ation and Specifications 2 2 1 SAE Fastener Torque Chart Continued SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners Ref 4150707 Torque Torque Torque Loctite 242 271 1 on OR Vibra TITE 111 or or Vibra TITE 131 20 140 OR Precoat 85 Tensile Clamp Load See Note 4 0 18 o oe o me a 9 120 s 000908 pp 40 0388 001018 oo 8 e 0364 001400 I 36 0 0144 LL 24 0 1900 001780 pp lam 002090 20 0250 0038 80 w tee 0250 S280 164 w 148 17 m j sem t8 im rte im Nm 16 03750 oors 7000 45 s s s s a osso 0 0878 7900 so m o so mme 14 04375 9550 x 95 6 o so 70 04375 0 187 10700 so no 70 95 60 60 0500 12750 105 1s 95 130 so no 05000 01599 14400 120 165 no 90 120 0 1820 155 210 140 190 115 155 E 170 230 155 210 130 175 0 6250 0 2260 210 285 190 260 1
148. ations Detailed transmission service instructions are provided in the following publications Service Manual P N 8990455 Parts Manual 6036 P N 8990417 6042 P N 8990467 8042 10042 amp 10054 P N 8990395 6 4 TRANSMISSION REPLACEMENT Note Contact your local JLG Service Department if internal transmission repair is required during the warranty period Note Cleanliness is of extreme importance Before attempting to remove the transmission thoroughly clean the exterior of the transmission to help prevent dirt from 6036 6042 8042 10042 10054 entering during the replacement process Avoid spraying water or cleaning solution onto or near the transmission shift solenoids and other electrical components 6 4 1 Transmission Removal A WARNING NEVER lift a transmission alone enlist the help of at least one assistant or use a Suitable hoist or overhead crane and sling with the minimum lifting capacity of 1000 Ib 454 kg 1 Park the machine on a firm level surface level the machine fully retract the boom raise the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated 3 Temporarily block up or support the boom 4 Open the rear door Allow the system fluids to cool 5 Drain the hydraulic oil reservoir
149. ats to hold the slider head and tighten the cable nut to a maximum of 55 Ib ft 75 Nm d Repeat steps for remaining cables 3 Properly connect the battery 4 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 5 Test the joystick function Boom Control Joystick Move the joystick handle rearward activating the boom lift function The boom should RISE Move the joystick handle forward activating the boom lower function The boom should LOWER Move the joystick handle to the right activating the boom extend function The boom should EXTEND Move the joystick handle to the left activating the boom retract function The boom should RETRACT Attachment Tilt Sway Control Joystick Move the joystick handle rearward activating the attachment tilt function The boom should TILT UP Move the joystick handle forward activating the attachment tilt function The boom should TILT DOWN Move the joystick handle to the right activating the frame sway function The boom should SWAY RIGHT 6036 6042 8042 10042 10054 Cab and Covers Move the joystick handle to the left activating the frame sway function The boom should SWAY LEFT Auxiliary Control Joystick Move the joystick handle to the right the auxiliary attachment should LOWER OPEN Move the joystick handle to the left the auxiliary attachment should RAISE CLOSE 6 Install console
150. aulic fluid causes failure of internal seals and damage to the polished surfaces within the valve Note ALWAYS replace seals o rings gaskets etc with new parts to help ensure proper sealing and operation Lubricate seals and o rings with clean hydraulic oil 5 Install the solenoid valve 6 Install the pressure sensing valve Torque to 65 lb ft 88 Nm c Extend Lockout Valve Installation 1 Place the extend lockout valve into position on the mounting plate on the machine frame 2 Install the bolt and nut securing the valve to the frame 3 Connect all the previously labeled hydraulic hoses fittings solenoid wire terminal leads etc to the outrigger valve 4 Check the routing of all hoses and wiring for sharp bends or interference with any rotating members and install tie wraps and or protective conduit as required Tighten all hose clamps 5 Properly connect the battery 6 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 7 Start the engine and run at approximately 1 3 1 2 throttle for about one minute without moving the machine or operating any hydraulic functions 8 Inspect for leaks and check the level of the hydraulic fluid in the reservoir Shut the engine OFF Note Check for leaks and repair as required before continuing Add hydraulic fluid to the reservoir as needed 9 Wipe up any hydraulic fluid spillage in on near and around the machine work are
151. bil TRAK System Test Procedures 10 7 10 6 Stabil TRAK Boom Interlock Electrical Circuit Operation and Troubleshooting 10054 10 10 10 7 Boom Ouirigger Interlock System Test 10054 10 12 10 7 1 System Test 10 12 10 8 Stabil TRAK Hydraulic Circuit Operation and Troubleshooting 10 14 6036 6042 8042 10042 10054 10 1 Wi Stabil TRAK System and Boom Interlock System 10 1 STABIL TRAK SYSTEM COMPONENT TERMINOLOGY To understand the safety operation and maintenance information presented in this section it is necessary that the operator mechanic be familiar with the names and locations of the major assemblies of the Stabil TRAK system The following illustration identifies the components that are referred to throughout this section STABIL TRAK A CYLINDER TE STABIL TRAK MANIFOLD FRAME SWAY mn CYLINDER BOOM PROXIMITY SWITCH MODEL 10054 SHOWN MH2962 10 2 6036 6042 8042 10042 10054 Stabil TRAK System and Boom Interlock System 10 2 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
152. boom Place the Extend Retract cylinder on a clean flat surface At the front of the first boom section remove rubber bumper to the Extend Retract cylinder retainer Inspect the rubber bumper If it is in good condition the rubber bumper can be reused If the bumper is showing signs of cracking or deterioration it should be replaced Remove the two yoke plates to the mount at the front of the boom Inspect the yoke plates for wear or distortion If any wear or distortion is detected both plates must be replaced If no wear is detected the plates can remain assembled to the extend chain clevis Inspect all wear pads for wear Refer to Section 3 9 Boom Wear Pads First Boom Section Installation On the rear of the boom assemble the Extend and Retract bulkhead fittings to the mounting plate on the right side Insert the fittings from the bottom up and secure in place with the bulkhead fitting nuts on the top side Tighten securely Repeat this procedure for the Attachment Tilt fittings on the left side Note Keep the caps on the threaded ends of the fittings to protect the threads from damage and to keep dirt and debris from entering the hydraulic system 2 If equipped with Auxiliary hydraulics assemble the Auxiliary hydraulic bulkhead fittings to the mounting plate on the left side Insert the fittings from the bottom up into the outer set of holes and secure in place with the bulkhead fitting nuts on the top side
153. boom pivot pin closest to the capscrew hole mark the capscrew mounting hole location Coat the entire pin with anti seize compound Insert the pivot pin from the outside of the boom assembly making sure the marks for the capscrew mounting hole stay in line with the capscrew mounting holes in the boom mounting hub 3 21 Boom 10 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 Align the rod end of the right Lift Lower cylinder with the self aligning bearing on the boom assembly Coat the entire Lift Lower cylinder pin with anti seize compound Insert the pin through the rod end of the cylinder and the self aligning bearing Secure with lock bolt Repeat procedure with left Lift Lower cylinder Use a hoist or suitable support to position the right side Slave cylinder to its original orientation onto the lower cylinder mount Coat the entire Slave cylinder pin with anti seize compound Insert the pin through the rod end of the cylinder and the self aligning bearing Secure with lockbolt Repeat procedure for left side Slave cylinder Install the boom proximity sensor on the right side mounting p
154. boom rear cover 33 Properly connect the battery 34 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 6036 6042 8042 10042 10054 3 47 3 8 QUICK ATTACH ASSEMBLY 4 Raise the boom until the attachment pivot pins have seated fully in the hooks on the attachment This machine is equipped with a quick attach assembly 5 Tilt the attachment up slightly The quick attach link system for easy attachment changes should be tight up against the rear of the attachment and the holes in the link and the attachment should 3 8 1 Disconnecting from an Attachment be aligned 1 Park the machine on a hard level surface 6 Place the travel select lever in the NEUTRAL 2 Place the transmission control lever in the N position engage the parking brake switch unbuckle NEUTRAL position and engage the parking brake the seat belt and exit the machine using both hand switch holds ground the attachment and tilt the carriage completely through the attachment and the quick backward Shut the engine OFF attach link Be sure that the quick attach lock lever 4 Exit the machine using both hand holds has lowered and seated itself into the groove in the quick attach pin Note If removing a standard carriage with forks spread 8 If equipped connect Auxiliary hydraulic hoses the forks apart on the carriage shaft This will help give the ca
155. cal regulations regarding waste storage disposal and recycling Safety Practices 1 6 4 ENGINE Stop the engine before performing any service unless specifically instructed otherwise Operational Hazards VENTILATION Avoid prolonged engine operation in enclosed areas without adequate ventilation SOFT SURFACES AND SLOPES NEVER work on a machine that is parked on a soft surface or slope The machine must be on a hard level surface with the wheels blocked before performing any service FLUID TEMPERATURE NEVER work on a machine when the engine cooling or hydraulic systems are hot Hot components and fluids can cause severe burns Allow systems to cool before proceeding FLUID PRESSURE Before loosening any hydraulic or diesel fuel component hose or tube turn the engine OFF Wear heavy protective gloves and eye protection NEVER check for leaks using any part of your body use a piece of cardboard or wood instead If injured seek medical attention immediately Diesel fluid leaking under pressure can explode Hydraulic fluid and diesel fuel leaking under pressure can penetrate the skin cause infection gangrene and other serious personal injury Relieve all pressure before disconnecting any component part line or hose Slowly loosen parts and allow release of residual pressure before removing any part or component Before starting the engine or applying pressure use components parts hoses and pipes
156. cylinder 6036 6042 8042 10042 10054 19 Remove the rubber bumper from the Extend Retract cylinder retainer Inspect the rubber bumper If it is in good condition the rubber bumper can be reused If the bumper is showing signs of cracking or deterioration it should be replaced 20 Remove the Extend Retract cylinder from the boom 3 6 5 1 First Boom Section Installation Using a suitable hoist and sling position the Extend Retract cylinder with the port elbows facing down Place the rod end of the cylinder through the cylinder retainer at the front of the boom Coat the base end of the cylinder with anti seize compound Insert the base end cylinder pin through both mounting ears and the base end of the Extend Retract cylinder Secure the pin in place with a retaining ring on each side of the pin Lift the rod end of the Extend Retract cylinder enough to insert the threaded stud on the rubber bumper into the hole in the Extend Retract cylinder retainer Secure the rubber bumper in place with a new locknut Tighten securely Lower the rod end of the Extend Retract cylinder and allow it to rest on the rubber bumper 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 On the end of the
157. cylinder pivot pin noise and or wear Insufficient lubrication Worn bushing s Lubricate at regular intervals Refer to Section 2 6 Lubrication Schedules Replace worn pins as needed Replace bushing s and lubricate at regular intervals 5 Boom will not raise or lower Broken hydraulic hoses or tubes and or connection leaks Lift lower hydraulic system not operating properly Faulty lift lower cylinder Seized boom pivot pin bearing Locate break replace hose s or tube s tighten connections Refer to Section 8 Hydraulic System Repair cylinder Refer to Section 8 8 Hydraulic Cylinders Replace bearing 3 54 6036 6042 8042 10042 10054 Boom C ipd Problem Cause Remedy 6 Drooping chain or jerky boom extend or retract functions Chain s tension not properly adjusted Chain s stretched or binding Wear pads loose contaminated excessively worn or damaged Contaminated corroded or rusted wear pad sliding surfaces Extend Retract hydraulic system not operating properly Damaged boom section Adjust chain s Replace chains as needed Refer to Section 3 7 Boom Extend and Retract Chains Replace wear pad Refer to Section 3 9 Boom Wear Pads Remove contamination and or corrosion from wear pad sliding surface
158. d Note The head gland bearing will need to be inspected to determine if replacement is necessary DO NOT attempt to salvage cylinder seals sealing rings or o rings ALWAYS use a new complete seal kit when rebuilding hydraulic components Consult the parts catalog for ordering information c Cylinder Cleaning Instructions 1 Discard all seals back up rings and o rings Replace with new items from seal kit to ensure proper cylinder function 2 Clean all metal parts with an approved cleaning solvent such as trichlorethylene Carefully clean cavities grooves threads etc Note If a white powdery residue is present on threads or parts it can be removed by using a soft brass wire brush Wipe clean with Loctite Cleaner prior to reassembly 8 33 Hydraulic System n 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 400 600 grit emery cloth Use the emery cloth in a rotary motion to polish out and blend the scratch es into the surrounding surface 3 Check the piston rod assembly for run out If the rod is bent it must be replaced e Cylinder Assembly Instructions 1 Use the proper tools for specific installation tasks C
159. d 1 Oillevel plugs loose and or Replace o rings as needed and housing planet carrier o rings damaged or missing tighten plugs to 96 Ib ft 130 Nm 2 O ring between hub and Replace o ring housing planet carrier damaged or missing 3 Shaft seal damaged or missing Replace seal and or fork joint and or worn or damaged shaft shaft sealing surfaces 4 Housing capscrews loose Tighten housing capscrews to 41 Ib ft 55 Nm 5 Housing planet carrier damaged Replace housing planet carrier 6 Oil leaking from steering 1 Hose fittings loose Tighten fittings cylinder d 2 Steering cylinder o rings and or Replace o rings and seals seals worn or damaged 3 Piston rod seal worn or Replace piston rod seal damaged 4 Oylinder tube damaged Replace cylinder tube 5 12 6036 6042 8042 10042 10054 Axles Drive Shafts Wheels and Tires P Problem Cause Remedy 7T Axle overheating Oil level too high Axle and or wheel end housings filled with incorrect oil or oil contaminated or oil level low Dragging park brake Fill oil to correct level with Mobilfluid 4249 ISO 46 Refer to Section 2 4 Fluid and Lubricant Capacities Drain axle and fill to correct level with Mobilfluid 4249 ISO 46 Refer toSection 2 4 Fluid and Lubricant Capacities Adjust park brake cable as needed 8 High steering effort required Steerin
160. d or protective conduit as required Tighten all hose clamps 5 Properly connect the battery 6 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 7 Start the engine and run at approximately 1 3 1 2 throttle for about one minute without moving the machine or operating any hydraulic functions 8 Inspect for leaks and check the level of the hydraulic fluid in the reservoir Shut the engine OFF Note Check for leaks and repair as required before continuing Add hydraulic fluid to the reservoir as needed 9 Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools 10 Install the transmission covers 11 Close and secure the rear door 8 7 9 Extend Lockout Valve 10054 only MH6190 6036 6042 8042 10042 10054 Model 10054 has an extend lockout valve 5 which prevents the boom from being extended beyond 42 feet unless the outriggers are lowered onto firm terrain Once the outriggers are lowered pressure switches located on each outrigger cylinder close and energize the solenoid on the boom extend lockout valve The boom can then be fully extended a Extend Lockout Valve Removal 1 Park the machine on a firm level surface level the machine fully retract the boom raise the boom place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key
161. d replace the chain Elongation It is important to measure the chain in the section that moves over the sheaves because it receives the most frequent articulation Measuring the chain near its clevis terminals could give an inaccurate reading The ends of the chains near the clevis terminal will not have flexed as frequently if at all as the middle of the chains It is best to measure in 12 pin increments from pin center to pin center For example if the links are one inch from pin center to pin center the distance should be 12 in 305 mm If the links are 3 4 in 19 0 mm apart the distance after 12 pins should be 9 in 228 6 mm MY1360 If the distance measured 3 is 3 greater than the normal length 4 discard and replace the chain 6036 6042 8042 10042 10054 Distorted or Battered Link Plates MZ1466 Distorted or battered link plates 5 on a leaf chain can cause tight joints and prevent flexing Turning or Protruding Pins Highly loaded chain operating with inadequate lubrication can generate abnormal frictional forces between pin and link plates When chain is allowed to operate in this condition a pin or series of pins can begin to twist out of a chain resulting in failure 21465 Examine the pin head rivets to determine if the VEE flats are still in correct alignment 6 Chain with rotated displaced hea
162. d the rear of the first boom section begins to extend it forces the second boom section out of the first boom section Boom System Operation The fourth third second and first boom sections are connected by extend and retract chains These chains are routed around sheaves on the third and second boom sections As the second and third boom sections are forced out the extend chain pulls the fourth boom section out of the third As hydraulic pressure is applied to the retract port on the Extend Retract cylinder the third boom section is pulled back into the fourth boom section and the retract chain pulls the third and fourth boom sections back into the second boom section This mechanical linkage formed by the chains and supporting hardware extends and retracts the second third and fourth boom sections at the same rate The first boom section does not extend or retract but lifts and lowers via action of the Lift Lower cylinders 3 6 BOOM ASSEMBLY MAINTENANCE These instructions must be completed in sequence The fourth boom section must be removed before removing the third boom section The third boom section must be removed before removing the second boom section The fourth third and second boom section must be removed at one time before removing the first boom section Before beginning conduct a visual inspection of the machine and work area and review the task about to be undertaken Read understand and follow these
163. de bottom and top wear pads 18 202 SL ZZ GES ev MH2441 Lay the fourth boom section extend chain 18 on the top of the fourth boom section with the threaded clevis end toward the rear of the boom Coat the threads on the clevis with multi purpose grease and insert the clevis through the hole in the anchor plate Install a washer and locknut onto the clevis Tighten the locknut enough so the threads are even with the top of the locknut Note The hose carrier only folds one way DO NOT force it DO NOT twist the hose carrier while folding 3 25 Boom MH2411 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 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 Lift the upper part of the hose carrier assembly and place the hose carrier guide under the hose carrier with the angled guides toward the front Slide the hose guide into the fourth boom section and place the front notches onto the rear wear pad mounting capscrew Be sure the notch in the side of the hose guide is under the flat washer on each side of the boom Rotate the back of the hose guide up toward the top of the fourth boom section as far as it will go Tighten the rear wear
164. deeper je ped 7 12 Section 8 Hydraulic System issu 8 1 8 1 Hydraulic Component Terminology 8 2 8 2 Safety Information 8 4 8 3 Hydraulic Pressure Diagnosis 8 4 8 4 Hydraulic CIKGUltSs c cx XR eee ee eM E EUR e RR re Ere rg ta 8 5 8 5 Hydraulic Fieservoir xz rai RD ex da Pee dea 8 21 8 6 Hydraulic System 8 22 8 7 Valves and 45 8 23 8 8 Hydraulic Cylinders 8 32 ii 6036 6042 8042 10042 10054 Section Subject Section 9 Electrical Systemi at Ga c Re De OON 9 1 Electrical Component Terminology 9 2 5 9 3 Safety Information 9 4 Fuses and Relays 9 5 Electrical System Schematics 9 6 Engine Start Circuit liliis nn 9 7 Charging rec 9 8 Window Wiper Washer Windshield Wiper
165. distance is less than 13 75 in 349 mm or greater than 14 25 in 362 mm 1 Verify that the retract chain clevis is not mounted in the last hole in the anchor plate 2 Make sure that the chain system is properly tensioned Refer to Section 3 7 5 Boom Chain Tension Check 3 To increase the separation distance Loosen the retract chain locknut on the bottom of the second boom section one or two turns and tighten the extend chain locknut the same number of turns A minimum of one full thread on the clevis must protrude beyond the collar of the locknut 4 To decrease the separation distance Loosen the extend chain locknut at the rear of boom one or two turns and tighten the retract chain locknut on the bottom of the second boom section the same number of turns A minimum of one full thread on the clevis must protrude beyond the collar of the locknut Note lf the fourth to third boom section separation distance cannot be achieved contact your local authorized service distributor 6036 6042 8042 10042 10054 3 7 8 Extend Chains Removal and Replacement 6036 6042 8042 amp 10042 1 Park the machine on level ground Place the transmission control lever NEUTRAL engage the parking brake switch level the boom and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Properly disconnect the battery 4
166. ds 7 or abnormal pin protrusion 8 should be replaced immediately DO NOT attempt to repair the chain by welding or driving the pin s back into the chain Once the press fit integrity between outside plates and pins has been altered it cannot be restored Any wear pattern on the pin heads or the sides of the link plates indicates misalignment in the system This condition damages the chain as well as increases frictional loading and should be corrected 3 51 b Boom Cracked Plates Inspect the chains very carefully front and back as well as side to side for any evidence of cracked plates If any one crack is discovered the chain should be replaced in its entirety It is important however to determine the cause of the crack before installing a new chain so the condition does not repeat itself MZ1467 uc MZ1468 The types of cracks are Fatigue Cracking Fatigue cracks 9 are a result of repeated cyclic loading beyond the chain s endurance limit Stress Corrosion Cracking The outside link plates are particularly susceptible to stress corrosion cracking 10 Corrosion Fatigue Cracking Corrosion fatigue cracks are very similar to fatigue cracks in appearance Corrosion fatigue is the combined action of an aggressive environment and cyclic stress 220 21469 Other Modes of Failure Ultimate Strength Failure These types of failures are caused by overl
167. e Auxiliary hydraulic system With the sling still in place install the rod end of the slave cylinder pin and bolt Apply Loctite 242 torque lock bolt to 100 110 lb ft 135 149 Nm With the sling still in place install the rod end of each lift lower cylinder pin and bolt Apply Loctite 242 torque lock bolt to 200 215 lb ft 271 291 Nm Uncap and connect the hydraulic hoses at the rear of the boom Connect the boom proximity sensor at the rear of the boom Recheck wear pad gaps to ensure they meet the minimum gap requirement Shim as necessary Ensure that the boom chains are properly adjusted Refer to Section 3 7 6 Boom Chain Tension Adjustment 6036 6042 8042 amp 10042 Properly connect the battery Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel Start the engine and operate all boom functions several times Check for leaks and check the hydraulic fluid at the reservoir add fluid if required 6036 6042 8042 10042 10054 Boom C A i 35 BOOM SYSTEM FOUR SECTION 10054 3 5 1 The four section boom consists of the fourth third second and first boom assemblies with double intermediate boom extend chains a single inner boom extend chain a single inner boom retract chain and a single intermediate boom retract chain As the Extend Retract hydraulic cylinder which is anchored atthe front of the second boom section an
168. e battery If the engine alternator charging warning indicator illuminates perform the following checks 1 Check all battery cable connections at the battery and verify that they are clean and tight Check the external alternator wiring and connections and verify that they are in good condition Check the fan belt condition and tension Run the engine and check the alternator for noise A loose drive pulley loose mounting hardware worn or dirty internal alternator bearings a defective stator or defective diodes can cause noise Replace a worn or defective alternator 9 7 1 Alternator Alternator Removal Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the rear and side engine covers Allow the system fluids to cool Properly disconnect the battery Install a drive ratchet into the square hole in the serpentine belt tensioner bracket While lifting the automatic belt tensioner away from the belt remove the fan serpentine belt 6036 6042 8042 10042 10054 Note Record how the alternator is installed to ensure correct installation later 6 Label and disconnect the wire leads attached to the alternator Remove the lower mounting capscrew securing the alternator to the lower mounting hole on the engine While supporting the alternator with one hand remove the upper longer mounting hardware f
169. e bottom of the boom one or two turns and tighten the two extend chain locknuts equally the same number of turns A minimum of one full thread on the clevis must protrude beyond the collar of the locknut 4 To decrease the separation distance Loosen the extend chain locknuts at the rear of boom equally one or two turns and tighten the retract chain locknut 5 the same number of turns A minimum of one full thread on the clevis must protrude beyond the collar of the locknut 5 Install the rear boom cover 6 If the third to second boom separation distance cannot be achieved contact your local JLG service distributor 3 33 5 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 X OA0493 11 MH1781 1 Adjust the two second and third boom section extend chains If the chain sag measurement 10 is less than 2 85 in 72 mm tighten the two extend chain adjustment locknuts 11 If the chain sag measurement 10 is more than 3 85 in 98 mm loosen the two extend chain adjustment locknuts 11 3 34
170. e capscrews and lockwashers securing the band 4 to the air cleaner bracket Remove the air cleaner assembly Oe pris 100 7 8 2 Note Apply Loctite 242 threadlock to the capscrew threads before installation 8 Start engine and check for exhaust leaks at all Air Cleaner Assembly Installation exhaust connections Adjust or repair as needed 9 Close and secure the rear door 1 Secure the band 4 to the air cleaner bracket with the previously used hardware 7 8 AIR CLEANER ASSEMBLY 2 Install the air cleaner assembly NEVER run the engine with only the inner safety 4 element installed 3 Install the clamps to secure the hose 3 to the air cleaner assembly Install the clamp to secure the air cleaner inlet tube 2 to the air scoop 1 Note Hefer to the appropriate Operation amp Safety 5 Tighten all clamps for your machine for the correct element change 6 Properly connect the battery 7 Remove the Do Not Operate Tags from both the 7 8 1 Air Cleaner Assembly Removal ignition key switch and the steering wheel 1 Park the machine on a firm level surface level the 8 Close and secure the rear door machine fully retract the boom lower the boom place the travel select lever in the NEUTRAL position engage the parking brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that t
171. e head gland into the cylinder barrel and tighten with a spanner wrench Refer to Section 8 34 8 8 4 Oylinder Torque Specifications for torque specifications for the head gland 8 If applicable install new counter balance valve into block on the cylinder barrel f Cylinder Installation 1 Grease the bushings at the ends of the hydraulic cylinder Using an appropriate sling lift the cylinder into it s mounting position 2 Align cylinder bushing and install pin lock bolt or retaining clip 3 Connect the hydraulic hoses in relation to the labels or markings made during removal 4 Before starting the machine check fluid level of the hydraulic fluid reservoir and if necessary fill to full mark with Mobilfluid 4249 ISO 46 5 Start the machine and run at low idle for about one minute Slowly activate hydraulic cylinder function in both directions allowing cylinder to fill with hydraulic oil 6 Inspect for leaks and check level of hydraulic fluid in reservoir Add hydraulic fluid if needed Shut the engine OFF 7 Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools 8 Close and secure the rear door 8 8 2 Cylinder Pressure Checking Attach a 4000 psi 276 bar gauge to the test port on the hydraulic pump to check the system pressure For more information refer to Section 8 3 1 Pressure Checks and Adjustments Note hydraulic cylinder pressure is greater t
172. e left side Slave cylinder capscrew hole mark the capscrew mounting hole 12 Install the boom proximity sensor on the right side location Coat the entire pin with anti seize mounting plate With the boom properly shimmed compound position the boom assembly all the way to the right 8 Insert the pivot pin from the outside of the boom side assembly making sure the marks for the capscrew 2 mounting hole stay in line with the capscrew mounting holes in the boom mounting hub 1 MH1391 13 Insert the boom proximity sensor through the hole in the right side mounting plate Install the jam nut onto the boom proximity sensor on the inside of the plate Adjust the inner and outer jam nuts on the sensor until the gap 2 between the sensor and the boom is 0 12 in mm Torque the inside jam nut to 36 Ib in 4 1 Nm to hold the sensor in position 9 Shim the boom as required using the shims 20 to maintain 0 10 2 5 mm maximum 1 between the boom mounting hub and the self aligning bearing in the frame If an additional shim is required to maintain the maximum gap the extra shim MUST be inserted on the right side of the boom 10 Align the rod end of the right Lift Lower cylinder with the self aligning bearing on the boom assembly Coat the entire Lift Lower cylinder pin with anti seize compound Insert the pin through the rod end of the cylinder and the self aligning bearing Secure with lock bolt Repeat procedure with
173. e machine Wipe up any hydraulic fluid spillage in on near and around the machine 8 28 b Steer Select Manifold and Valve Disassembly Cleaning Inspection and Assembly 1 Place the steer select assembly on a suitable work surface 2 Separate the steer select valve from the manifold by removing the four socket head capscrews Discard the four o rings 3 Remove the solenoid valves and cartridges from the steer select housing 4 Clean all components with a suitable cleaner before inspection 5 Inspect the solenoid cartridges for proper operation Check by shifting the spool to ensure that it is functioning properly Check that the spring is intact Inspect the cartridge interior for contamination 6 Inspect internal passageways of the steer select manifold and valve for wear damage etc If inner surfaces of the manifold DO NOT display an ultra smooth polished finish or components are damaged in any way replace the manifold or appropriate part Often dirty hydraulic fluid causes failure of internal seals and damage to the polished surfaces within the secondary function manifold Note ALWAYS replace seals o rings gaskets etc with new parts to help ensure proper sealing and operation Lubricate seals and o rings with clean hydraulic oil 7 Install the solenoid valves and cartridges in the steer select housing 8 Attach the steer select valve to the manifold using four new oiled o rings and the four soc
174. e mounting ears on the right side of the boom Place the sheave between the ears and insert the sheave pin from the left side Align the hole in the pin retainer plate with the threaded hole in the left ear Secure the pin 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 MH1501 Install the hose reel assembly 7 left side and bottom wear pads to the rear of the second boom section 4 Install the boom side and top wear pads Grease the sections of the boom in areas where the wear pads will slide ole Boom 10 11 12 3 12 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 Using a suitable sling carefully slide the second boom section into the first boom section Leave enough room at the front of the boom to install the center wear pad Install the center wear pad mount and wear pad to the bottom front of the first boom section Install the side and top wear pads to the front of the first boom section
175. e or lower during frame sway g g Frame sway back toward 0 leaving the machine swayed to the right approximately 1 to 2 e Step 8 a Depress the service brake pedal b Disengage the parking brake switch c With the range select lever in 1 FIRST gear move the travel select lever to the R REVERSE position d Release the service brake pedal to deactivate the Stabil TRAK system e The Stabil TRAK light should go OFF f The front left tire should return to the ground while the machine travels in reverse Sod g Depress the service brake pedal to stop the machine Has Step9 a With the service brake pedal depressed and the boom angle at exactly 45 move the range select m lever to 3 THIRD gear b Move the travel select lever to FORWARD 92 c Release the service brake pedal to deactivate the Stabil TRAK system The Stabil TRAK light should go OFF d Slowly drive the machine forward against the block to stop the machine from moving forward e With the front left tire against the block frame sway the machine no more than 5 to the left f Check that the front left tire remains on the ground It is normal for the front left tire to raise slightly when swaying to the left but the tire should immediately lower when the frame sway function is stopped g Frame sway the machine back to 0 and pause briefly 9 h Frame sway the machine no more than 5 to the right 5 i Check that the front right tire
176. e released and steering held maximum over relief pressure should be 550 psi 38 bar maximum 550 psi 38 bar pressure is incorrect adjust or replace the pressure reducing valve in the secondary function manifold When adjusting the pressure reducing valve connect gauge to location 6 With engine at idle and steering held over relief adjust valve until gauge reads 500 550 psi 34 38 bar 7 N A Brake Valve 400 psi 28 bar With engine OFF pump brake pedal twice DO NOT Manual minimum overstroke the brake pedal If pressure is incorrect check Brake for external leaks If no leaks are found refer to Section Pressure 8 7 3 Service Brake Valve 7 N A Brake Valve 550 psi With engine at idle depress and hold brake pedal DO Service 38 bar NOT turn the steering wheel DO NOT overstroke the Brake minimum brake pedal Check pressure If pressure is incorrect refer Pressure to Section 8 7 3 Service Brake Valve 8 8 6036 6042 8042 10042 10054 Hydraulic System i Test Adjust Component Pressure Pressure Test Procedures Location Location Description Reading 8 C Auxiliary 3000 psi With engine at low idle move auxiliary control lever left or Hydraulics 207 bar 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
177. e two extend chains 11 on the top of the third boom section with the threaded clevis ends toward the rear of the boom Coat the threads on each clevis with multi purpose grease and insert the clevis through the holes in the anchor plate Install a washer and locknut onto each clevis Tighten the locknut enough so the threads are even with the top of the locknut 7 Atthe rear of the third boom section place the male ends of the hydraulic hoses in the third boom section to prevent damage while installing the third boom section into the second boom section 8 Grease the sections of the boom in areas where the wear pads will slide 9 Using a suitable sling carefully slide the third boom section into the second boom section Leave enough room at the front of the boom to install the remaining wear pads 10 Install the top and side wear pads to the inside of the second boom section 11 Pull the male ends of the hydraulic hoses out the rear of the third boom section Stretch the hoses out straight behind the machine 6036 6042 8042 10042 10054 MH1691 12 Assemble the hoses to the hose reel 12 at the rear of the boom Note Keep the hoses in the same order as they come from the hose clamps DO NOT allow the hoses to cross 13 Tie the strings positioned inside the first boom section to the male end of the hydraulic hoses coming off the bottom of the hose reel assembly 14 Working from the front of the boom pu
178. eaded part of clevis all the way through tab Coat the entire threaded portion of the clevis with multi purpose grease Install a flat washer and locknut onto the clevis Thread the nut onto the clevis until the threads are flush with the top of the nut Install the bottom wear pads to the first boom section with the previously used hardware Second Boom Section Installation 11 MH2261 At the rear of the second boom section assemble the retract chain sheave to the mounting ears on the right side of the boom Place the sheave between the ears and insert the sheave pin 11 from the left 6036 6042 8042 10042 10054 side Align the hole in the pin retainer plate with the threaded hole in the left ear Secure the pin 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 MH1501 Install the hose reel assembly 12 left side and bottom wear pads to the rear of the second boom section Install the boom side and top wear pads of the second boom section Grease the sections of the boom in areas where the wear pads will slide 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 o
179. ecially if the water level was above the vent tube breather drain the axle and inspect internal parts for water damage and contamination Before assembling and refilling the unit with the specified lubricant s clean examine and replace damaged parts as necessary Note Use a suitable puller for bearing removal Clean inspect and lubricate all bearings just prior to reassembly If replacement of a damaged bearing cup or cone is necessary replace the cup and cone as a set 5 4 5 Axle Replacement 6036 amp 6042 a Axle Removal The front and rear axle assemblies differ in that the front axle assembly is equipped with a parking brake mechanism and a limited slip feature the rear axle has neither The following steps outline a typical axle removal procedure suitable for either the front or the rear axle assembly Cleanliness is extremely important Before attempting to remove the axle thoroughly clean the machine Avoid spraying water or cleaning solution on the stabilizer solenoids and other electrical components If using a steam cleaner seal all openings before steam cleaning 6036 6042 8042 10042 10054 Note Clear the work area of all debris unnecessary personnel etc Allow sufficient space to raise the machine and to remove the axle 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the travel select lever in the NEUTRAL position engage the parki
180. ection Air Cleaner Dry Type Replaceable Primary and Safety Elements Description 8042 10042 amp 10054 Before S N 0160040220 excluding 0160039850 0160040126 0160040129 amp 0160040171 Engine Make Model Cummins QSB4 5 Displacement 274 in 4 5 liters Low Idle 1000 rpm High Idle 2500 rpm Horsepower 110 hp 82 Kw 2500 rpm Peak Torque 360 Ib ft 488 Nm 1500 rpm Fuel Delivery Fuel Injection Air Cleaner Dry Type Replaceable Primary and Safety Elements 2 12 6036 6042 8042 10042 10054 General Information and Specifications Description 8042 10042 amp 10054 S N 0160040220 amp After including 0160039850 0160040126 0160040129 amp 0160040171 Engine Make Model Cummins QSB3 3 Displacement 274 in 4 5 liters Low Idle 900 rpm High Idle 2400 rpm Horsepower 110 hp 82 Kw 2400 rpm Peak Torque 306 Ib ft 415 Nm 1600 rpm Fuel Delivery Fuel Injection Air Cleaner Dry Type Replaceable Primary and Safety Elements 2 3 5 Tires Note Standard wheel lug nut torque is 430 470 Ib ft 583 637 Nm Note Pressure for foam filled tires are for initial fill ONLY a 6036 Size Tire Type Minimum Ply Fill Type Pressure Star Rating Pneumatic 55 psi 3 8 bar 13 0 x 24 G 2 L 2 Bias Ply Traction 12 Ply Foam Approx 542 Ib 246 kg 65
181. ecurely but the chain must pivot freely Remove the wire from the clevis Repeat this procedure for the left side extend chain At the rear of the boom tighten the two locknuts on the extend chain clevis until the amount of threads protruding beyond each locknut is the same as the measurement recorded during removal of the chains Check and adjust boom chain tension Refer to Section 3 7 5 Boom Chain Tension Check Install the boom rear cover Properly connect the battery Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 6036 6042 8042 10042 10054 Boom C x 3 7 9 Retract Chain Removal and Replacement 6036 6042 8042 amp 10042 1 Park the machine on level ground Place the transmission control lever NEUTRAL engage the parking brake switch level the boom and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Properly disconnect the battery 4 Remove the boom rear cover EN OA0513 5 Atthe front underside of the boom record the amount of threads extending beyond the locknut 13 This measurement will be the starting point for adjustment of the boom retract chain 6 Atthe front underside of the boom loosen the locknut far enough that it can be removed by hand 14 MA9441 7 Attach a wire or string
182. ed 3 Properly disconnect the battery 4 Temporarily block up or support the boom 6036 6042 8042 10042 10054 5 Open the rear door Allow the system fluids to cool 6 Remove the transmission covers 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 Inspect the sender and the wiring harness connector terminals for continuity Replace a defective or faulty sender with a new part c Transmission Temperature Sender Installation and Testing 1 Thread the transmission temperature sender into the transmission housing snugly then connect the sender connector to the wiring harness connector 2 Properly connect the battery 3 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 4 Check for proper fluid level 5 Start the engine allow it to reach operating temperature and observe the operator display cluster for warning indication If the sender is not defective the problem could be elsewhere possibly in a shorted wire damaged transmission improper or low fluid etc 6 Install the transmission covers 7 Close and secure the rear door 9 19 Electrical System 9 10 5 Service Brake Switch MH6210 The service brake switch 12 works in conjunction with the Stabil TR
183. eel assembly 9 lower wear pad and spacer Reassemble the capscrews lockwashers and flat washers to hold the lower wear pad in place for second boom section removal Remove hose reel side plate lower left side wear pad and shims Label and tag each set of wear pads being removed 6036 6042 8042 10042 10054 11 12 13 14 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 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 MH1451 Label disconnect and cap the hydraulic hoses from the bottom tube assemblies at the mounting plate 10 Pull the hose ends out from between the second and first boom sections and out the rear of the boom Using a suitable sling or support secure the front of the Extend Retract cylinder MH1051 Remove the retaining ring from one side of the Extend Retract cylinder rod end mounting pin 11 Using a sling or suitable support pull the second boom section straight out of the first boom section Reposition the slings as needed so the second boom section balances when removed from the first boom section Set the second boom section down on blocks on a hard level surface Remove the remaining wear pads Label and tag each set of wear pads being removed 3 7 uic Boom
184. el Close and secure the rear door 6036 6042 8042 10042 10054 Electrical System 9 10 8 Outrigger Pressure Switches 10054 Only a Removal ar WwW nm 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 Raise both outriggers fully and shut the engine OFF Open the rear door Allow the system fluids to cool Properly disconnect the battery Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated MAQ0250 Disconnect the pressure switch wiring connector 1 from the harness connector 2 Remove the outrigger pressure switch 3 from the outrigger cylinder Wipe up any spilled hydraulic oil Installation Install the pressure switch 3 and torque to 25 38 lb ft 34 41 Nm Connect the pressure switch wiring connector 1 to the harness connector 2 Properly connect the battery Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel Close and secure the rear door 6036 6042 8042 10042 10054 9 11 DISPLAY MONITOR AND GAUGES 9 11 1 a 1 Instrument Cluster Instrument Cluster Removal Park the machine on a firm level surface
185. em Test Procedures FREE PIVOT MODE LOCKED MODE Service Brake Test Neutral Test Park Brake Test w Step 1 Enter the machine Fasten the seat belt Place the machine on a hard level surface Have the boom fully retracted and horizontal Place an 8 in 203 mm wood or cement block in front of the front left tire Turn the key to the RUN position Check to be sure the Stabil TRAK light is OFF fo OH2500 N Step Start the engine Turn the parking brake switch OFF Move the range select lever to 1 FIRST gear Move the travel select lever the F FORWARD position Drive the machine up on the block Use the frame sway control to level the machine back to 0 Step Depress the service brake pedal Move the travel select lever to the N NEUTRAL position 9 P Raise the boom to exactly 60 The Stabil TRAK light should come ON when the boom angle is at about 40 and remain ON Step 4 a Use your left foot to depress the service brake pedal With the range select lever in 2 SECOND gear move the travel select lever to the R REVERSE position Ease your left foot partially off the service brake pedal make sure that the Stabil TRAK light remains ON d With your right foot increase the engine rpm slightly as necessary just enough to back the machine
186. ent 8042 10042 amp 10054 5 7 5 5 Axle Assembly and Drive Shaft Troubleshooting 5 11 5 6 Shafts ss a 5 14 5 6 1 Drive Shaft Inspection and Service 5 14 5 6 2 Drive Shaft Maintenance 5 14 5 6 3 Drive Shaft 5 14 5 6 4 Drive Shaft Cleaning and Drying 5 14 5 6 5 Drive Shaft 5 14 5 Repeat the above procedure on the rear drive shaft 5 14 5 7 1 Removing Wheel and Tire Assembly from Machine 5 15 5 7 2 Installing Wheel and Tire Assembly onto 5 16 5 8 Brakes 22 02 cil yo x SR de wx E Rue E ES 5 16 5 8 1 Brake Disc 5 16 5 9 Towing a Disabled 5 18 6036 6042 8042 10042 10054 5 1 ES Axles Drive Shafts Wheels and Tires 5 1 AXLE DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGY 6036 amp 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 wheel
187. extend chain forward and place in between the chain sheave mounts Guide the wire 19 and the threaded clevis into the boom by placing the threaded clevis between the top of the third boom section and the second boom section Have an assistant guide extend chain into the front of the boom while pulling the wire and threaded clevis toward the rear of the boom Guide the threaded clevis into the hole in the anchor plate Place the flat washer onto the threaded end of the threaded clevis and assemble the locknut Thread locknut onto the threaded clevis until the threads are flush with the top of the nut Remove the wire from the clevis Repeat this procedure for the left side extend chain After both of the chains are replaced inside the boom assemble the double sheave to the mount at the front of the second boom section Place the double extend chain sheave between the mounts and under the extend chains at the front of the second boom section Insert the sheave pin through the mounts and the double sheave Line up the mounting hole in the sheave pin with the threaded hole in the sheave mount and secure in place with the capscrew and the lockwasher Tighten securely Pull the anchor clevis up around the double chain sheave and position the clevis one at a time between the yoke plates Coat the capscrews with anti seize compound Insert the capscrews through the yoke plates and clevis and secure in place with locknuts Tighten eac
188. ey switch 6 to the dash 7 Label and disconnect the ignition switch connectors and remove the switch from the machine b Disassembly DO NOT disassemble the ignition switch Replace a defective switch with a new part 9 24 Switch Position Test from RED wire to OFF RUN START PUR Wire Pin B on 5 Pin X X Connector RED BLK Wire Pin C on 5 X X Pin Connector If all terminals do not show proper continuity replace the ignition switch d Ignition Switch Installation 1 Connect the ignition key switch to the previously labeled connectors 2 The ignition switch has a drain hole located on the shaft between the backing nut and the face of the ignition switch cylinder behind the dash panel Align the ignition switch so that when it is in the OFF position the key slot is positioned vertically straight up and down and the indicator mark for the drain hole is pointing down Install the nut securing the ignition switch to the dash DO NOT overtighten 3 Install the lower access panel 4 Properly connect the battery 5 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 6 Close and secure the rear door Note further information is needed refer to Section 9 5 Electrical System Schematics 6036 6042 8042 10042 10054 Electrical System 9 12 2 b Dash Switches Switch Removal Park the machine on a fir
189. first stop and allow any pressure to escape Remove the radiator cap Place a suitable container beneath the radiator drain Place a funnel at the base of the radiator to channel the drained coolant into a container Loosen the drain petcock and slowly allow the coolant to drain Transfer the coolant into a properly labeled container Dispose of properly if coolant needs to be replaced Tighten the radiator drain petcock Label and disconnect all hoses and tubes attached to the radiator 2 charge air cooler 3 and oil cooler 4 Working at the rear of the machine remove the capscrews and lockwashers securing the radiator assembly Remove the radiator assembly through the rear of the machine Radiator Oil Cooler Installation Secure the radiator 2 charge air cooler 3 and oil cooler 4 to the machine frame with the previously used hardware 6036 6042 8042 10042 10054 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 Visu
190. from the external surfaces DO NOT use a solvent for this wiping operation Regular application of lubricant is necessary to make sure that all working surfaces are adequately lubricated In extremely dusty conditions it may be necessary to lubricate the chains more often Refer to Section 2 5 Service and Maintenance Schedules and Section 2 6 Lubrication Schedules for detailed information Lubrication of chains on vehicles working consistently in extreme hot or cold conditions requires special consideration Contact the local distributor for guidance 6036 6042 8042 10042 10054 3 11 FORKS Forks should be cleaned and inspected prior to being attached to carriage If the following criteria is not met forks must be removed from service immediately Daily Inspection MH6460 1 Inspect forks 4 for cracks paying special attention to heel 5 and mounting tubes 6 2 Inspect forks for broken or bent tips 7 and twisted blades 8 and shanks 9 Yearly Inspection 1 Straightness of the upper face of blade 8 and the front face of shank 9 should not exceed 0 5 percent of the length of blade or height of shank 2 Angle 10 between upper face of blade and front face of shank should not exceed 93 degrees 3 Thickness of blade 13 and shank 14 should not be reduced to 90 percent of original thickness 4 Ensure fork length 12 is adequate for intended loads 5 Fork markings should be
191. g Function 2400 2600 psi wheel all the way in one direction and hold while Manifold 165 179 checking pressure If pressure is incorrect adjust or replace the pressure reducing cartridge 6 PBG N A Secondary Park Brake With engine at idle park brake released and no Function minimum functions operated pressure should be 400 psi Manifold 400 psi 28 bar 28 bar minimum With engine at idle park maximum brake released and steering held over relief 500 600 psi P eSsure should be 500 600 psi 34 41 bar 84 41 bar maximum After releasing steering wheel the pressure MUST NOT drop more than 50 psi in one minute If pressure drop is incorrect refer to Section 8 7 3 Service Brake Valve If pressure is incorrect adjust per test 7 6036 6042 8042 10042 10054 n Hydraulic System Test Valve Adjust Component Pressure Pressure Test Procedures Location Port Location Description Reading 7 PBG D Secondary 500 600 psi With engine at idle park brake released and Function 34 41 bar steering held over relief while checking Manifold pressure If pressure is incorrect adjust or replace the pressure reducing valve in the secondary function manifold 8 N A Brake Valve 400 psi 28 bar With engine OFF pump brake pedal twice DO Manual Brake minimum NOT overstroke the brake pedal If pressure is Pressure incorrect check for external leaks If no leaks are found refer to Sec
192. g hydraulic system not operating properly Excessive joint housing swivel bearing preload Worn or damaged swivel bearings Refer to Section 8 4 Hydraulic Circuits Correct bearing preload by adding or removing shims as needed Replace swivel bearings as needed 9 Slow steering response Steering hydraulic system not operating properly Steering cylinder leaking internally Refer to Section 8 4 Hydraulic Circuits Repair or replace steering cylinder as needed 10 Excessive noise when brakes are engaged Brake discs worn Brake discs damaged Check brake discs for wear Refer to Section 5 8 1 Brake Disc Inspection Replace brake discs 11 Brakes will not engage Brake hydraulic system not operating properly Brake piston o rings and seals damaged leaking Refer to Section 8 4 Hydraulic Circuits Replace o rings and seals 12 Brakes will not hold the machine or braking power reduced Brake discs worn Brake hydraulic system not operating properly Brake piston o rings and seals damaged leaking Check brake discs for wear Refer to Section 5 8 1 Brake Disc Inspection Refer to Section 8 4 Hydraulic Circuits Replace o rings and seals 6036 6042 8042 10042 10054 5 13 Axles Drive Shafts Wheels and Tires hs 5
193. g the JLG Pressure Test Kit The kit is contained in a durable polyethylene carrying case for demanding field service conditions Hydraulic Pressure Test Kit The hydraulic pressure test kit is used to pressure test the various hydraulic components in the hydraulic system The kit includes Gauges for testing high and low pressure circuits Fittings couplers and hoses MZ1460 Contact JLG Parts Department Toll Free at 1 877 554 5438 or 717 485 6472 for ordering information CHEESE 70000652 Dia Ero call i0lbs Consult Factory 70000101 0198 ir ale 7lbs Consult Factory 70027911 Digital oe 7 lbs Consult Factory 6036 6042 8042 10042 10054 Hydraulic System n 8 3 1 When diagnosing trouble in the hydraulic system use the hydraulic testing information in Section 8 4 1 Hydraulic Pressures Pressure Checks and Adjustments In general follow the steps below whenever conducting pressure checks and performing adjustments 1 Park the machine on a firm level surface Engage the park brake place the travel select lever in N NEUTRAL level the boom and turn the engine OFF 2 The test port is located at the top right corner of the main control valve Install a pressure gauge capable of measuring at least 1096 more pressure than that which the circuit being checked operates under 3 Start the engine Operate mac
194. g hazardous materials disposal 7 6 c Cleaning and Drying If contaminated fuel or foreign material is in the tank the tank can usually be cleaned Note leak is suspected in the fuel tank contact your local authorized Service Department To clean the fuel tank 1 Have a dry chemical Class B fire extinguisher near the work area 2 Depending on which side of the tank is contaminated fuel or hydraulic oil remove the fuel or oil tank drain plug and safely drain any fuel or hydraulic oil into a suitable container Dispose of fuel or hydraulic oil properly 3 Clean the fuel hydraulic oil tank with a high pressure washer or flush the tank with hot water for five minutes and drain the water Dispose of contaminated water properly 4 For the fuel tank side add a diesel fuel emulsifying agent to the tank Refer to manufacturer s instructions for the correct emulsifying agent to water mixture ratio Refill the tank with water and agitate mixture for 10 minutes Drain the tank completely Dispose of contaminated water properly 5 Refill the fuel tank with water until it overflows Completely flush the tank with water Empty the fuel tank and allow it to dry completely d Assembly The fuel hydraulic oil tank is a one piece unit and cannot be disassembled The fuel level indicator and hydraulic filters can be removed and reused on the new replacement tank Dispose of the old tank according to local regulation
195. g on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the rear door Allow the system fluids to cool 4 Properly disconnect the battery 5 Remove the nuts and the lock washers from the washer mounting bolts 6 Pull the washer reservoir out and away from the mounting bracket 7 Rotate the washer reservoir label and remove the cab harness connectors from the washer reservoir connectors 8 Remove the windshield washer hose from the reservoir b Disassembly DO NOT disassemble the pump The pump is not serviceable Replace pump if found to be defective 9 16 c Installation and Testing 1 Connect the windshield washer hoses to the reservoir 2 Connect the cab wiring harness connectors to the reservoir connectors Install the reservoir tank onto the welded studs Install the lock washers and nuts and secure Fill the washer fluid reservoir with washer fluid Properly connect the battery Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 8 Turn the ignition key switch to the RUN position and press the washer switch Verify that fluid is sprayed on both the windshield and rear glass 9 Close and secure the rear door 9 9 HEATER AND FAN 9 9 1 Note lf the suspect component is found to be within the heater box the heater box must be removed as a complete unit and replaced Cab Hea
196. gine ensure that the harness has been completely separated disconnected from the engine Move the harness clear of the engine and with the help of an observer ensure that the engine clears the harness during removal 9 Label and disconnect all electrical wire connections on the engine 10 Label disconnect and cap the fuel inlet line at the fuel lift pump 11 Label disconnect and cap the fuel return line from the injector pump 12 Remove the engine to transmission drive shaft Refer to Section 5 6 3 Drive Shaft Removal Note Before the engine can be removed from the machine the air conditioning hoses need to be removed from the air conditioning compressor This procedure must be completed by an authorized air conditioning service technician This service technician will also need to be available when the new engine is installed to re 6036 6042 8042 10042 10054 install the air conditioning hoses and to the air conditioning compressor 13 Loosen the clamps on the sleeve reducer at the engine and on the air suction pipe 14 Remove the air cleaner assembly Refer to Section 7 8 1 Air Cleaner Assembly Removal 15 Remove the exhaust pipe from the exhaust manifold Refer to Section 7 7 1 Exhaust System Removal T Ea 98 i1 P MAQ0320 7 6 5 16 At the front right engine mount 5 remove the hardware securing the mount to the frame Repeat procedure for left engine mou
197. gine OFF 2 Block all four wheels to help prevent the machine from moving Assure that there is sufficient overhead and side clearance for cab removal 3 Open the rear door Allow the system fluids to cool 4 Properly disconnect the battery Note Steps 5 thru 10 apply to machines equipped with cab heater 4 8 N TT WV Working under the cab loosen the clamp screw 1 Place a suitable container beneath the radiator drain plug or petcock Slowly turn the radiator cap to the first stop and allow any pressure to escape Remove the radiator cap Place a funnel at the base of the radiator to channel the drained coolant into the container Loosen the drain plug or petcock and allow the coolant to drain Transfer the coolant to a container with a cover and label as Used Antifreeze Dispose of the used coolant at an approved recycling facility Close the radiator drain plug or petcock MA8781 and disconnect the heater control cable 2 from the heater control valve Label disconnect and cap the heater hoses Remove the heater access panel Label disconnect and cap the heater hoses and route them through the opening in the bottom of the cab Remove the console panel in the cab dn i 1 f ALY ase Nl MA8471 6036 6042 8042 10042 10054 Cab and Covers a
198. gu HELL piopuew anu Nd We uojoun4 18 ONIS faepuooes eod 4 4 T ud igi A T em TC 708 av w 0s 8 20s Win a gt won E 882 vez Or ee est zor HHz 1 V pn Sv vir Er 9 WE A V vor gest aiv eT o dnopeg z oL S ar 5x wms l l yeg ESZ age Med se zv UoyMS 18 Ove 18 ONIS Aejay se woog 8 Kejou sa I asp sonus 201 or dn yoeg F3 feng JOZIIGEIS x oL e o s v L 291 Ver ve m ma IAM 2 9 10895 ed de eggs dep 91 5 Es l Z pz or voz UMS voL vor vel wore verQ word vor 10 6 Stabil TRAK System and Boom Interlock System d 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 Remove any attachment from the quick attach before performing the tes
199. h locknut securely but the chain clevis must pivot freely 3 41 ole Boom 24 25 26 27 28 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 Check and adjust the retract chain tension Refer to Section 3 7 5 Boom Chain Tension Check Install the boom rear cover Properly connect the battery Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel Fourth Boom Section Extend Chains Removal and Replacement Park the machine on level ground Place the transmission control lever in NEUTRAL engage the parking brake switch level the boom and shut the engine OFF Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Properly disconnect the battery Remove the boom rear cover X SS 1 Ha m T MH1781 At the rear of the boom locate the extend chain locknut
200. han the main control valve pressure increase the main control valve pressure by adjusting the main relief Generally one half turn clockwise will be adequate to check an individual circuit Activate the circuit and if pressure is obtained turn the main relief counter clockwise one half turn Re check the main relief setting and adjust if necessary 6036 6042 8042 10042 10054 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 STEERING CYLINDER AXLE CENTER SECTION 6036 6042 8042 10042 10054 8 35 n Hydraulic System 8 8 4 Cylinder Torque Specifications a Lift Lower Cylinder Model Nut Valve Locking Collar 6036 6042 1750 2000 Ib ft 30 35 Ib ft 300 400 Ib ft 2373 2712 Nm 41 47 Nm 407 542 Nm 8042 10042 10054 1735 1885 Ib ft 30 35 Ib ft 300 400 Ib ft 2352 2556 Nm 41 47 Nm 407 542 Nm b Extend Retract Cylinder Model Head Piston Valve Set Screw 6036 300 400 Ib ft 300 400 Ib ft 45 50 Ib ft 12 13 Ib ft 407 542 Nm 407 542 Nm 61 68 Nm 18 19 Nm 6042 300 400 Ib ft 330 390 Ib ft 40 50 Ib ft 10 26 Ib ft 407 542 Nm 447 529 Nm 54 67 Nm 13 35 Nm 8042 1004
201. he frame and align the pivot pin bearings with the holes in the frame 5 Coat the axle pivot 3 with a light film of clean engine or hydraulic oil DO NOT use an anti seize compound 6 Install the axle pivot pin and shims 4 Add or remove shims until a maximum gap of 0 6 in 1 5 mm is obtained Balance the number and thickness of shims equally of both sides Secure the pivot pin with one capscrew and a new locknut MT0822 Note If new frame sway front or stabilizer rear cylinder bearings 5 have been installed in the axles or machine frame the fracture in the bearing race must be positioned at the 9 o clock position as shown below 7 Move the cylinder into position on the axle cylinder anchor Insert a cylinder mount pin 2 through the cylinder and cylinder anchor Secure the cylinder mount pin with one capscrew and new locknut 5 10 10 14 Apply multi purpose grease through the self tapping lube fitting to lubricate the self align bearing and the cylinder mount pin Install the drive shaft assemblies Refer to Section 5 6 5 Drive Shaft Installation If reinstalling an axle previously removed from the machine position the driveshaft yoke on the axle according to the alignment marks made earlier If installing a new axle note the position of the driveshaft yoke at the transmission Align the driveshaft yoke on the axle in the same plane as the yoke on the transmission Install the wheel
202. he machine should not be operated 3 Open the rear door Allow the system fluids to cool 4 Properly disconnect the battery MAQO0300 7 8 6036 6042 8042 10042 10054 Engine Cummins QSB3 3T QSB4 5T 7 9 ENGINE REPLACEMENT 7 9 1 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 Engine 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 NEUTRAL position engage the parking brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated Open the rear door Allow the system fluids to cool Properly disconnect the battery Remove the rear door and engine side covers oS Drain and remove the radiator assembly Refer to Section 7 4 2 Radiator Oil Cooler and Replacement 7 Remove the radiator overflow tube overflow tank and hose support 8 Label disconnect and cap the heater hoses attached to the engine if equipped Note The engine harness is routed and attached to the engine using hold down clamps and plastic wire ties at various places on the engine Before removing en
203. he retract chain clevis 12 with a threaded eye or a flat washer tack welded to a capscrew The outside diameter of the eye or flat washer must be smaller than the diameter of the threads on the clevis The wire must be long enough to pull the clevis and chain through the boom The wire must be heavy enough to pull the weight of the entire chain back through the boom during the reassembly 14 From the rear of the boom using the wire attached to the rear anchor clevis pull the retract chain through the middle of the two center hoses on the chain reel and over the top of the chain reel and out of the rear of the boom 15 Remove the wire still attached from the clevis on the old chain 16 Install the wire still attached to the new chain clevis 17 Coat the threads of the threaded clevis on the new chain with multi purpose grease 15 MH6021 18 From the front of the boom have an assistant pull on the tow wire while guiding the chain clevis between the two center hoses of the hose reel and under the chain sheave 13 on the left side of the boom and down the boom between the third 14 and second 15 boom sections Keep the retract chain lined up squarely with the chain sheave and help feed the retract chain in while pulling on the wire from the front of the boom MH5991 3 46 19 Guide the threaded end of the clevis through the hole in the tab 16
204. he steering column and steering valve by inserting them through the lower dash panel opening Position steering valve in the cab to its original orientation Secure the steering valve and column with the previously used hardware Torque to 13 lb ft 18 Nm Note ALWAYS use new o rings when servicing the machine 2 Install new o rings into the fittings Lubricate the o rings with clean hydraulic oil 3 Uncap and connect the previously labeled load sense hose to the steering valve 4 Install new o rings into the steering valve fittings Lubricate the o rings with clean hydraulic oil 5 Uncap and connect the remaining previously labeled four hoses to the steering valve 6 Connect the horn button wire to the cab wiring harness 4 4 7 Install the travel select lever connect the instrument panel harness connector install the steering wheel assembly Torque the steering wheel nut to 50 lb ft 68 Nm 8 Properly connect the battery 9 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 10 Start the engine and check the operation of steering system Check for hydraulic fluid leaks Check the hydraulic fluid level in the tank and add fluid as required 11 Install the left right and lower dash panels 12 Close and secure the rear door C Steering Test Conduct a pressure check of the steering hydraulic circuits at the main control valve Refer to Section 8 3 1 Pressure
205. he travel select lever 2 disconnect the the cab behind the seat Information specified on the instrument panel harness connector 3 serial number plate includes the cab model number the cab serial number and other data Write this information down in a convenient location to use in cab 7 Label disconnect and cap the four hoses from the side of the steering valve 4 Cap the fittings on the steering valve Label disconnect and plug the load sense hose at the front of the steering valve Cap the 4 3 CAB COMPONENTS fitting on the steering valve 8 Disconnect the horn button wire from the cab wiring harness 4 3 1 Steering Column and Steering Valve 9 Support the bottom of the steering valve a Steering Valve Removal remove the four capscrews and lockwashers Remove the steering valve through the lower dash 1 Park the machine on a firm level surface level the panel opening 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 6036 6042 8042 10042 10054 4 3 Cab and Covers MA8861 10 Remove the steering column 5 by pushing it down and removing it through the lower dash panel opening Note DO NOT disassemble the steering valve The steering valve is not serviceable and must be replaced in its entirety if defective b Steering Valve Installation 1 Install t
206. heels and Tires 5 5 AXLE ASSEMBLY AND DRIVE SHAFT TROUBLESHOOTING Problem Cause Remedy 1 Excessive axle noise while driving Oil level too low Axle and or wheel end housings filled with incorrect oil or oil level low Incorrect alignment of ring and pinion gears Incorrect pinion input shaft bearing preload Worn or damaged bearings Worn or broken gear teeth Contamination in the axle Axle housing damaged Fill oil to correct level Refer to Section 2 4 Fluid and Lubricant Capacities Drain axle and or wheel end housings and fill to correct level with Mobilfluid 4249 ISO 46 Refer to Section 2 4 Fluid and Lubricant Capacities Correct alignment by adding or removing shims as needed Correct bearing preload by adding or removing shims as needed Replace bearings as needed Replace gears as needed Drain axle and or wheel end housings and fill to correct level with Mobilfluid 4249 ISO 46 Refer to Section 2 4 Fluid and Lubricant Capacities Replace damaged parts 2 Intermittent noise when traveling Universal joint s worn or damaged Differential ring and or pinion gears damaged Repair or replace universal joints as needed Determine cause and repair as needed when traveling 3 Vibration or intermittent noise 1 Drive shaft universal joint assembly
207. hile tightening to avoid hose twist After the connection has been properly tightened mark a straight line across the connecting parts not covering the dots indicating that the connection has been properly tightened 6036 6042 8042 10042 10054 General Information and Specifications 2 3 SPECIFICATIONS 2 3 1 Travel Speeds 6036 amp 6042 8042 10042 amp 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 Fourth Gear 20 mph 32 km hr 20 mph 32 km hr 2 3 2 Hydraulic Cylinder Performance Note Machine with no attachment or load engine at full throttle hydraulic oil above 130 F 54 C minimum engine at operating temperature FUNCTION APPROXIMATE TIMES seconds 6036 6042 8042 10042 10054 Boom Extend Less than 15 0 Less than 19 0 Less than 19 0 Less than 19 0 Less than 19 0 Boom Retract Less than 15 0 Less than 19 0 Less than 17 0 Less than 17 0 Less than 17 0 Boom Lift Retracted Less than 15 0 Less than 17 0 Less than 17 5 Less than 17 5 Less than 17 5 Boom Lower Retracted Less than 10 0 Less than 13 0 Less than 15 5 Less than 15 5 Less than 15 5 Right UP or DOWN Attachment Tilt Up 4 0 6 0 6 5 Less than
208. hine functions several times to allow hydraulic oil to reach operating temperature The hydraulic oil temperature should be between 100 120 F 38 49 C If a temperature gauge or thermometer is unavailable the hydraulic oil reservoir should be warm to the touch 4 Refer to Section 8 4 1 Hydraulic Pressures for testing procedures 5 Fully depress the accelerator pedal if required Place and hold the joystick in the position needed to operate the particular machine function being checked Continue holding the joystick in position until pressure readings are taken 6 Checkthe pressure gauge reading It should read as specified in the Pressure Readings column of the charts found in Section 8 4 1 Hydraulic Pressures If the reading is not as specified turn the engine OFF and check other components in the system Verify that all related hydraulic components and electrical switches sensors solenoids etc are operating correctly 7 Adjust the relief valve by turning the adjustment screw Turning clockwise will increase the pressure turning the screw counterclockwise will decrease the pressure 8 Start the engine and check the pressure again Turn the engine OFF If there is pressure reading in the gauge bleed it off then disconnect or remove the pressure gauge from the machine 6036 6042 8042 10042 10054 8 4 HYDRAULIC CIRCUITS This section covers the hydraulic circuits and includes listings for all hydraul
209. hrough the housing during installation 5 7 Axles Drive Shafts Wheels and Tires MH6260 8 Label disconnect and cap the outrigger hydraulic hoses 6 Cap all fittings to keep dirt and debris from entering the hydraulic system 9 Support the outrigger assembly using a suitable jack hoist or overhead crane 10 Remove the capscrews hex nuts flat washers and mount plates 7 Hecord the number and thickness of shims to ensure correct installation 11 Remove the outrigger assembly using a suitable jack hoist or overhead crane Remove the shims 8 from the pivot pin 12 Move the outrigger assembly away from the machine and carefully lower it to the ground Block up or support the assembly so that it does not move or fall 13 Inspect the pivot bearing 9 Replace the bearing if worn or damaged b Outrigger Installation 1 Using a suitable jack hoist or overhead crane and sling remove the outrigger assembly from its supports Balance the assembly and prevent it from tipping turning or falling while positioning it on the machine DO NOT raise or otherwise disturb the machine while installing the outrigger assembly 5 8 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
210. i SEU 8 AE E AY NC NB EN QE P ENE 16 18 19 20 21 22 23 24 25 26 Remove the capscrew 6 securing the lifting ring 7 to the transmission housing Once the lifting ring has been removed reinstall the capscrew into the hole Move the lifting ring to the holes 8 used to secure the black wire and clamp Secure the lifting ring using the capscrews and tighten securely Label disconnect and cap the transmission oil cooler inlet and outlet hoses on the transmission Connect a lifting strap or chain to the lifting eye at the top of the transmission and to a suitable hoist or overhead crane Operate the hoist or crane to remove slack from the chain but DO NOT raise the transmission at this time Place blocks under the transmission to help support it during removal MH6290 Remove the capscrews and lockwashers securing the front transmission mount 9 to the transmission Remove the two capscrews hex locknuts and rebound washers Remove the front transmission mount Remove the four capscrews and lockwashers securing the rear transmission mount 1 to the transmission Remove the two capscrews hex locknuts and rebound washers Remove the rear transmission mount Inspect the rubber mounts Replace the mounts if damaged Carefully remove the transmission from the machine Avoid causing damage to the transmission or surrounding parts 60
211. ic fluid level in the tank and add fluid as required Note When the engine is initially started run it briefly at low idle and check the machine for any visual sign of fluid leakage STOP the engine immediately if any leakage is noted and make any necessary repairs before continuing 18 20 21 Wait for the engine to cool and check the coolant level Add coolant to the overflow bottle as required to bring the coolant to the proper level Install the mirrors and all other cab components as needed if removed Unblock the wheels Close and secure the rear door 6036 6042 8042 10042 10054 Section 5 Axles Drive Shafts Wheels and Tires Contents PARAGRAPH TITLE PAGE 5 1 Axle Drive Shaft and Wheel Component Terminology 6036 amp 6042 5 2 5 2 Axle Drive Shaft and Wheel Component Terminology 8042 10042 amp 10054 5 3 5 3 General 5 4 5 4 Axle 5 4 5 4 1 Axle Serial Number 5 4 5 4 2 Axle 5 5 4 5 4 3 Axle Internal 5 4 5 4 4 Axle 5 5 5 4 5 Axle Replacement 6036 amp 6042 5 5 5 4 6 Axle Replacem
212. ic function pressures where and how to check those pressures and a hydraulic schematic Electrical and hydraulic functions are often related Verify that the electrical components of the circuit are functioning properly whenever troubleshooting the hydraulic circuit Always check the following before beginning to troubleshoot a circuit that is not functioning correctly 1 Checkthe hydraulic oil level in the reservoir Oil level should be to the middle of the sight glass with all cylinders retracted 2 Check hoses tubes fittings and other hydraulic components for leaks bends kinks interference etc 3 Check for air in the hydraulic system Erratic machine performance and or spongy cylinder operation are signs of air in the hydraulic system If air in the hydraulic system is suspected you will hear air leakage when hydraulic fittings are loosened and see air bubbles in the hydraulic fluid Loose fittings faulty o rings or seals trapped oil leaks system opened for service etc can cause air in the system Determine what is causing air to enter the system and correct it Bleed air from the system 8 5 Hydraulic System 8 4 1 Hydraulic Pressures a Checking Pressure 1 Start the machine and warm the hydraulic system to operating temperature 2 Shut off the machine and install a gauge of suitable pressure rating according to the following chart to the appropriate test port Test Gauge Fit
213. ier 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 Remove the hose carrier support from the hose carrier Note replacing the third boom section with a new boom section the quick attach assembly and the Attachment Tilt cylinder should be removed at this time Refer to Section 3 8 3 Quick Attach Removal 26 27 28 29 Using a sling or suitable support pull the fourth boom section straight out of the third boom section Reposition the slings as needed so the fourth boom section balances when removed from the third boom section Set the boom section down on a hard level surface Support the boom as needed to prevent it from tipping over MH1871 At the rear of the boom section remove the extend chain clevis 8 from the extend chain clevis anchor At the rear of the fourth boom section remove the remaining wear pads shims and hardware Label and tag each set of wear pads being removed Inspect all wear pads for wear Refer to Section 3 9 Boom Wear Pads En Boom MH1901 MH1961 30 Inside the boom section remove the hardware securing the hose carrier 9 to the bottom of the 35 Remove the hose carrier assembly 11 from the boom boom by carefully pulling both the upper and lowers portions through the rear of the boom at the same 31 On each
214. ies incorrectly tightened Drive shaft universal joint s worn or damaged Drive shaft s damaged unbalanced Tighten capscrews to correct torque Repair or replace universal joints as needed Replace drive shaft s as needed 6036 6042 8042 10042 10054 hs Axles Drive Shafts Wheels and Tires Problem Cause Remedy 4 Oil leaking from axle differential housing and or axle housings k Drain and or inspection plugs loose and or o rings damaged or missing Replace o rings as needed and tighten plugs to 96 Ib ft 130 Nm 2 Hose fittings loose Tighten fittings 3 Axle shaft seal damaged or Replace seal and or joint missing and or worn or coupling fork shaft axle shaft damaged shaft sealing surfaces 4 Input shaft multi seal ring Replace multi seal ring and or damaged or missing and or input shaft Adjust ring and worn or damaged pinion input pinion alignment and bearing shaft sealing surfaces preload as described in the Dana Repair Manuals 5 Axle casing to brake housing Replace o rings and seals and or brake housing to differential assembly o rings and or seals worn or damaged 6 Axle housing mounting nuts and Tighten housing nuts and capscrews loose capscrews to 288 Ib ft 890 Nm 7 Differential and or axle Replace housing s as needed housing s damaged 5 Oil leaking from wheel en
215. in resulting in failure susceptible to stress corrosion cracking 10 Corrosion Fatigue Cracking Corrosion 7 fatigue cracks are very similar to fatigue eee cracks in appearance Corrosion fatigue is the 21465 Stress Corrosion Cracking The outside link plates O O are particularly MZ1468 combined action of an aggressive environment and cyclic stress These types of failures are Examine the pin head rivets to determine if the Other Modes of Failure VEE flats are still in correct alignment 6 Chain Ultimate Strength Failure with rotated displaced heads 7 or abnormal pin protrusion 8 should be replaced immediately DO NOT attempt to repair the chain by welding or driving the pin s back into the chain Once the press fit integrity between outside plates and pins has been altered it cannot be restored Any wear pattern on the pin heads or the sides of the link plates indicates misalignment in the system This condition damages the chain as well as increases frictional loading and should be corrected 3 30 caused by overloads far in ENS excess of the design load MZ1469 Either fractured plates 1 or 2 enlarged holes 2 can MC occur If either of these failures occurs the chain should be replaced immediately MZ1470 Tight Joints All joints in the chain should flex O
216. in addition to abrasive exposures such as sand and grit Some effects can be as follows e Moisture Corrosive rusting reduces chain strength by pitting and cracking Temperature Low temperature reduces chain strength by embrittlement Going in and out of cold storage results in moisture from condensation Chemical Solutions or Vapors Corrosive attack on the chain components and or the mechanical connections between the chain components Cracking can be and often is microscopic Going from microscopic cracking to complete failure can be either abrupt or may require an extended period of time Abrasives Accelerated wearing and scoring of the articulating members of the chain pins an d plates with a corresponding reduction in chain strength Due to the inaccessibility of the bearing surfaces pin surfaces and plate apertures wear and scoring are not readily noticeable to the naked eye 3 50 Following are some examples of dynamic shock loading which can impose abnormal loads above the endurance limit of a leaf chain High velocity movement of load followed by sudden abrupt stops e Carrying loads in suspension over irregular surfaces such as railroad tracks potholes and rough terrain Attempting to inch loads which are beyond the rated capacity of the vehicle The above load cycles and environmental conditions make it impossible to predict chain life It is therefore necessary to conduct freq
217. ine has been completed under the supervision of an experienced and qualified operator An Operation amp Safety Manual is supplied with each machine and must be kept in the manual holder located in the cab In the event that the Operation amp Safety Manual is missing consult your local authorized service distributor before proceeding 1 2 14 DO NOT OPERATE TAGS Place Do Not Operate Tags on the ignition key switch and the steering wheel before attempting to perform any service or maintenance Remove key and disconnect battery leads 1 5 SAFETY INFORMATION To avoid possible death or injury carefully read understand and comply with all safety messages In the event of an accident know where to obtain medical assistance and how to use first aid kit and fire extinguisher fire suppression system Keep emergency telephone numbers fire department ambulance rescue squad paramedics police department etc nearby If working alone check with another person routinely to help assure personal safety 1 5 1 Safety Alert System and Signal Words DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury A WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in mi
218. ion 9 10 5 c Service Brake Switch Adjustment 6 Install the lower dash panel 7 Properly connect the battery 8 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel Close and secure the rear door 6036 6042 8042 10042 10054 4 3 3 a 1 Throttle Pedal Throttle Pedal Removal 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 Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated Properly disconnect the battery MH6240 4 Disconnect the electrical harness connector 4 Remove the bolts 5 securing the throttle pedal to the throttle pedal bracket 6 Remove the throttle pedal assembly from the cab Throttle Pedal Installation Position the throttle pedal in its mounting location within the cab Secure the throttle pedal in place with previously used hardware Reconnect the wire harness plug to the front of the throttle pedal 4 Properly connect the battery Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 4 5 Cab and Covers a 4 3 4 These removal and installation instructions apply to the boom control attachment tilt sway and auxiliary hydraulic
219. ion 6 TransmisslOH o6 err Saa 6 1 6 1 Transmission Assembly Component 6 2 6 2 Transmission Serial 6 3 6 3 Transmission Specifications and Maintenance 6 3 6 4 Transmission 6 3 6 5 Transmission 6 7 Section 7 Engine Cummins QSB3 3T QSB4 5T 7 1 7 1 IntrOd ctlOn 22 LLLI A ILLI ELEM LIBRES 7 2 7 2 Engine Serial Number 7 4 7 8 Specifications and Maintenance 7 4 7 4 Engine Cooling System 7 4 7 5 Engine Electrical 7 5 7 6 Fuel SyStem oed de dest rn etii 7 5 7 7 Engine Exliaust System voc ae ek epp equ gb nd at da gee 7 7 7 8 Air Gleaner Assembly x aca cies ERR X Re MER ECHO Ex RU Fe Du mut adc aa 7 8 7 9 Engine 7 9 7 10 Isolation Coupler 7 10 7 11 Troubleshootirig rem ded ER beber
220. is between the two anchor plates Line up the hole in the clevis with the anchor plate hole position recorded during removal MH2671 6036 6042 8042 10042 10054 Boom C t 26 Insert the shoulder bolt 17 through the plates and clevis and secure in place with a locknut Tighten the locknut securely 27 Pull the extend chain up and around the sheave at the front of the third boom section 28 Place the extend chain clevis between the mounting plates at the front of the third boom section Coat the shoulder bolt with anti seize compound and insert through the plates and clevis Secure the shoulder bolt in place with a locknut Tighten securely but the chain clevis should pivot freely 29 Return to the operator compartment and start the engine Slowly extend the boom to gain access to the retract chain adjustment nut on the lower left side of the second boom section Shut the engine OFF 30 Tighten the adjustment nut until the threads of the threaded clevis are flush with the top edge of the nut This will be a starting point for adjustment of the fourth boom section retract chain 31 Check and adjust the retract chain tension Refer to Section 3 7 5 Boom Chain Tension Check 32 Install the
221. ition key switch and the steering wheel stating that the machine should not be operated 3 Temporarily block up or support the raised boom 4 Openthe rear door Allow the system fluids to cool 5 With the engine OFF operate all the hydraulic functions to relieve trapped pressure 6 Remove the transmission covers Thoroughly clean the main control valve and surrounding area including all hoses and fittings before proceeding 7 Place a suitable container to catch hydraulic fluid drainage beneath the frame MH6190 8 Label disconnect and cap all the hydraulic hoses tubes and wires at the main control valve 1 9 Wipe up any hydraulic fluid spillage in on near and around the machine and the work area 6036 6042 8042 10042 10054 MA8482 10 Record the distance 2 from the outer jam nut to the end of the ferrule on all cables to ensure correct adjustment when reinstalling cables Note Hecord the location and label all cables to ensure correct installation 11 Disconnect the control cables a Remove the spring pin 3 and anchor pin Save the spring pin and anchor pin for installation b Loosen the outer jam nut 4 and remove the control cable from the bracket Save the jam nut for installation c Route the cable clear of the main control valve d Repeat steps for the remaining control cables 12 Remove the bolts and nuts 3 securing the main control valve to the frame 13 Remove
222. joysticks Joystick Assemblies 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 NEUTRAL position engage the parking brake and turn the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated 3 Properly disconnect the battery 4 Remove the console panel in the cab MA8521 Note Record the location and label all cables to ensure correct installation 5 Disconnect control cables at the joystick a Push the control lever to expose the flats 1 on the slider head Place a wrench on the flats to hold the slider head and loosen the cable nut 2 b Loosen the upper jam nut 3 and remove the cable from the bracket c Repeat steps for remaining control cables 4 6 oe 9 MAQ0050 6 Remove the four capscrews 4 and remove the joystick assembly from the machine b Joystick Assembly Installation 1 Secure the joystick to the cab with the previously used hardware 2 Connect the control cables at the joystick a Install the end of the control cable into the slider head 5 as recorded during removal Tighten the upper jam nut 3 b Loosely install the cable nut 2 into the slider head c Engage the control lever to expose the flats 1 on the slider head Place a wrench on the fl
223. ket head capscrews Steer Select Valve and Manifold Installation 1 Install the steer select valve to the mounting plate on the frame using two capscrews 2 Connect all the previously labeled hydraulic hoses fittings solenoid wire terminal leads etc to the steer select valve 3 Check the routing of all hoses wiring and tubing for sharp bends or interference with any rotating members and install tie wraps and or protective conduit as required Tighten all hose clamps 4 Properly connect the battery 5 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 6036 6042 8042 10042 10054 Hydraulic System n 6 Start the engine and run at approximately 1 3 1 2 throttle for about one minute without moving the machine or operating any hydraulic functions 7 Inspect for leaks and check the level of the hydraulic fluid in the reservoir Shut the engine OFF Note Check for leaks and repair as required before continuing Add hydraulic fluid to the reservoir as needed 8 Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools 9 Install the transmission covers 10 Close and secure the rear door d Steering Test Refer to Section 8 4 1 Hydraulic Pressures 1 Conduct a pressure check of the steering hydraulic circuit 2 Check each steering mode for proper function 8 7 7 Unloader Valve 6036 amp 6042 only
224. l inspection of the machine and work area and review the task about to be undertaken Read understand and follow these instructions 3 4 A WARNING NEVER weld or drill the boom unless approved in writing by the manufacturer The structural integrity of the boom will be impaired if subjected to any repair involving welding or drilling 3 4 1 1 Remove any attachment from the quick attach assembly Refer to Section 3 8 1 Disconnecting from an Attachment Boom Removal Note If replacing the third section boom remove the quick attach from the third section Refer to Section 3 8 3 Quick Attach Removal 2 Park the machine on a hard level surface level the machine fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 3 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 4 Open the rear door Allow the system fluids to cool 5 Move the Attachment Tilt joystick in both directions to relieve any trapped pressure in the Attachment Tilt system If the machine is equipped with Auxiliary controls move the Auxiliary hydraulic joystick in both directions to relieve any trapped pressure in the Auxiliary hydraulic system 6 Properly disconnect the battery 7 Label disconnect and cap the hydraulic hoses at the rear of the boom Cap all fit
225. late With the boom properly shimmed position the boom assembly all the way to the right side 3 22 12 13 14 15 16 MH1391 Insert the boom proximity sensor through the hole in the right side mounting plate Install the jam nut onto the boom proximity sensor on the inside of the plate Adjust the inner and outer jam nuts on the sensor until the gap 7 between the sensor and the boom is 0 12 in mm Torque the inside jam nut to 36 Ib in 4 1 Nm to hold the sensor in position MH1151 Install the Extend and Retract tubes 8 to the inside bulkhead fitting and the Extend Retract cylinder Install the Extend and Retract tube clamp halves 9 Uncap and connect the previously labeled hydraulic hoses and attach to their appropriate cylinder locations Install the Extend and Retract and Auxiliary if equipped tube assemblies to their appropriate bulkhead fittings Secure with tube clamps Uncap and connect the previously labeled Attachment Tilt and Auxiliary if equipped hydraulic hoses to their appropriate bulkhead fittings 6036 6042 8042 10042 10054 Boom C A M 17 18 19 3 6 6 1 OY MH1461 Inside the rear of the boom slide the threaded clevis end 10 of the retract chain down the right side of the boom Guide the threaded part of the clevis out through the hole in the tab on the bottom of the boom Pull thr
226. lean tools are required for installation 2 Install new seals back up rings and o rings on the piston and new seals back up rings o rings and bearing on the head gland Note The extend retract cylinder has a spacer that MUST be installed over the rod AFTER the head gland and BEFORE the piston head 3 Fasten the rod eye in a soft jawed vise and place a padded support under and near the threaded end of the rod to prevent any damage to the rod Note Protect the finish on the cylinder rod at all times Damage to the surface of the rod can cause seal failure 4 Lubricate and slide the head gland over the cylinder rod Install the piston head on to the end of the cylinder rod Loctite 243 and install the set screw in the piston head Refer to Section 8 8 4 Cylinder Torque Specifications for torque specifications for the piston head and the set screw Note Avoid using excess force when clamping the cylinder barrel in a vise Apply only enough force to hold the cylinder barrel securely Excessive force can damage the cylinder barrel 5 Place the cylinder barrel in a soft jawed vise or other acceptable holding devise Note When sliding the rod and piston assembly into the cylinder barrel prevent the threaded end of the cylinder barrel from damaging the piston head Keep the cylinder rod centered within the barrel to prevent binding 6 Carefully insert the cylinder rod assembly into the cylinder barrel 7 Screw th
227. 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 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the rear door Allow the system fluids to cool Properly disconnect the battery Remove the right access panel OQ 260 Unscrew the locking ring from below the instrument cluster 4 Pull the instrument cluster up and away from the cut out and unplug the harness connector Instrument Cluster Bulb Removal Remove the instrument cluster from the cab Refer to Section 9 11 1 a Instrument Cluster Removal 2 Remove the instrument cluster rear cover plate 3 Rotate the bulb assembly 1 4 turn counterclockwise and remove bulb Instrument Cluster Installation and Testing Connect the harness connector to the instrument cluster terminal Place the instrument cluster into the cut out and install the plastic retaining ring and secure Install the right access panel 4 Properly connect the battery Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel Turn the ignition to the RUN position All lights must illuminate for 3 seconds Close and secure the rear door 9 23 Electrical System 9 12 DASH SWITCHES Note For information
228. liary hydraulics label cap and remove the hoses from the bulkhead fittings If replacing the fourth boom section with a new boom section Remove the female coupler male nipple and bulkhead fittings from the bulkhead plate inside the boom head 8 Remove the rear cover from the boom MH1451 9 At the front of the first boom section label and remove the hydraulic hoses from the bottom tube assemblies at the mounting plate 16 Cap the hose ends 3 15 Boom MH1691 10 Label and remove the hydraulic hoses from the hose reel 17 18 MH1781 11 At the rear of the boom locate the fourth boom section extend chain locknut 18 Measure the amount of threads protruding beyond the locknut and record the measurement for reassembly 12 Loosen but DO NOT remove the locknut 13 At the rear of the boom locate the two third boom section extend chain locknuts 19 Measure the amount of threads protruding beyond each locknut and record the measurements for reassembly 14 Loosen but DO NOT remove the locknuts 15 Return to the cab start the engine and extend the boom approximately 2 in 51 mm Retract the boom slightly until there is
229. ll each hose through the boom assembly through the opening at the bottom of the first boom section 15 Remove the strings from the hoses MH1451 16 Atthe front of the first boom section assemble the hose assemblies and tube assemblies to the mounting plate 13 Note Where the hose assemblies come out of the outer boom lubricate the radius in the first boom section with soap and water to allow proper tensioning of hoses 17 Place the retract chain up around the retract chain sheave on the right side of the boom Stretch the chain forward and place the clevis between the two anchor plates Align the hole in the clevis with the second hole from the rear of the anchor plates 3 13 b Boom 18 19 20 21 22 23 24 25 26 27 28 29 Insert the shoulder bolt from the top down and secure in place with a locknut SH1871 Assemble the two extend chains to the mount if the yoke plates 14 were removed from the extend chains Secure in place with a locknut Tighten the locknut securely but the yoke plates must pivot freely Align the holes in the yoke plates with the hole in the mount on the first boom section Coat the shoulder bolt 15 with anti seize compound and insert the shoulder bolt through the yoke plates and the mount on the boom Secure in place with a locknut Tighten the locknut securely but the yoke plates must pivot freely Install the quick at
230. llation ize Rr EE her RR TREE 7 9 7 10 Isolation 7 10 7 10 1 Isolation Coupler Removal 7 10 7 10 2 Isolation 1 7 11 7 11 Troubleshooting irr IRI RR AER RE 7 12 6036 6042 8042 10042 10054 7 1 Engine Cummins QSB3 3T QSB4 5T 7 1 INTRODUCTION 7 1 1 Disclaimer and Scope These instructions are written for worldwide use In territories where legal requirements govern engine smoke emission noise safety factors etc apply all instructions data and dimensions provided herein in such a way that after maintenance service and repair of the engine engine operation does not violate local regulations Note These instructions cover only the routine maintenance removal installation and troubleshooting of the engine Refer to the local Cummins Engine Distributor and the applicable Cummins Engine Service Manual for assistance with comprehensive engine diagnosis repair and component replacement A gradual running in break in of a new engine is not necessary Full load can be applied to a new engine as soon as the engine is put into service and the coolant temperature is atleast 140 F 60 C Extended light load operation during the early life of the engine is not recommended DO NOT run the engine at high no load speeds
231. m Using a sling or suitable support pull the third boom section straight out of the second boom section Reposition the slings as needed so the third boom section balances when removed from the second boom section Set the boom section down on a hard level surface Support the boom as needed to prevent it from tipping over Remove the remaining wear pads shims and hardware Label and tag each set of wear pads being removed Inspect all wear pads for wear Refer to Section 3 9 Boom Wear Pads 6036 6042 8042 10042 10054 3 6 3 1 Second Boom Section Removal 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 MH 2121 Remove the retract chain sheave 14 from the inside of the second boom section Using a suitable sling or support secure the front of the Extend Retract cylinder Remove the retaining ring from one side of the Extend Retract cylinder rod end mounting pin MH2171 On the left side of the first boom section remove the boom extend interlock proximity sensor 15 and mounting bracket Using a sling or suitable support pull the second boom section straight out of the first boom section Reposition the slings as needed so the second boom section balances when removed from the first boom section While pulling the second boom section out of the first boom section guide the retract chain into the rear of the b
232. m 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 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the rear door Allow the system fluids to cool Properly disconnect the battery E 7 W 0280 Carefully pry the switch and wiring 7 out of the mounting plate 8 Label and disconnect the wiring from the switch Remove the switch Disassembly DO NOT disassemble the dash switch Replace a defective switch with a new part 6036 6042 8042 10042 10054 Inspection and Replacement Inspect the switch terminals for continuity and shorting in both the engaged and disengaged positions Replace a defective or faulty switch with a new switch d 1 2 Switch Installation Connect the switch to the cab harness connector Position the switch over the rectangular switch bezel and snap into position Properly connect the battery Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel Start the machine and check the replaced switch for proper function Cl
233. m ns d E A ne poc A 0 L 133H8 19 TIWLDId 20783513 OL SLOANI tnos edid 5 rm 4 WE wi exe voa m 122 HHO asus HR 1338 LHOIDIHOM VE SHIM pem ost Ere 1HO VOU saws 302 OL SLO3NNOO DL UA MS 33HS LH NAVOY e anm OL SIO3NNOO 1 t 1 FA QUU Li woa no m 1 Wd OHNNOO Tear KRA MP 5 1 TT WS as rm 9NI D wy Su ww JO VOL OL S193NNOO Spe noa ain WO S 6036 6042 8042 10042 10054 38OHIS NOOV38
234. machine especially under load The use of hydrofill as a tire fill substance is not recommended because of possible environmental impact Large bore valve stems are used to help expedite tire inflation and deflation An inner tube may be used if a tire does not provide an airtight seal Check tire inflation pressures when the tires are cold When mounting a tire on the wheel the tire must be mounted on the wheel respective of the directional tread pattern of the tire this produces a left or right tire and wheel assembly 6036 6042 8042 10042 10054 The wheel and tire assemblies must be installed with the directional tread pattern arrows 5 facing in the direc tion of forward travel 5 7 1 Removing Wheel and Tire Assembly from Machine 1 Park the machine on a firm level surface fully retract the boom lower the boom place the transmission control lever NEUTRAL engage the park brake and shut the engine OFF 2 Place an Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated 3 Loosen but DO NOT remove the lug nuts on the wheel and tire assembly to be removed 4 Place a suitable jack under the axle pad closest to the wheel being removed Raise the machine and position a suitable support beneath the axle Allow sufficient room to lower the machine onto the support and to remove the wheel and tire assembly 5 Lower the machine onto the supp
235. me with two carriage bolts and two hex flange nuts Verify the correct operation of the solenoids before considering replacement of the secondary function manifold The manifold itself is not serviceable and must be replaced if defective Note DO NOT loosen disassemble or attempt to adjust any of the pressure valves unless specifically instructed by the manufacturer to do so Tampering with a pressure valve will irrevocably alter pressure in the affected circuits 8 25 Hydraulic System 8 7 3 Service Brake Valve b Service Brake Valve Installation 1 Install the service brake valve with the four capscrews and four lockwashers onto the steering 1 Park the machine on a firm level surface level the column support machine fully retract the boom lower the boom place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF a Service Brake Valve Removal Note ALWAYS replace seals o rings gaskets etc with new parts to help ensure proper sealing and operation Lubricate seals and o rings with clean 2 Place a Do Not Operate Tag on both the ignition key hydraulic oil switch and the steering wheel stating that the machine should not be operated 2 Use new oiled o rings as required Uncap and connect the previously labeled hoses to the service 3 Open the rear door Allow the system fluids to cool brake valve 4 Properly disconnect the battery 3 Check the rou
236. medy 7 Oil leaking from transmission 1 Cil leaking from vent high oil level Drain plug loose and or o rings damaged or missing Hose fittings loose Oil leaking at valve bodies possible valve body gaskets damaged or missing and or mounting capscrews not tight Housing capscrews loose Oil leaking at pump possible pump to housing o rings missing or damaged and or pump mounting capscrews not tight Oil leaking at converter bell possible converter leak and or input shaft seal damage Oil leaking at output shaft output shaft seal damaged Housing damaged 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 Replace o rings as needed and tighten plug to 26 Ib ft 35 Nm Tighten fittings Replace gaskets and or tighten capscrews to 7 lb ft 9 5 Nm Tighten capscrews to 34 Ib ft 46 Nm Replace o rings and or tighten capscrews to 85 lb ft 115 Nm Replace converter and or input shaft seal Replace output shaft seal Replace housing as needed 6 10 6036 6042 8042 10042 10054 Section 7 Engine Cummins QSB3 3T QSB4 5T Contents PARAGRAPH TITLE PAGE 7 1 Introduction 2 5 culos loi I N 7 2 7 1 1 Disclaimer and 7 2
237. mpt to raise both outriggers they should not rise If the outriggers rise STOP and retract the boom and have the system repaired before using the machine again If the outriggers cannot be raised attempt to lower the outriggers fully until both front wheels are off the ground the outriggers should lower a Place the travel select lever in the F FORWARD position and the gear select lever in the 1 FIRST gear position Attempt to accelerate the machine the machine should not move If the machine attempts to move STOP and have the system repaired before using the machine Note Perform Steps 5 thru 9 with the engine rpm at idle Attempt to frame sway the machine to the right and left it should frame sway but at a slower speed than normal b The Stabil TRAK light should remain ON Return the machine to a level position a Place the travel select lever in the N NEUTRAL position move the neutral lock lever to the NEUTRAL LOCK position Fully retract the boom Raise the outriggers Engage the parking brake switch shut the engine OFF and remove the key Step 1 SES b QS Step 2 a 1 Step 3 a d Step 4 b e gua Step 5 a Step 6 b c SES d mz e Exit the machine using both handholds 6036 6042 8042 10042 10054 10 13 Wi Stabil TRAK System a
238. nd 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 If OK Y Check solenoid cartridge in the Stabil TRAK manifold Refer to Section 10 3 1 Stabil TRAK Solenoid Valves If OK Y Inspect check valves on the Stabil TRAK cylinder Refer to Section 10 3 1 Stabil TRAK Solenoid Valves 10 14 Not OK Not OK Not OK Refer to Section 9 5 Electrical System Schematics gt Replace cartridge Replace check valve s 6036 6042 8042 10042 10054 31200353 e 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 Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany Phone 49 0 421 69 350 20 Fax 49 0 421 69 350 45 JLG Polska UI Krolewska 00 060 Warsawa Poland Phone 48 0 914 320 245 Fax 48 0 914 358 200 JLG La
239. nd assemble the drive shaft flange to the coupler using new hardware Torque to 48 lb ft 65 Nm 8 If engine mounts were previously removed or loosened carefully lower the engine down onto the front engine mounts Reassemble the rebound washer and secure in place with a new locknut Torque to 60 lb ft 81 Nm Repeat this procedure for the engine mount on the other side 9 Thoroughly clean the transmission yoke and secure in place with new straps and hardware Torque to 55 60 Ib ft 75 81 Nm 10 After the drive shaft is in place grease both u joints and the slip joint using multi purpose grease 11 Properly connect the battery 12 Close and secure the rear door 13 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel O Engine Cummins QSB3 3T QSB4 5T 7 11 TROUBLESHOOTING Trouble Possible Causes see key below Low Cranking Power Will Not Start Difficult Starting Lack of Power Misfiring Excessive Fuel Consumption Black Exhaust Blue White Exhaust Low Oil Pressure Knocking Erratic Running Vibration High Oil Pressure Overheating Excessive Crankcase Pressure Poor Compression Starts and Stops 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 22 31 32 33 5 7 8 9 10 11 12 13 14 15 16 18 19 20 21 22 24 29 31 32 33 61 63 8 9 10 11 12 13 14 18 19 20 21 22 23 24 25 26 27 31 3
240. nd parking brake will be engaged 3 Pressurize the parking brake with the pressurizing unit Close the needle valve on the pressurizing unit 6036 6042 8042 10042 10054 Axles Drive Shafts Wheels and Tires hs gt T NE 4 Working through the level plug hole 2 carefully use a screwdriver to spread the brake discs apart MT2851 Note DO NOT damage the surfaces of the brake discs when spreading the brake discs mim amp 3 2841 5 Using a feeler gauge check the 3 between the brake discs 4 If the measurement is greater than the maximum gap replace the brake discs Machine Maximum Gap 6036 6042 4 25 mm 0 16 in 3 disc version 5 60 mm 0 22 in 4 disc version 8042 5 60 mm 0 22 in 10042 10054 6 75 mm 0 26 in Note If the brake discs are worn beyond their tolerance the brake disc must be replaced on both sides of the axle at the same time 6 Repeat steps 4 and 5 for the other side of the axle 6036 6042 8042 10042 10054 7 Fill the axle with Mobilfluid 4249 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 differe
241. ne and operate all boom functions several times Check the chain tension again and adjust as necessary Check for leaks and check the hydraulic fluid level in the tank add fluid if required 35 Clean up all debris hydraulic fluid etc in on near and around the machine 36 Install the rear cover to the boom 37 Close and secure the rear door 3 28 3 7 BOOM EXTEND AND RETRACT CHAINS 3 7 1 Boom Chain Inspection A WARNING Worn pins stretched or cracked links or corrosive environments can cause chain failure A chain failure could result in uncontrolled boom movement loss of load or machine instability Under normal operating conditions the boom chains will need to be inspected every 250 hours of operation The retract chains need to be exposed and inspected every 1000 hours of operation Environmental conditions and dynamic impulse shock loads can drastically affect normal operating conditions and require more frequent inspection intervals Environments in which material handling machines operate can vary widely from outdoor moisture to temperature to mildly corrosive or highly corrosive industrial atmospheres in addition to abrasive exposures such as sand and grit Some effects can be as follows e Moisture Corrosive rusting reduces chain strength by pitting and cracking Temperature Low temperature reduces chain strength by embrittlement Going in and out of cold storage results in moisture f
242. needed to help balance the cab during removal When the cab is completely clear of the machine carefully lower it to the ground Block up or support the cab so that it does not move or fall Assure that no personnel enter the cab while it is being removed from the machine Inspect the condition of the fittings clamps hydraulic hoses etc Replace parts as indicated by their condition Inspect and replace other machine parts that are exposed with the cab removed Repair or replace as required CAB INSTALLATION Block all four wheels to help prevent the machine from moving Assure that there is sufficient overhead and side clearance for cab installation Attach a clevis 5 to each of the cab lifting brackets Route a sling 6 with a minimum lifting capacity of 1000 Ib 453 kg to carry the weight of the cab through the clevis to a hoist or over head crane Make sure the sling is centered between the clevis to ensure even lifting Carefully begin to align the cab with the mounting holes in the frame Stop and check that wiring hydraulic hoses cables etc will not be pinched or damaged as the cab is positioned Readjust the position of the sling as needed to help balance the cab during installation Install the two upper cab to frame capscrews and washers Torque to 480 Ib ft 651 Nm Install the two lower cab to frame capscrews and washers Torque to 480 lb ft 651 Nm Under the cab install new o rings into
243. nent Pressure Pressure Test Procedures Location Port Location Description Reading 2 VG A Unloader Main System With engine at high idle use the boom control Valve Relief 2900 lever to fully retract the boom Hold over relief 3100 psi and check pressure If pressure is incorrect 200 214 bar adjust or replace cartridge 2 A Auxiliary 2900 3100 psi With engine at high idle move auxiliary control Hydraulics 200 214 bar lever left or right Hold auxiliary control lever over relief and check pressure If pressure is incorrect check unloader pressure per location 2 If location 2 is ok check port reliefs on the aux section of the main control valve 2 VG N A Attachment 2900 3100 psi CONSULT FACTORY Tilt Reliet 200 214 bar FORWARD or REARWARD 3 VG B Unloader Standby Note DO NOT touch any functions while the Valve Pressure pressure gauge is connected You will damage 250 300 psi pressure gauge 17 21 bar With engine at idle and no functions operated check standby pressure If pressure is incorrect adjust or replace the differential pressure sense cartridge on the unloader valve 4 LSG N A Unloader Load Sense With engine at idle load sense is 0 psi Valve 0 3000 psi With the engine at FULL throttle use the boom 0 207 bar control lever to fully retract the boom Hold over relief Pressure should be 2750 3000 psi 190 207 bar 5 PSG C Secondary Steering Relief With engine at FULL throttle turn the steerin
244. ng Internal Hardware Failure 351 627 12 Injector Power Supply 352 1079 4 4 Sensor Supply Voltage Number 1 Circuit Low 386 1079 3 3 Sensor Supply Voltage Number 1 Circuit High 387 1043 3 3 Accelerator Pedal or Lever Position Sensor Supply Voltage Circuit High 412 608 2 SAE J1587 J1922 Data Link Can not Transmit 415 100 1 1 Engine Oil Rifle Pressure Low 418 97 0 15 Water In Fuel Indicator High 426 639 2 SAE J1939 Data Link Can not Transmit 427 639 9 J1939 Datalink Abnormal Update Rate 428 97 3 3 Water In Fuel Indicator Sensor Circuit High 9 28 6036 6042 8042 10042 10054 Electrical System Fault Code SPN Code FMI Code Description 429 97 4 4 Water In Fuel Indicator Sensor Circuit Low 431 558 2 2 Accelerator Pedal or Lever Idle Validation Circuit Erratic 432 558 13 13 Accelerator Pedal or Lever Idle Validation Circuit Out of Calibration 433 102 2 Intake Manifold Pressure Sensor Circuit Data incorrect 434 627 2 2 Power Supply Lost with Ignition On Erratic 435 100 2 2 Oil Pressure Switch Sensor Circuit Erratic 436 105 2 Intake Manifold 1 Temperature Erratic 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 Supply Voltage Circuit Low 449 157 0 Injector Metering Rail Number
245. ng brake straighten all wheels and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated 3 Open the rear door Allow the system fluids to cool 4 Properly disconnect the battery OA1321 5 f the axle will be disassembled after removal place a suitable receptacle under the axle drain plug 1 Remove the drain plug and allow the axle oil to drain into the receptacle Transfer the used axle oil into a suitable covered container and label the container as Used Oil Dispose of used oil at an approved recycling facility Te MA9091 6 Front Axle Remove the front access panel 2 to gain access to the front axle hose connections and mounting bolts Rear Axle Open the right and left side engine compartment doors to gain access to the rear hose connections and mounting bolts 5 5 ES 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 Place suitable supports under both sides of the frame and lower the machine onto the
246. ng the rod and piston assembly out of the barrel prevent the threaded end of the barrel from damaging the piston Keep the rod centered within the barrel to help prevent binding 6 Carefully pull the rod assembly along with the head gland out of the cylinder barrel 7 Fasten the rod eye in a soft jawed vise and place a padded support under and near the threaded end of the rod to prevent any damage to the rod 8 Remove the set screw from the piston head Note It may be necessary to apply heat to break the bond of the sealant between the piston and the rod before the piston can be removed Some cylinder parts are sealed with a special organic sealant and locking compound Before attempting to disassemble these parts remove any accessible seals from the area of the bonded parts Wipe off any hydraulic oil then heat the part s uniformly to break the bond A temperature of 300 400 F 149 204 C will destroy the bond Avoid overheating or the parts may become distorted or damaged Apply sufficient torque for removal while the parts are still hot The sealant often leaves a white powdery residue on threads and other parts which must be removed by brushing with a soft brass wire brush prior to reassembly 9 Remove the piston head from the rod and carefully slide the head gland off the end of the rod 10 Remove all seals back up rings and o rings from the piston head and all seals back up rings and o rings from the head glan
247. nor or moderate injury 6036 6042 8042 10042 10054 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 1 Personal Hazards PERSONAL SAFETY GEAR Wear all the protective clothing and personal safety gear necessary to perform the job safely This might include heavy gloves safety glasses or goggles filter mask or respirator safety shoes or a hard hat LIFTING NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist 1 6 2 Equipment Hazards LIFTING OF EQUIPMENT Before using any lifting equipment chains slings brackets hooks etc verify thatitis of the proper capacity in good working order and is properly attached NEVER stand or otherwise become positioned under a suspended load or under raised equipment The load or equipment could fall or tip DO NOT use hoist jack or jack stands only to support equipment Always support equipment with the proper capacity blocks or stands properly rated for the load HAND TOOLS Always use
248. nt 6 17 Remove the hardware securing the rear engine mount 7 18 Remove the exhaust pipe bracket 19 Position a fork truck behind the machine and drive forward placing the forks underneath the rear engine mount and front engine mount brackets Slightly lift the engine and slowly back engine out of the machine Have an assistant ensure that the engine clears all frame components during removal 20 Place engine on a flat level surface 21 If replacing engine attach a lifting chain to the front and rear engine lift brackets and lift engine clear of the ground 22 Remove the three engine mounting brackets 7 9 2 Note The engine harness is routed and attached at various places on the engine using hold down clamps and plastic wire ties Before installing engine and with Engine Installation 7 9 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 Ib ft 126 135 Nm 3 Place the engine on a flat level surface 4 Position a fork truck behind the engine and drive forward placing the forks underneath the rear engine mount and front right and left engine mount brackets Lift the engine and slowly drive it into
249. ntial 8 Reassemble the level plugs using new o rings 9 Install the axle fill plug into axle housing 10 Remove the remote portable hydraulic pressurizing unit from the port b Rear Axle 1 Block all four wheels to help prevent the machine from moving after the parking brake is disabled 2 Working through the level plug hole 2 carefully use a screwdriver to spread the brake discs apart Note DO NOT damage the surfaces of the brake discs when spreading the brake discs 3 Using a feeler gauge check the gap 3 between the brake discs 4 If the gap is greater than 0 16 in 4 25 mm for a 3 disc axle replace the brake discs If the gap is greater than 0 22 in 5 60 mm fora 4 disc axle replace the brake discs Note If the brake discs are worn beyond their tolerance the brake disc must be replaced on both sides of the axle at the same time 4 Repeat steps 2 and 3 for the other side of the axle 5 Fill the axle with Mobilfluid 4249 Tractor Hydraulic Fluid ISO 46 through the axle fill hole until the oil level is even with both axle level holes Fill the axle slowly allow time for the oil to run across the differential 6 Reassemble the level plugs using new o rings 7 Install the axle fill plug into axle housing Axles Drive Shafts Wheels and Tires hs 5 9 TOWING A DISABLED MACHINE Towing a disabled machine should only be attempted as a last resort after exhausting all other op
250. o 43 53 Ib ft 58 72 Nm Torque the top nut 6 to 66 82 Ib ft 89 111 Nm 6036 6042 8042 10042 10054 Hydraulic System n 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 to the main control valve MA8482 4 Connect the control cables to the main control valve a Slide the outer jam nut 7 over the end of the control cable and install the cable in the bracket with one nut on either side of the bracket DO NOT tighten the jam nuts at this time b Connect the end of the cable to the shaft from the control valve Secure with an anchor pin and spring pin 8 c Adjust the jam nuts until the distance 9 from the outer jam nut to the end of the ferrule is the same as recorded during removal Tighten the jam nuts d Repeat steps for remaining control cables 5 Check the routing of all hoses wiring and tubing for sharp bends or interference with any rotating members and install tie wraps and or protective conduit as required Tighten all tube and hose clamps 6 Fill
251. oads far in excess of the design load Either fractured plates 11 or enlarged holes 12 can occur If either of these failures occurs the chain should be replaced immediately Tight Joints MZ1470 All joints in the chain should flex ooi freely Tight 13 joints 13 meret resist flexing If the problem is caused by dirt or foreign substance packed in the joints clean and lubricate thoroughly before re installing the chain If the problem is caused by corrosion and rust or bent pins replace the chain 3 52 9 3 10 3 Expose Chains for Inspection e Extend Chains 1 Park the machine on a firm level surface Place the transmission control lever in NEUTRAL engage the park brake switch and raise the boom to a horizontal level position 2 Fully extend the boom until both extend chains are taut Shut the engine OFF The extend chains will be visible for inspection with the machine in this state While doing the chain inspection check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain If during the inspection any chain is found to be damaged or stretched the chain must be replaced It is recommended that when any chain is replaced that all the chains and clevises be replaced at the same time f Retract Chains The three retract chains are only partially visible through the rear of the boom with all the sections retracted It is
252. odes Chart Fault Code SPN Code FMI Code Description 0001 Exhaust Gas Pressure Sensor Number 1 Circuit High 0002 Exhaust Gas Pressure Sensor Number 1 Circuit Low 0003 Exhaust Gas Pressure Sensor Number 1 Circuit Erratic 0004 Exhaust Gas Temperature Sensor Number 1 Circuit Erratic 0005 Exhaust Gas Temperature Sensor Number 1 Circuit Low 0006 Exhaust Gas Temperature Sensor Number 1 Circuit High 111 629 12 12 Engine Control Module 115 612 2 Engine Magnetic Crankshaft Speed Position 122 102 3 3 Intake Manifold Pressure Sensor Circuit High 123 102 4 4 Intake Manifold Pressure Sensor Circuit Low 124 0 16 Intake Manifold 1 Pressure Sensor Circuit 131 91 3 3 Accelerator Pedal or Lever Position Sensor Circuit High 132 91 4 4 Accelerator Pedal or Lever Position Sensor Circuit Low 133 974 3 3 Remote Accelerator Pedal or Lever Position Sensor Circuit High 134 974 4 4 Remote Accelerator Pedal or Lever Position Sensor Circuit Low 135 100 3 Oil Pressure Sensor Circuit High 141 100 4 4 Oil Pressure Sensor Circuit Low 143 100 1 18 Engine Oil Rifle Pressure 144 110 3 8 Engine Coolant Temperature 1 Sensor Circuit High 145 110 4 4 Engine Coolant Temperature 1 Sensor Circuit Low 146 110 0 16 Engine Coolant Temperature High Warning 147 1 Accelerator Pedal or Lever Position 1 Sensor Circuit
253. on the axle pivot pin and the mounting plate under the axle flanges 4 Install the two mount plates 7 onto the top of the axle and secure with the previously used hardware Note ALWAYS use new o rings when servicing the machine 5 Install new o rings into the fittings Lubricate the o rings with clean hydraulic oil 6 Uncap and connect the previously labeled hydraulic hoses 6 to their appropriate locations 7 Tie the strings left in the outrigger housing during removal to each pressure switch wiring connector and pull the harness through the outrigger housing 8 Connect the wiring connectors to the outrigger cylinder pressure switches Secure the harnesses to the cylinders with wire ties 9 Check the hydraulic reservoir oil level 10 Properly connect the battery 11 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 12 Start the engine Turn the steering wheel several times lock to lock operate the frame tilt function several times in both directions and check the function of the brakes Check for hydraulic leaks and tighten or repair as necessary c Axle Removal The front and rear axle assemblies differ in that the front axle assembly is equipped with a parking brake mechanism and a limited slip feature the rear axle has neither The following steps outline a typical axle removal procedure suitable for either the front or the rear axle assembly Cleanliness is e
254. on the front windshield wiper rear window wiper and washer systems refer to Section 9 8 Window Wiper Washer Windshield Wiper Motor 9 12 1 Ignition Key Switch a Ignition Switch Removal 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on the steering wheel stating that the machine should not be operated 3 Open the rear door Allow the system fluids to cool 4 Properly disconnect the battery c Inspection and Replacement To determine the proper operation of the ignition key switch test the terminals on the back of the switch for continuity with an ohmmeter Test the ignition key switch for continuity by checking from the ignition BLUE wire to each of the following wires in each corresponding switch position Continuity X should be present as indicated in the following chart Switch Position OFF RUN START WHT Wire Pin B on 3 Pin X Connector Test from BLUE wire to Test the ignition key switch for continuity by checking from the ignition RED wire to each of the following wires in each switch position Continuity X should be present as indicated in the following chart MAQ0270 5 Remove the lower access panel 5 6 From under the dash remove the hex nut securing the ignition k
255. ons 2 6 LUBRICATION SCHEDULES a 50 Hour 6036 6042 8042 amp 10042 LI IF EQUIPPED OH4162 2 22 6036 6042 8042 10042 10054 General Information and Specifications b 50 Hour 10054 6036 6042 8042 10042 10054 OH4242 2 23 Ay General Information and Specifications c 250 Hour 6036 amp 6042 6042 ONLY D OA1820 2 24 6036 6042 8042 10042 10054 General Information and Specifications d 250 Hour 8042 10042 amp 10054 6036 6042 8042 10042 10054 OH4172 2 25 Ay General Information and Specifications e 1000 Hour OH4181
256. oom Set the boom section down on a hard level surface Support the boom as needed to prevent it from tipping over 3 19 ic Boom Remove the remaining wear pads shims and hardware Label and tag each set of wear pads being removed Inspect all wear pads for wear Refer to Section 3 9 Boom Wear Pads MH2141 At the underside of the second boom section remove the locknut 16 from the retract chain clevis Pull the retract chain out of the boom through the rear of the boom 3 6 4 First Boom Section Removal 1 Attach a suitable overhead lifting device and sling to the Lift Lower cylinder and remove slack in the sling Securely support the first boom section Remove all wear pads shims and hardware Label and tag each set of wear pads being removed T 2 17 MH1111 4 At the underside of the boom remove the retract chain locknut 17 Measure the amount of threads protruding beyond the locknut and record the measurement for reassembly of the chain 3 20 5 Remove the retract chain by pulling it out the rear of the boom Label disconnect and cap the Attachment Tilt and Auxiliary if equipped hydraulic hoses on the mounting plate 18 Label disconnect and cap the Attachment Tilt and Auxiliary if equipped hydraulic tubes from the bulkhead fittings Label disconnect and cap the Extend Retract hydraulic hoses from the bulkhead fit
257. ort 6 Remove lug nuts and lug washers in an alternating pattern 7 Remove the wheel and tire assembly from the machine 5 15 hs Axles Drive Shafts Wheels and Tires 5 7 2 Note The wheel and tire assemblies must be installed with the directional tread pattern arrows facing in the direction of forward travel INSTALL TIRES ONTO WHEELS TO ROTATE IN PROPER DIRECTION Installing Wheel and Tire Assembly onto Machine 8042 10042 amp 10054 TREAD ARROWS MUST POINT FORWARD 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 1 Brake Disc Inspection Check the brake discs for wear every 1 000 hours of operation or yearly For more information on brake disc inspection refer to the appropriate axle repair manual 460 a Front Axle 1 Position wheel onto studs on wheel end of axle 1 Block all four wheels to help prevent the machine Iste wheel Tug washers from moving after the parking brake is disabled 3 Start all nuts by hand to prevent cross threading DO NOT use lubricant on threads or nuts 5 16 6036 amp 6042 MH4341 2 Attach a remote portable hydraulic pressurizing unit to the breather port 1 on the axle Note DO NOT turn the key switch to the ON position DO NOT release the parking brake switch Oil pressure will be lost a
258. ose and secure the rear door 9 25 Electrical System 9 13 TROUBLESHOOTING 9 13 1 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 Fault Detection For more information contact your local authorized Cummins service distributor 9 13 2 Flash Out of Fault Codes Fault flash out mode can be entered through the use of a diagnostic switch or the accelerator pedal To enter the fault flash out mode the key switch must be in the RUN position with the engine not running When a diagnostic switch is used to enter the fault flash out code mode the ECM will automatically flash the first fault code after the switch is turned to the RUN position The diagnostic increment decrement is used to sequence forward or backwards through the active faults To enter fault flash out mode using the accelerator pedal fully depress and release the pedal 3 times Once in diagnostic mode cycling the accelerator pedal will sequence forward through the active faults The following graphic depicts the pattern of the fault code flash out scheme as indicated by the stop lamp 9 26 Example Fault Code
259. osition the brake switch so the Stabil TRAK dash light comes ON at the 150 50 psi 10 3 3 4 bar brake pressure 9 Repeat steps 6 through 8 until the Stabil TRAK dash light comes ON at 150 50 psi 10 3 3 4 bar brake pressure 10 After the required pressure is achieved use a wrench and fully tighten the locknut against the service brake switch bracket In order to test the switch for proper operation the boom must be raised above the 40 position the parking brake switch must be in the OFF position and the machine must be in a forward or reverse gear mode Proper operation of the switch will activate the Stabil TRAK dash panel indicator If the Stabil TRAK indicator does not activate when all conditions are met the boom angle sensor must be adjusted Refer to Section 9 10 6 c Boom Angle Sensor Installation 11 Shut off the engine 12 Remove the blocks from the front tires 13 Remove the pressure gauge 14 Install the lower access panel 9 10 6 Angle Sensor MAQ0240 The boom angle sensor 14 is located at the rear of and on the right side of the machine When the boom is lifted above 40 the boom sensor sends a signal to the Stabil TRAK indicator on the instrument cluster a Boom Angle Sensor Removal 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the
260. ottom lip of the switch plunger through the hole in the bottom of the dust cover 6 Connect the cab harness electrical connectors to the service brake switch connectors 7 Properly connect the battery 8 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 9 Adjust the brake switch Refer to Section 9 10 5 c Service Brake Switch Adjustment Service Brake Switch Adjustment Note The service brake switch adjustment will require two people Enlist the help of an assistant before attempting to follow the adjustment procedure 1 Remove the lower access panel 2 Loosen locknut securing the switch body to the service brake switch bracket 3 Connect a 1000 psi 69 bar pressure gauge to the test port on the service brake valve A WARNING NEVER attempt to adjust the service brake switch without an assistant Anytime the engine is running and the parking brake is disengaged there must be an operator located in the cab and the two front tires must be blocked 4 Block both front tires 5 Start the engine and run at low idle 6 Position the boom above 40 release the park brake and place the transmission control lever in forward 4th gear 7 Slowly depress and hold the brake pedal to maintain 150 50 psi 10 3 3 4 bar brake pressure 6036 6042 8042 10042 10054 Electrical System 8 Using the switch dust cover and the locknut in combination p
261. ove and install the wiper motor housing Refer to Section 4 3 1 Steering Column and Steering Valve 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the rear door Allow the system fluids to cool Properly disconnect the battery Remove the right side instrument panel Qr dm to Remove the lower access panel below the instrument panel 7 Disconnect the right side defroster hose from the dash panel hose connector 9 9 MA8431 8 Disconnect the cab harness connectors from the wiper motor 3 9 From the outside and front of the cab remove the windshield wiper blade arm 4 nuts and washer from the motor shaft 10 Disconnect the washer hose from the hose connector 11 Remove the wiper arms knurled driver and rubber cap from the motor shaft 9 14 12 Remove the metal hex jam nut and metal washer from the motor shaft 13 Remove the motor mounting bolts panto adapter and gasket from the motor shaft Note Retain all hardware removed from the wiper assembly for possible reuse on the replacement motor housing 14 Remove the motor from the inside of the cab b Disassembly DO NOT disassemble the mo
262. ower rear position on each side of the heater will be secured with an insert nut 7 11 Remove the eight capscrews six nuts and six lockwashers 12 Carefully pull the heater assembly forward Label and disconnect the wiring harness connections at the blower 13 Remove the heater assembly 8 14 If the heater assembly is to be replaced Remove the four hex slotted capscrews and remove the mounting bracket from the heater assembly b Heater Assembly Installation 1 Connect the wiring harness connections to the blower Note The capscrew 6 at the lower rear position on each side of the heater will be secured with an insert nut 7 2 Slide the heater mounting bracket assembly 8 into the seat riser and secure with the eight capscrews six lockwashers and six nuts 3 Pull the hoses through the grommets Uncap and connect the previously labeled hoses to the heater 4 Install the heater access panel and secure with the previously used hardware 5 Fill the cooling system completely with coolant allowing time for the coolant to fill the engine block The cooling system capacity is listed in Section 2 4 Fluid and Lubricant Capacities 6 Properly connect the battery 4 7 Cab and Covers 7 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel Note When the engine is initially started run it briefly at low idle and check the machine for an
263. pad mounting capscrews enough to hold the hose guide 3 26 10 11 MH2471 With the hose guide tilted up in the back insert the female ends of the two left side hoses from the hose carrier one at a time over the top of the angled guide 1 on the front side of the hose guide Push the hoses into the hose channel on the left side of the fourth boom section and down to the front of the boom section Repeat this procedure for the two right side hoses into the hose channel on the right side of the boom Insert a capscrew through the hole in the fourth boom section Secure the hose guide in place with a flat washer and locknut Torque to 28 34 lb ft 38 46 Nm Run the hose carrier out and in by hand to check for interference Note DO NOT allow the hydraulic hoses to cross inside the boom 12 13 At the front of the boom pull the previously labeled hydraulic hoses out the opening in the back of the boom head Let the hoses hang out of the boom head Grease the sections of the boom in areas where the wear pads will slide Using a suitable sling lift the fourth boom section While guiding the hoses into the third boom section carefully slide the fourth boom section into the front of the third boom section 6036 6042 8042 10042 10054 Boom N I 15 16 17 18 19 20 21 MH1861 Reassemble the hose car
264. pillage in on near and around the machine and the work area 8 5 2 1 Be sure the reservoir is clean and free of all debris Hydraulic Oil Reservoir Filling 2 Install a new hydraulic oil filter 3 Fill the reservoir with Mobilfluid 4249 ISO Grade 46 oil Refer to Section 2 4 Fluid and Lubricant Capacities 4 Properly connect the battery 5 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 6 Close and secure the rear door 8 5 3 The hydraulic reservoir and fuel tank are one unit and are removed together Refer to Section 7 6 2 Fuel Hydraulic Oil Tank for information on hydraulic reservoir fuel tank replacement Hydraulic Oil Reservoir Replacement 8 21 Hydraulic System 8 6 HYDRAULIC SYSTEM PUMP For internal service instructions contact your local authorized service distributor 8 6 1 Pump Replacement a Pump Removal 1 Park the machine on a firm level surface level the machine fully retract the boom raise the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Temporarily block up or support the raised boom Open the rear door Allow the system fluids to cool Properly disconnect the battery Drain the hydraulic reservoir Refe
265. port the boom 5 Properly disconnect the battery 7 b Label and disconnect the wiring connector from the Coolant Temperature Switch 8 Unthread the switch from the engine Coolant Temperature Switch Disassembly DO NOT disassemble the Coolant Temperature Switch Replace a defective switch with a new part 1 2 Coolant Temperature Switch Installation Thread the switch into the engine Tighten securely Connect the previously labeled wiring connector to the switch Properly connect the battery Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 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 2 Hydraulic Oil Temperature Switch The hydraulic oil temperature switch 9 is threaded into a fitting at the lower inside wall of the hydraulic oil tank a Hydraulic Oil Temperature Switch Removal 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and
266. ption Reading 8 N A Brake Valve minimum With engine at idle depress and hold brake pedal Service Brake 550 psi DO NOT turn steering wheel DO NOT overstroke Pressure 38 bar the brake pedal Check pressure If pressure is incorrect refer to Section 8 7 4 Brake Test 9 D Auxiliary 3000 psi With engine at low idle move auxiliary control lever Hydraulics 207 bar left or right Hold control lever over relief and check pressure If pressure is incorrect check main relief per location 3 10 N A Stabilizer 75 150 psi With the engine at idle check the pressure of the Oylinder 5 2 10 3 bar cylinder 6036 6042 8042 10042 10054 8 15 Hydraulic System Hydraulic Schematics 154 921 991 x 007 x 008 X404 X S X 00 S M3ONTIAD LSIOH eve x SEZ X 07201 X X GNA X S X 0U9 1 z s 9 L 9 n 8 4 2 a Model 6036 MAQ0070A 6036 6042 8042 10042 10054 8 16 n Hydraulic System b Model 6042 AWA 3vu8 20H38 ESA THM vua 158 9 SLOL X 009 X04
267. r Abnormal Update Rate 2772 3226 0 15 After treatment Outlet NOx Sensor High Least Severe 2773 3226 0 After treatment Outlet NOx Sensor High Most Severe 2961 412 0 15 Exhaust Gas Recirculation EGR Temperature High Least Severe 2962 412 0 16 Exhaust Gas Recirculation EGR Temperature High More Severe 2963 110 0 15 Engine Coolant Temperature High Least Severe 2964 105 0 15 Intake Manifold Temperature High Least Severe 2973 102 2 2 Intake Manifold Pressure Sensor Circuit Erratic 2976 3361 2 Dosing Control Unit Temperature Erratic 9121 2791 0 15 Exhaust Gas Recirculation EGR Valve Actuator Over Temperature 9122 641 0 15 Variable Geometry Turbocharger Actuator Over Temperature 9 32 6036 6042 8042 10042 10054 Section 10 Stabil TRAK System and Boom Interlock System Contents PARAGRAPH TITLE PAGE 10 1 Stabil TRAK System Component Terminology 10 2 10 2 Extend Interlock System Component Terminology 10054 Only 10 3 10 3 Stabil TRAK 10 4 10 3 1 Stabil TRAK Solenoid Valves 10 4 104 Stabil TRAK Electrical Circuit Operation and Troubleshooting 6042 8042 amp 10042 10 5 10 5 Stabil TRAK System 10 7 10 5 1 Stabil TRAK System Test Instructions 10 7 10 5 2 Sta
268. r Label and disconnect the wire from the starter solenoid housing stud Record how the wires are installed to ensure correct installation later Loosen but DO NOT remove the fasteners securing the starter to the flywheel housing Support the starter securely as it is relatively heavy and will fall if not supported Support the starter and remove the fasteners securing the starter to the engine Remove the negative ground cable from its starter mounting bolt Remove the starter from the machine Starter Installation Position the starter in its mounting opening on the flywheel housing Position the ground cable over the correct starter mounting bolt Secure the starter with the previously used hardware Connect the positive battery cable to the upper solenoid stud Install the wires to the upper solenoid stud and secure with lock washer and nut Connect the wire to the solenoid mounting stud Properly connect the battery Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel Close and secure the rear and side engine covers 6036 6042 8042 10042 10054 Electrical System 9 7 CHARGING CIRCUIT Before using a battery charger an attempt can be made to recharge the battery by jump starting the machine Refer to the appropriate Operation amp Safety Manual Allow the engine to run which will enable the alternator 2 to charge th
269. r assembly at the rear of the boom DO NOT allow the hoses to cross 23 24 27 28 Install the hose clamp support bracket and top left side wear pad Position the hydraulic hoses with the edge of the tape at the hose clamps Hold the hoses in this position and tighten the hose clamps MH1691 Assemble the hoses to the hose reel 5 at the rear of the boom Tie the strings positioned inside the first boom section during installation to the male end of the hydraulic hoses coming off the bottom of the hose reel assembly Working from the front of the boom pull each hose through the boom assembly through the opening at the bottom of the first boom section Remove the strings from the hoses 3 27 b Boom Cy 1451 29 At the front of the first boom section assemble the hose assemblies and tube assemblies to the mounting plate 6 Note Where the hose assemblies come out of the outer boom lubricate the radius in the first boom section with soap and water to allow proper tensioning of hoses 30 Install the quick attach and Attachment Tilt cylinder to the front of the boom Refer to Section 3 8 4 Quick Attach Installation 31 Uncap and connect the previously labeled hoses to the Attachment Tilt cylinder 32 Properly connect the battery 33 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 34 Start the engi
270. r door Allow the system fluids to cool 4 Properly disconnect the battery Note Rotating the fan belt by hand gives greater access to removing the drive shaft mounting capscrews 5 Remove the capscrews and straps that secure the drive shaft to the transmission yoke 6 Remove the capscrews and lockwashers securing the drive shaft to the coupling flange Note It may be necessary to loosen remove the motor mounts on either side of the engine to gain access to the bottom capscrews on the outer half of the coupler Place 6036 6042 8042 10042 10054 Engine Cummins QSB3 3T QSB4 5T 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 MH6360 7 Remove the capscrews and lockwashers securing the outer half of the coupler 8 8 Remove the capscrews securing the small access cover 9 Remove the capscrews and locknuts securing the coupler 9 to the flywheel Turn the engine by hand using the fan belt until the capscrews line up with the access hole 10 At this time use a suitable cleaner solvent and thoroughly clean the mounting lip of the flywheel Wipe any debris from the inside of the
271. r plate 17 ELKEELKE CANE E EE LND 555 JCC 7 16 BCXCAOCOCOCOUOCOCOCAOCAUCACOCOCOCOC 96 39 cue 6905 0 Measure the separation between the third 15 and second 16 section boom top plates The distance 17 should be at least 8 5 in 216 mm and not greater than 11 in 279 mm with the boom fully retracted and the chains properly tensioned A distance of less than 8 5 in 216 mm could result in interference and cause damage to boom components OH2862 6036 6042 8042 10042 10054 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 2 Make sure that the chain system is properly tensioned Refer to Section 3 7 5 Boom Chain Tension Check 18 MH1781 3 To increase the separation distance Loosen the retract chain locknut 13 on the bottom of the boom one or two t
272. r surfaces of any component DO NOT display an ultra smooth polished finish or are damaged in any way replace the damaged part Often dirty hydraulic fluid causes failure of internal seals damage to the polished surfaces within the component and wear of and or harm to other parts e Main Control Valve Assembly Note ALWAYS replace seals o rings gaskets etc with new parts to help ensure proper sealing and operation Lubricate seals and o rings with clean hydraulic oil Assemble each Valve Section 1 Reassemble any check valves compensator valves anti cavitation valves or shock valves from each individual valve sections if equipped 2 Install the control spool being careful not to nick or scratch the valve section bore or the control spool 3 Install the end caps on each end of the valve section 8 24 Assemble the Main Control Valve 1 Place all three tie rods with the nuts through the end main control valve section 2 Stand the end main control valve section on end 3 Install the proper o rings and load sense shuttle on the inner face of the end main control valve section Align the next valve section over the three tie rods and slide onto the end main control valve section 4 Using the proper o rings and load sense shuttle repeat step three for the remaining valve sections and lastly the inlet end valve section MH6200 5 Install the three nuts on the tie rods Torque the two bottom nuts 5 t
273. r to Section 8 5 1 Hydraulic Oil Reservoir Draining S 7 Thoroughly clean the pump 3 and surrounding area including all hoses and fittings before proceeding MH6490 8 Label disconnect and cap the hydraulic hoses attached to the pump 9 Remove the bolts lockwashers and washers securing the pump to the transmission Remove the o ring located between the transmission and the pump Wipe up any hydraulic oil spillage 10 Remove the hydraulic fittings from the pump to use for later installation Note Before removing any fittings from the pump note their orientation to ensure correct installation Note DO NOT disassemble the operating pump The pump is pre set from the manufacturer Any adjustments or repairs performed by anyone other than an authorized dealer could void the warranty 8 22 10 11 Pump Installation Install the fittings on the pump in the same orientation as noted during removal 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 Align the bolt holes with the pump mount holes Secure the pump to the transmission with the previously used hardware Uncap and connect the previously labeled hydraulic hoses to their appropriate locations Fill the hydraulic reservoir Refer to Section 8 5 2 Hydraulic Oil Reservoir Filling
274. rator Pedal or Lever Position Sensor 2 Circuit Low 1242 091 2 2 Accelerator Pedal or Lever Position Sensor Number 1 and 2 Erratic 1633 625 2 Komnet Datalink Cannot Transmit 1639 703 11 Auxiliary Equipment Sensor Input Number 3 OEM Switch 1654 1323 11 31 Engine Misfire Cylinder 1 1655 1324 11 31 Engine Misfire Cylinder 2 1656 1325 11 31 Engine Misfire Cylinder 3 1657 1326 11 31 Engine Misfire Cylinder 4 1658 1327 11 31 Engine Misfire Cylinder 5 1659 1328 11 31 Engine Misfire Cylinder 6 1663 3241 11 31 Catalyst Inlet Temperature Sensor Swapped with Outlet 1664 3050 11 31 Catalyst Missing 1665 3241 4 Exhaust Gas Temperature 1 Circuit Low 1666 3241 3 Exhaust Gas Temperature 1 Circuit High 1667 3241 2 Exhaust Gas Temperature 1 Erratic 1668 1761 4 4 Catalyst Tank Level Sensor Circuit Low 1669 1761 3 Catalyst Tank Level Sensor Circuit High 1671 1761 1 18 Catalyst Tank Level Low Moderately Severe 1673 1761 1 Catalyst Tank Level Low Most Severe 1674 3249 4 Exhaust Gas Temperature 2 Circuit Low 1675 3249 3 Exhaust Gas Temperature 2 Circuit High 1676 3249 2 Exhaust Gas Temperature 2 Circuit Erratic 1677 3031 4 Catalyst Tank Temperature Low 1678 3031 3 Catalyst Tank Temperature High 1679 3031 2 Catalyst Tank Temperature Erratic 1681 3361 12 Catalyst Dosing Control Unit 9 30 6036 6042 8042 10042 10054 Electrical System
275. readed clevis with multi purpose grease At the rear of the boom attach the string or wire to the new retract chain threaded clevis end with a threaded eye or a flat washer tack welded to a capscrew The outside diameter of the eye or flat washer must be smaller than the diameter of the threads on the clevis From the rear of the boom have an assistant push the threaded clevis end of the new retract chain under the chain sheave and down between the second and first boom sections while pulling the retract chain through the boom using the previously attached string or wire Keep the retract chain to the right side of the boom push and pull the threaded clevis down to the tab at the front underside of the boom 9 2561 Reassemble the flat washer and a locknut 9 onto the threaded clevis Tighten the locknut until the threaded end of the clevis is flush with the top of the locknut At the rear of the boom place the retract chain up and over the chain sheave Place the clevis between the two anchor plates Line up the hole in the clevis with the anchor plate hole position recorded during removal Insert the shoulder bolt through the plates and clevis and secure in place with a locknut Tighten the locknut securely Check and adjust the retract chain tension Refer to Section 3 7 5 Boom Chain Tension Check 6036 6042 8042 10042 10054 Boom N M VU 18 In
276. repair the Stabil TRAK system before testing the boom outrigger interlock system 10 7 1 System Test Procedures If Steps 1 through 5 prove positive the Boom Outrigger Interlock System is functioning properly and the machine can be returned to service If any of these steps indicate that the Boom Outrigger Interlock system is not functioning properly follow the procedures in Section 10 6 Stabil TRAK Boom Interlock Electrical Circuit Operation and Troubleshooting 10054 to repair the system 10 12 6036 6042 8042 10042 10054 Stabil TRAK System and Boom Interlock System Boom Outrigger Interlock System Test Procedures Place the machine with no load on a hard level surface such as blacktop or concrete Fasten your seat belt With the outriggers in the raised position and the boom in a horizontal position extend the boom The boom should extend until the letter E appears and then should STOP If the boom extends beyond the letter retract the boom fully and have the system repaired before using the machine again Attempt to frame sway the machine to the right and left it should frame sway normally Lower both outriggers to the ground DO NOT lift the front wheels of the machine off the ground at this time The Stabil TRAK light should come ON when the outriggers are lowered b With the boom still in a horizontal position extend the boom c Atte
277. rier support to the hose carrier on the right side Install the hose carrier support 2 and lower wear pad with the previously used hardware Place the retract chain up around the retract chain sheave on the left side of the boom Stretch the chain forward and place the clevis between the two anchor plates Line up the hole in the clevis with the anchor plate hole location recorded during removal Insert the shoulder bolt and secure in place with a locknut Tighten the locknut Install the side and top wear pads Place the fourth boom section extend chain sheave 3 between the mounts at the front of the third boom section Insert the sheave pin through the mounts and the sheave Secure in place with the previously used hardware After the sheave is assembled apply a good grade of multi purpose grease to the grease fitting at the end of the pin Turn the sheave by hand to distribute grease evenly Place the fourth boom section extend chain up and around the sheave at the front of the third boom section MH2521 6036 6042 8042 10042 10054 22 Place the extend chain clevis between the mounting plates at the front of the second boom section Coat the shoulder bolt 4 with anti seize compound and insert through the plates and clevis Secure the shoulder bolt in place with a locknut Tighten securely but the chain clevis should pivot freely Note Keep the four hoses in line as they come out of the hose carrie
278. ring joints pins and inside link plates gradually incur wear due to articulation 3 7 2 1 Park the machine on a firm level surface raise the boom to a horizontal level position place the transmission control lever NEUTRAL engage the park brake switch Inspection Guidelines 2 Fully extend the boom until the extend chain is taut Shut the engine off 3 The extend chains will be visible for inspection with the machine in this state 4 While doing the chain inspection check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain 5 Inspect the retract chains every 1000 hours of operation 6 Inspect the chains for the following conditions 6036 6042 8042 10042 10054 Edge Wear ANN a LA MZ1463 Check the chain for wear on the link plate edges caused by running back and forth over the sheave The maximum reduction of material should not exceed 5 Measure and compare to a normal link plate height by measuring a portion of chain that does not run over the sheave If the measured plate height 1 is 5 less than the normal plate height 2 discard and replace the chain Elongation It is important to measure the chain in the section that moves over the sheaves because it receives the most frequent articulation Measuring the chain near its clevis terminals could give an inaccurate reading The ends of the chain
279. rol Circuit High 2353 2971 6 6 Exhaust Gas Recirculation EGR Valve Control Clrcuit High 2357 2791 7 7 Exhaust Gas Recirculation EGR Valve Control Not Responding 2359 411 0 16 Exhaust Gas Recirculation EGR Differential Pressure Sensor High 2362 1072 4 Engine Brake Actuator Circuit 1 Low 2363 1073 4 Engine Brake Actuator Circuit 2 Low 2366 1072 3 Engine Brake Actuator Circuit 1 High 2367 1073 3 Engine Brake Actuator Circuit 2 High 2373 1209 3 3 Exhaust Gas Pressure Sensor Circuit Shorted High 2374 1209 4 4 Exhaust Gas Pressure Sensor Circuit Shorted Low 2375 412 3 EGR Temperature Sensor Circuit High 2376 412 4 4 Recirculation Exhaust Gas EGR Temperature Sensor Circuit Low 2377 647 3 Fan Control Circuit High 2381 2795 4 4 Turbocharger Position Sensor Circuit Shorted High 2382 2795 4 4 Turbocharger Position Sensor Circuit Shorted Low 2383 641 5 5 Variable Geometry Turbocharger Actuator Circuit Low 2384 641 4 4 VGT Actuator Driver Circuit Low 2385 641 3 3 VGT Actuator Driver Circuit High 2386 2975 6 6 Turbocharger Actuator Motor Circuit High 2387 2975 7 7 Turbocharger Actuator Motor Not Responding 2388 2795 13 13 Variable Geometry Turbocharger Actuator Position Failed Calibration 2554 1209 2 2 Exhaust Pressure Sensor Circuit Erratic 2555 729 4 Intake Air Heater 1 Circuit Low 2557 697 3 Auxiliary PWM Driver 1 High 2558 697 4 Auxiliary PWM Driver 1 Low 2771 3234 9 After treatment Outlet NOx Senso
280. rom condensation Chemical Solutions or Vapors Corrosive attack on the chain components and or the mechanical connections between the chain components Cracking can be and often is microscopic Going from microscopic cracking to complete failure can be either abrupt or may require an extended period of time Abrasives Accelerated wearing and scoring of the articulating members of the chain pins an d plates with a corresponding reduction in chain strength Due to the inaccessibility of the bearing surfaces pin surfaces and plate apertures wear and scoring are not readily noticeable to the naked eye 6036 6042 8042 10042 10054 Boom C X i Following are some examples of dynamic shock loading which can impose abnormal loads above the endurance limit of a leaf chain High velocity movement of load followed by sudden abrupt stops e Carrying loads in suspension over irregular surfaces such as railroad tracks potholes and rough terrain Attempting to inch loads which are beyond the rated capacity of the machine The above load cycles and environmental conditions make it impossible to predict chain life It is therefore necessary to conduct frequent inspections until replacement life can be predicted The boom chain s normal life expectancy can be expressed as a maximum percent of elongation This is generally 396 As the chain flexes back and forth over the sheave the bea
281. rom the upper alternator mount Remove the alternator from the machine Alternator Installation Position the alternator and align with the upper alternator mount on the engine bracket Insert the upper longer mounting hardware through the alternator mount Thread the longer capscrew into the alternator front mount DO NOT tighten completely at this time Align the lower alternator mount hole with the lower mounting bracket on the engine and insert the lower mounting capscrew Tighten the lower capscrew and upper capscrew securely Place a drive ratchet into the square hole on the serpentine belt tensioner bracket Apply pressure against the tensioner bracket and route the serpentine belt onto the alternator and engine pulleys Release and check the tensioner pulley to verify that it is pivoting freely in order to provide the proper tension on the belt Check for proper belt alignment Refer to the appropriate Operation amp Safety Manual Connect the previously labeled wire leads to the alternator Properly connect the battery 6 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel Close and secure the rear and side engine covers 9 13 Electrical System 9 8 WINDOW WIPER WASHER WINDSHIELD WIPER MOTOR 9 8 1 Windshield Wiper Motor a Removal Note It may be necessary to remove several hydraulic hoses from behind the dash in order to rem
282. rriage better support to stand alone 9 If equipped connect Auxiliary electric harness 10 Return to the cab fasten the seat belt and resume 5 If equipped disconnect Auxiliary electric harness operation 6 If equipped disconnect Auxiliary hydraulic hoses 3 8 3 Quick Attach Removal 1 Remove the lock bolt holding the Attachment Tilt cylinder rod end pin to the quick attach assembly Remove the Attachment Tilt Cylinder pin 2 Support the quick attach assembly Remove the capscrew and locknut securing the quick attach pivot pin to the quick attach assembly Remove the quick attach assembly Record the location and quantity of OS0332 the shim washers as the pin is being removed 7 Raise the quick attach pin lock lever 2 and pull out 2 Spec INS above piis a eullace the lock pin 3 at the bottom of the quick attach Use fine emery cloth to fix minor nicks or corrosion q If damaged or if it cannot be repaired the pin must be 8 Return to the operator cab fasten the seat belt and replaced lower the attachment to the ground in a level position Tilt the attachment forward This will rotate 3 8 4 Quick Attach Installation the quick attach link back away from the attachment 1 Assemble the quick attach to the boom head Line 9 Lower and then retract the boom until the up the quick attach between the mounts on the attachment pivot pins have disconnected from the boom head The quick attach should be centered in att
283. ry possible contingency during operation maintenance or testing When additional information is desired consult your local authorized service distributor Many factors contribute to unsafe conditions carelessness fatigue overload inattentiveness unfamiliarity even drugs and alcohol among others For optimal safety encourage everyone to think and to act safely Appropriate service methods and proper repair procedures are essential for the safety of the individual doing the work for the safety of the operator and for the safe reliable operation of the machine All references to the right side left side front and rear are given from the operator seat looking in a forward direction Supplementary information is available from JLG in the form of Service Bulletins Service Campaigns Service Training Schools the manufacturer website other literature and through updates to the manual itself 1 2 DISCLAIMER All information in this manual is based on the latest product information available at the time of publication The manufacturer reserves the right to make changes and improvements to its products and to discontinue the manufacture of any product at its discretion at any time without public notice or obligation 1 3 OPERATION amp SAFETY MANUAL The mechanic must not operate the machine until the Operation amp Safety Manual has been read and understood training has been accomplished and operation of the mach
284. s 4 and four new bolts 3 securing the bearing crosses to the axle Torque bolts to 55 60 Ib ft 75 81 Nm 5 Repeat the above procedure on the rear drive shaft 6036 6042 8042 10042 10054 Axles Drive Shafts Wheels and Tires 5 7 WHEELS AND TIRES WARNING Mismatched tire sizes ply ratings or mixing of tire types radial tires with bias ply tires may compromise machine stability and may cause machine to tip over It is recommended that a replacement tire to be the same size ply and brand as originally installed Refer to the appropriate parts manual for ordering information If not using an approved replacement tire It is recommended that replacement tires have the following characteristics Equal or greater ply load rating and size of original Tire tread contact width equal or greater than original Wheel diameter width and offset dimensions equal to the original Approved for the application by the tire manufacturer including inflation pressure and maximum tire load The rims installed have been designed for stability requirements which consist of track width tire pressure and load capacity Size changes such as rim width center piece location larger or smaller diameter etc without written factory recommendations may result in unsafe condition regarding stability Foam filled tires have a positive effect on the weight stability and handling characteristics of the
285. s concerning hazardous materials disposal regulations e Inspection Note If a leak is suspected in the fuel tank contact your local authorized Service Department 1 Inspect the tank thoroughly for any cracks slices leaks or other damage 2 With the tank removed from the machine plug all openings except one elbow fitting Install the eloow fitting and apply approximately 1 1 5 psi 7 10 kPa of air pressure through the elbow Check the reservoir for leaks by applying a soap solution to the exterior and look for bubbles to appear at the cracked or damaged area 6036 6042 8042 10042 10054 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 4 Connect the previously labeled electrical components to the tank 5 Uncap and connect the previously labeled hydraulic hoses to their appropriate locations 6 Fill the tank according to specifications Refer to Section 2 4 Fluid and Lubricant Capacities 7 Check tank for leaks 8 Install the two frame top covers
286. s near the clevis terminal will not have flexed as frequently if at all as the middle of the chains It is best to measure in 12 pin increments from pin center to pin center For example if the links are one inch from pin center to pin center the distance should be 12 in 305 mm If the links are 3 4 in 19 0 mm apart the distance after 12 pins should be 9 in 228 6 mm MY1360 If the distance measured 3 is 3 greater than the normal length 4 discard and replace the chain 3 29 b Boom Distorted or Link Plates Cracked Plates Inspect the chains very carefully front and back as well as side to side for any evidence of cracked plates If any one crack is discovered the chain should be replaced in its entirety It is important however to determine the cause of the crack before installing a new chain so the condition does not repeat itself Cron The types of cracks are MZ1466 Fatigue Cracking Fatigue cracks 9 are Distorted or battered link plates 5 on a leaf chain can a result of repeated cause tight joints and prevent flexing cyclic loading beyond pane Turning or Protruding Pins endurance imit Highly loaded chain operating with inadequate lubrication can generate abnormal frictional forces between pin and link plates When chain is allowed to operate in this condition a pin or series of pins can begin to twist out of a cha
287. s 0 psi With engine Function 0 3000 psi at idle use the boom control lever to fully retract the Manifold 0 207 bar boom Hold over relief and check pressure Pressure should be 3000 psi 207 bar 5 E Secondary Steering Relief With engine at idle turn the steering wheel all the Function 2400 2600 psi way one direction Hold over relief and check Manifold 165 179 bar pressure If pressure is incorrect adjust or replace the pressure reducing cartridge 6 N A Secondary Park Brake With engine at idle and no hydraulic functions Function Release operated disengage the park brake check pressure Manifold 500 600 psi This is not an adjustment 34 41 bar 7 F Secondary Park Brake With engine at idle and park brake released turn the Function Pressure steering wheel all the way in one direction Hold over Manifold 500 600 psi relief and check pressure If pressure is incorrect 34 41 bar adjust or replace the pressure reducing cartridge in the secondary function manifold 8 N A Brake Valve minimum With engine OFF pump brake pedal twice DO NOT Manual Brake 400 psi overstroke the brake pedal If pressure is incorrect Pressure 28 bar check for external leaks If no leaks are found refer to Section 8 7 4 Brake Test 6036 6042 8042 10042 10054 n Hydraulic System Test Adjustment Component Pressure Pressure Test Procedures Location Location Descri
288. s and lubricate If the surfaces cannot be reconditioned replace the boom section s Refer to Section 8 4 Hydraulic Circuits Replace the damaged boom section Refer to Section 3 4 Boom Assembly Maintenance 7 Boom will not raise or lower 1 Broken hydraulic hoses or tubes and or connection leaks Lift Lower hydraulic system not operating properly Faulty Lift cylinder Seized boom pivot pin bushing Locate break replace hose s or tube s tighten connections Refer to Section 8 4 Hydraulic Circuits Repair cylinder Refer toSection 8 8 1 General Cylinder Instructions Replace bushing 8 Excessive Lift Lower cylinder pivot pin noise and or wear Insufficient lubrication Worn self aligning bushing s Lubricate at regular intervals Refer to Section 2 5 Service and Maintenance Schedules Replace worn pins as needed Refer to Section 8 8 1 General Oylinder Instructions Replace bushing s and lubricate at regular intervals Refer to Section 2 6 Lubrication Schedules 6036 6042 8042 10042 10054 3 55 D Boom Cy i Problem Cause Remedy 9 Rapid boom pad wear Incorrect wear pad gap Rapid cycle times with heavy loads Contaminated corroded or rusted wear pad sliding surfaces Operating in extremely dusty abrasive conditions
289. s and tires The following illustration identifies the components that are referred to throughout this section ENGINE TO TRANSMISSION d DRIVE SHAFT FRAME SWAY CYLINDER STEERING a CYLINDER 2 e FRONTAXLE ASSEMBLY 5 2 FRONT DRIVE SHAFT REAR DRIVE SHAFT STABILIZER CYLINDER EJ a 6042 ONLY lt e T a Pu AXLE ASSEMBLY MA9181 6036 6042 8042 10042 10054 Axles Drive Shafts Wheels and Tires P 5 2 AXLE DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGY 8042 10042 amp 10054 To understand the safety operation and maintenance information presented in this section it is necessary that the operator mechanic be familiar with the names and locations of the major assemblies of the axles drive shafts wheels and tires The following illustration identifies the components that are referred to throughout this section ENGINE TO TRANSMISSION DRIVE STABILIZER d SWAY CYLINDER i REAR AXLE eK 299 ASSEMBLY E STEERING x Sg FRONT DRIVE SHAFT 5 x FRONTAXLE a ASSEMBLY Em 5 MH3241 6036 6042 8042 10042 10054 5 3 Axles Drive Shafts Wheels and Tires 5 3 GENERAL INFORMATION A WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1 Safety Practices of this
290. s must pivot freely Install the double extend chain sheave Apply grease to the sheave Turn the sheave by hand to distribute the grease evenly MH1991 Align the holes in the yoke plates with the hole in the mount on the first boom section Coat the shoulder bolt with anti seize compound and insert the shoulder bolt 17 through the yoke plates and the mount on the boom Secure in place with a locknut Tighten the locknut securely but the yoke plates must pivot freely Place the retract chain around the retract chain sheave on the right side of the boom Stretch the chain forward and place the clevis between the two anchor plates Align the hole in the clevis with the hole location recorded in the removal procedure Insert the shoulder bolt and locknut tighten securely 6036 6042 8042 10042 10054 3 6 8 Fourth Boom Section Installation MH2381 Lay the hose carrier assembly out flat on a level surface Stretch the four male ends of the hoses out straight from the hose carrier assembly Measure from the male end of each hose back toward the hose carrier assembly 196 in 498 cm and apply tape around each hose at that point The tape is for proper tensioning of the hoses during reassembly of the hose clamps Insert the hose channel assembly into the rear of the fourth boom section Slide the hose channel assembly into the boom and line up the holes for the side wear pads Install the si
291. sion and the shaft and slip yoke so that these components can be returned to their original positions when reinstalled Yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration TO TRANSMISSION FF Y Ors SUA gt gt TO AXLE 4 7 Remove the four bolts 1 and two straps 2 securing the bearing cross to the transmission output shaft flange Discard bolts MT0350 8 Remove the four bolts 3 and two straps 4 securing the bearing crosses to the axle Discard bolts 9 Remove the front drive shaft assembly 10 Repeat the above procedure on the rear drive shaft 5 6 4 1 Disassemble and clean all parts using an approved cleaning fluid Allow to dry Drive Shaft Cleaning and Drying 2 Remove and burrs or rough spots from all machined surfaces Re clean and dry as required 5 6 5 1 Raise the drive shaft assembly into position The slip yoke end of the drive shaft mounts toward the axle If reinstalling a drive shaft previously removed align the flange yokes according to the alignment marks made during removal Drive Shaft Installation Note The yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration 2 Apply Loctite 242 to all mounting bolts 3 Install the two straps 2 and four new bolts 1 securing the bearing crosses to the transmission Torque bolts to 55 60 Ib ft 75 81 Nm 4 Install the two strap
292. stall the boom rear cover 19 Properly connect the battery 20 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel Fourth Boom Section Retract Chain Removal and Replacement 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 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Properly disconnect the battery 4 Remove the boom rear cover Start the engine and extend the boom until the retract chain adjustment nut on the bottom of the second boom section is visible Shut the engine OFF Atthe front underside of the boom locate the retract chain locknut Record the amount of threads extending beyond the locknut This measurement will be the starting point for adjustment of the retract chain after installation 10 OH0661 7 Loosen the locknut 10 on the retract chain clevis DO NOT remove the locknut at this time but loosen the nut as far as possible to gain as much slack as possible in the retract chain Return to the operator cab start the engine and slowly retract the boom all the way back and then extend the boom approximately 1 in 25 mm or just 6036 6042 8042 10042 10054 until all the tension on the retract chain is relieved Shut the engine OF
293. stem c Pressure Specifications 6036 ATTACHMENT TILT FRONT AXLE CYLINDER FRAME SWAY CYLINDER gw s 1 1 jme FRONT STEERING CYLINDER MAIN CONTROL VALVE HUTTLE VALVI LFT LWR EXT RET STEER i SELECT VALVE LT POWER SUNT HYDRAULIC RESERVOIR 77 OPERATOR S SECONDARY FUNCTION MANIFOLD EXTEND RETRACT CYLINDER PS PSG PBG PP PPG PB LEFT RIGHT LIFT LOWER LIFT LOWER CYLINDER CYLINDER LS LSG LEFT RIGHT SLAVE te CYLINDER CYLINDER UNLOADER VALVE REAR STEERING _ CYLINDER UN REAR AXLE HYDRAULIC Iu OIL COOLER MA6241 6036 6042 8042 10042 10054 n Hydraulic System Test Hydraulic Pump Flow Test Location 1 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 Adjust Component Pressure Pressure Test Procedures Location Location Description Reading 2 A Unloader Main System With engine at idle use the boom control lever to fully Valve Relief retract the boom
294. supports Ensure that the machine will remain in place during axle removal 10 Support the axle that is being removed with a suitable jack hoist or overhead crane and sling DO NOT raise the axle or the machine 11 Remove both wheel and tire assemblies from the axle that is being removed Refer to Section 5 7 1 Removing Wheel and Tire Assembly from Machine Note The wheel and tire assemblies must be re installed later with the directional tread pattern arrows facing in the direction of forward travel 12 Remove the drive shaft assembly Refer to Section 5 6 3 Drive Shaft Removal 13 Remove the capscrew and locknut securing the lower position cylinder mount pin to the cylinder Tap the cylinder mount pin out and move the cylinder to prevent it from interfering with axle removal 14 Remove the capscrews securing the axle supports to the machine frame 15 Remove the axles from the machine using the jack hoist or overhead crane and sling supporting the axle DO NOT raise or otherwise disturb the machine while removing the axle Balance the axle and prevent it from tipping turning or falling while removing it from beneath the machine Place the axle on a suitable support or holding stand b Axle Installation 1 Before proceeding ensure that the machine will remain in place during axle installation Block the front and rear of both tires on the axle that is already installed on the machine 2 If applicable
295. t DO NOT extend the boom at any time during the test Perform the test with the boom fully retracted Follow Steps 1 through 9 of the Stabil TRAK System test procedure exactly as written Note If the Stabil TRAK light goes OFF and the front left tire lowers to the ground at any time during Steps 4 through 7 the test was not performed properly or the Stabil TRAK system is not functioning properly Carefully repeat the steps starting with Step 1 6036 6042 8042 10042 10054 DO NOT raise the boom above 60 for Steps 3 6 DO NOT raise the boom above 45 for Steps 7 9 If the Stabil TRAK light goes OFF and the front left tire lowers to the ground consistently during Steps 4 through 7 the Stabil TRAK system is not functioning properly and the test should be stopped immediately If the Stabil TRAK system is not functioning properly follow the procedures in Section 10 8 Stabil TRAK Hydraulic Circuit Operation and Troubleshooting to repair the system 10 5 2 Stabil TRAK System Test Procedures If Steps 1 through 9 prove positive the Stabil TRAK system is functioning properly and the machine can be returned to service If any of these steps indicate that the Stabil TRAK system is not functioning properly follow the procedures in Section 10 8 Stabil TRAK Hydraulic Circuit Operation and Troubleshooting to repair the system 10 7 Stabil TRAK System and Boom Interlock System Stabil TRAK Syst
296. t the machine should not be operated Properly disconnect the battery Remove the boom rear cover 3 43 Boom 513 At the front underside of the boom locate the retract chain locknut 7 Record the amount of threads extending beyond the locknut This measurement will be the starting point for adjustment of the retract chain after installation At the front underside of the fourth boom section remove the locknut and flat washer holding the retract chain threaded clevis to the mounting tab Attach a wire or string to the threaded clevis with a threaded eye or a flat washer tack welded to a capscrew The outside diameter of the eye or flat washer must be smaller than the diameter of the threads on the clevis The wire or string will be used to pull the chain back through the boom during reassembly Note Record the location of the shoulder bolt to ensure correct installation MH2551 8 At the rear of the boom locate the two retract chain anchor plates Remove the locknut and shoulder bolt 8 holding the retract chain clevis to the anchor plates The two anchor plates can remain in place on the third boom section 3 44 11 12 15 16 From the rear of the boom pull the boom retract chain out of the rear of the boom Disconnect the string or wire from the retract chain clevis and allow it to hang out the rear of the boom Coat the threads of the th
297. tach and Attachment Tilt cylinder to the front of the boom Refer to Section 3 8 4 Quick Attach Installation If necessary install the Auxiliary hydraulic fittings to the front of the boom Uncap and connect the previously labeled hoses to the Attachment Tilt cylinder Properly connect the battery Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel Start the engine and operate all boom functions several times Check the chain tension again and adjust as necessary Check for leaks and check the hydraulic fluid level in the tank add fluid if required Clean up all debris hydraulic fluid etc in on near and around the machine Install the rear cover to the boom Close and secure the rear door 3 4 8 1 10 11 Boom Installation 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 Using suitable slings balance the boom assembly lift and guide the boom assembly into place Align the frame pivot bores with the boom assembly pivot bores Install the boom pivot pin Move the Attachment Tilt joystick in both directions to relieve any trapped pressure in the Attachment Tilt system If the machine is equipped with Auxiliary controls move the Auxiliary hydraulic joystick in both directions to relieve any trapped pressure in th
298. tation on the machine frame and secure with the previously used hardware Torque capscrews to 31 lb ft 42 Nm 2 Uncap and connect the previously labeled hydraulic hoses to their appropriate locations Note ALWAYS replace seals o rings gaskets etc with new parts to help ensure proper sealing and operation Lubricate seals and o rings with clean hydraulic oil 3 Check the routing of all hoses wiring and tubing for sharp bends or interference with any rotating members 4 Properly connect the battery 5 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 6 Start the engine and run at approximately 1 3 1 2 throttle for about one minute without moving the machine or operating any hydraulic functions 7 Inspect for leaks and check the level of the hydraulic fluid in the reservoir Shut the engine OFF Note Check for leaks and repair as required before continuing Add hydraulic fluid to the reservoir as needed 8 Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools 8 29 Hydraulic System n 8 7 8 Outrigger Valve 10042 amp 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 Verify the correct operation of the outrigger valve solenoids before considering replacement of the valve
299. ter Controls a Cab Heater Controls Removal MA8701 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the rear door Allow the system fluids to cool 4 Properly disconnect the battery 5 Remove the setscrew from the variable speed fan control knob or temperature control knob 6 Remove the right side control panel screws 7 Remove the screws and backing locknuts from the cab heater and fan control panel 6036 6042 8042 10042 10054 Electrical System 10 11 b Pull the control panel out from the dash panel and if removing variable speed fan control remove the cab harness connector If removing the temperature control knob disconnect the cable connector and remove control knob Remove the locknut from the suspect control shaft Remove the control panel from the panel Disassembly DO NOT disassemble the cab heater and fan controls The controls are not serviceable Replace controls if found to be defective 1 Installation and Testing Check that the variable speed fan control is in the OFF position If installing the temperature control attach the control
300. th the ignition key switch and steering wheel stating that the machine should not be operated 3 Open the rear door Allow the system fluids to cool 4 Properly disconnect the battery 5 Loosen the clamp 8 supporting the tail pipe 9 and muffler 10 from the muffler mounting bracket 11 6 Loosen the clamp 12 supporting the exhaust pipe 13 and muffler 10 from the muffler mounting bracket 14 7 Loosen the three clamps 15 on the exhaust pipe 13 8 Remove the clamps 8 amp 12 attaching the muffler 10 to the muffler mounting brackets 11 amp 14 9 Remove the muffler 10 and if needed the exhaust pipe 13 7 7 2 Note Install muffler in proper direction Exhaust System Installation Note Keep all clamps loosened until entire exhaust system is in place 1 Using clamps 8 amp 12 install the muffler 10 to the muffler mounting brackets 11 amp 14 7 7 O Engine Cummins QSB3 3T QSB4 5T If previously removed install the exhaust pipe 13 5 Remove the clamp securing the air scoop 1 to the Install the exhaust pipe 13 into the muffler 10 air cleaner inlet tube 2 Install the tail pipe 9 into the muffler 10 6 Remove the clamps securing the hose 3 to the air cleaner assembly Tighten all clamps 8 amp 15 Properly connect the battery Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 7 Remove th
301. the back of the machine Have an assistant ensure that the engine clears all frame hose and harness components during installation Position the engine brackets over rear and front frame mounts 5 Secure the rear engine mount 5 to the frame using the previously used hardware Torque to 80 90 lb ft 108 122 Nm 6 Secure the front left 4 and right 3 engine mounts to the frame using the previously used hardware Torque to 80 90 lb ft 108 122 Nm 7 Install the exhaust pipe mount bracket 8 Install the radiator overflow tube overflow tank and hose support 9 Install the engine to transmission drive shaft Refer to Section 5 6 5 Drive Shaft Installation 10 Uncap and connect the previously labeled fuel return line to the injector pump 11 Uncap and connect the previously labeled fuel inlet line to the fuel lift pump 12 Connect the previously labeled electrical wire connections on the engine 13 Uncap and connect the previously labeled heater hoses to the engine if equipped 14 Install the complete radiator assembly Refer to Section 7 4 2 Radiator Oil Cooler and Replacement 15 Properly connect the battery 16 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 17 Check that all hydraulic system electrical system cooling system fuel system and exhaust system connections are correct and connected tightly Note Have an assistant stand by with a Class B fire e
302. the fittings Lubricate the o rings with clean hydraulic oil 4 9 a Cab and Covers 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 7 IK N Big A Kaiten AY GRAS MA8471 9 Route the wiring harness connectors through the opening at the bottom of the cab Connect the previously labeled connectors 2 10 Install the console panel 11 Install the transmission covers 12 Working under the cab connect the coolant hoses to the heater hoses 4 10 a 8781 15 16 17 Connect the heater control cable 2 to the heater control valve 1 Fill the cooling system completely with coolant allowing time for the coolant to fill the engine block The cooling system capacity is listed in Section 2 4 Fluid and Lubricant Capacities Properly connect the battery Carefully examine all cab components fasteners etc one last time before engine start up Rectify any faulty conditions Start the engine and check the operation of all controls Check for hydraulic fluid leaks Check the hydraul
303. the machine is equipped with Auxiliary controls move the Auxiliary hydraulic joystick in both directions to relieve any trapped pressure in the Auxiliary hydraulic system Label disconnect and cap the hoses attached to the Attachment Tilt cylinder Cap all fittings to keep dirt and debris from entering the hydraulic system If the machine is equipped with Auxiliary hydraulics label cap and remove the hoses from the bulkhead fittings If replacing the third boom section with a new boom section Remove the female coupler male nipple and bulkhead fittings from the bulkhead plate inside the boom head 9 Remove the rear cover from the boom If equipped with Auxiliary hydraulics inside the third boom section loosen but DO NOT remove the capscrews securing the left side wear pad and hose clamp support bracket to the top of the third boom section 6036 6042 8042 10042 10054 11 12 13 MH2841 Remove the stack clamps 1 and hose clamp support bracket 2 to the left side of the third boom section MH0871 Pull the free ends of the hydraulic hoses 3 from the inside the third boom section and out of the rear of the boom Allow the hoses to hang from the rear of the boom Remove the top and side wear pads and spacers to the inside of the second boom section Label and tag each set of wear pads being removed 3 5 Boom 14 15 3 6 M
304. the main control valve from the frame b Main Control Valve Disassembly 1 To disassemble the individual sections of the main control valve remove the nuts from one end of the tie rods Pull the tie rods out through the sections 2 Disassemble each section assembly as required Some sections include a pre adjusted relief valve that regulates pressure in a specific circuit Note DO NOT adjust any of the relief valve assemblies Tampering with a relief valve will irrevocably alter pressure in the affected circuit requiring recalibration or a new relief valve 8 23 Hydraulic System n Disassemble each Valve Section 1 Carefully separate the load sense outlet section from the next section 2 Remove the o rings from between the two sections 3 Carefully separate each remaining sections being careful not to lose the load sense shuttle ball 4 Remove both end caps from each end of the valve sections then remove each control spool 5 Remove any check valves compensator valves anti cavitation valves or shock valves from individual valve section if equipped 6 Keep all parts being removed from individual valve sections tagged and kept together c Main Control Valve Parts Cleaning Clean all components with a suitable cleaner such as triclorethylene before continuing Blow dry d Main Control Valve Parts Inspection Inspect all parts and internal passageways for wear damage etc If inne
305. the proper tool for the job keep tools clean and in good working order and use special service tools only as recommended 6036 6042 8042 10042 10054 1 6 3 SOLVENTS Only use approved solvents that are known to be safe for use HOUSEKEEPING Keep the work area and operator cab clean and remove all hazards debris oil tools etc General Hazards FIRST AID Immediately clean dress and report all injuries cuts abrasions burns etc no matter how minor the injury may seem Know the location of a First Aid Kit and know how to use it CLEANLINESS Wear eye protection and clean all components with a high pressure or steam cleaner before attempting service When removing hydraulic components plug hose ends and connections to prevent excess leakage and contamination Place a suitable catch basin beneath the machine to capture fluid run off It is good practice to avoid pressure washing electrical electronic components In the event pressure washing the machine is needed ensure the machine is shut down before pressure washing Should pressure washing be utilized to wash areas containing electrical electronic components it is recommended a maximum pressure of 750 psi 52 bar at a minimum distance of 12 in 30 5 cm away from these components If electrical electronic components are sprayed spraying must not be direct and for brief time periods to avoid heavy saturation Check and obey all Federal State and or Lo
306. tic 691 1172 3 3 Turbocharger Number 1 Compressor Inlet Temperature Sensor High 692 1172 4 4 Turbocharger Number 1 Compressor Inlet Temperature Sensor Low 731 723 7 7 Engine Speed Sensor Position Camshaft and Crankshaft Misalignment 757 611 11 31 Engine Control Module Data Lost 6036 6042 8042 10042 10054 9 29 Electrical System Fault Code SPN Code FMI Code Description 778 723 2 Engine Speed Sensor Camshaft Error Erratic 779 703 11 Auxiliary Equipment Sensor Input 3 Switch 784 1590 2 Loss of Communication with Adaptive Cruise Control 951 166 2 Oylinder Power Imbalance Between Cylinders 957 27 2 EGR Valve Position Erratic 958 2795 2 VGT Position Sensor Erratic 1117 627 2 2 Power Lost Without Ignition Off Erratic 1139 651 7 Injector Solenoid Driver Cylinder 1 Not Responding 1141 652 7 Injector Solenoid Driver Cylinder 2 Not Responding 1142 653 7 Injector Solenoid Driver Cylinder 3 Not Responding 1143 654 7 Injector Solenoid Driver Cylinder 4 Not Responding 1144 655 7 Injector Solenoid Driver Cylinder 5 Not Responding 1145 656 7 Injector Solenoid Driver Cylinder 6 Not Responding 1228 27 2 2 EGR Valve Position Erratic 1229 2795 2 2 VGT Position Sensor Erratic 1239 2623 3 3 Accelerator Pedal or Lever Position Sensor 2 Circuit High 1241 2623 4 4 Accele
307. ting of all hoses and tubing for sharp 5 Remove the lower and front dash panels bends or interference with any rotating members and install tie wraps and or protective conduit as required Tighten all tube and hose clamps 4 Properly connect the battery 5 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 6 Start the engine and run at approximately one third to one half throttle for about one minute without moving the machine or operating any hydraulic functions 7 Inspect the service brake valve and connections for leaks and check the level of the hydraulic fluid in the reservoir Shut the engine OFF Note Check for leaks and repair as required before continuing Add hydraulic fluid to the reservoir as needed 8 Wipe up any hydraulic fluid spillage in on near and TEE around the machine work area and tools YY 6 Label disconnect and cap all hose attached to the Se natal the lower and mont service brake valve 1 10 Close and secure the rear door 7 Remove the four capscrews and four lockwashers mounting the service brake valve to the steering column support Note DO NOT disassemble the service brake valve The service brake valve is not serviceable and must be replaced in its entirety if defective 8 26 6036 6042 8042 10042 10054 Hydraulic System i 8 7 4 Brake Test Carefully bleed the brake lines as soon as the brake v
308. tings MH1151 9 Label disconnect and cap the Extend Retract hydraulic tubes 19 from the bulkhead fittings Remove the tube clamps 1 MH1201 10 Label disconnect and cap the hydraulic hoses attached to the Slave cylinders 2 6036 6042 8042 10042 10054 Boom N J Z 11 12 13 14 15 16 17 18 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 MH1221 On the right side boom pivot mounting plate remove the boom proximity sensor 3 With the boom securely supported block the Lift Lower cylinders Remove the lockbolts from the rod end of the cylinders and lower the cylinders onto the machine MH1241 Remove the boom pivot pins 4 and lockbolts Using a sling or suitable support carefully lift the first boom section away from the machine Set the boom section down on a hard level surface Support the boom as required to allow removal of the Extend Retract cylinder from the underside of the boom Inspect all wear pads for wear Refer to Section 3 9 Boom Wear Pads Use a hoist and slings to support the Extend Retract cylinder Remove the retaining rings from the ends of the Extend Retract
309. tings Always use matched sets according to machine specifications MAJOR COMPONENTS Never alter remove or substitute any items such as counterweights tires batteries or other items that may reduce or affect the overall weight or stability of the machine BATTERY DO NOT charge frozen battery Charging a frozen battery may cause it to explode Allow the battery to thaw before jump starting or connecting a battery charger 1 7 SAFETY DECALS Check that all safety decals are present and readable on the machine Refer to the Operation amp Safety Manual supplied with machine for information 6036 6042 8042 10042 10054 Section 2 General Information and Specifications Contents PARAGRAPH TITLE PAGE 2 1 Replacement Parts and Warranty 2 2 2 2 Torque Chants c eee 2 3 2 2 1 SAE Fastener Torque Chart 2 3 2 2 2 Mertic Fastener Torque 2 7 2 2 8 Hydraulic Hose Torque Chart 2 10 2 3 Specifications eae a mpm ee mr rar Rmo 2 11 2 3 1 Travel Sp eds i Lese 4g dS e we x Ra 2 11 2 3 2 Hydraulic Cylinder 2 11 2 3 3 Electrical 2 12 2 3 4 Engine Performance Specifications 2 12
310. tings Location 2 3 4 5 4000 psi gauge Unit equipped with 280 bar gauge fittings from factory 6 7 8 10 1000 psi gauge Unit equipped with 70 bar gauge fittings from factory 9 4000 psi gauge Requires a male or 280 bar gauge female quick disconnect coupler A CAUTION GAUGE DAMAGE may occur Malfunctioning hydraulic system circuits may have excessive pressure and can cause hydraulic pressure spikes Test circuit with the highest reading pressure gauge first If this gauge cannot record an accurate pressure reading use the next lower pressure gauge 3 Start the machine run the engine and follow the procedures in Section 8 4 1 e Pressure Specifications 8042 10042 amp l 10054 b Adjusting Hydraulic Pressure 1 Shut the machine off Remove the cap on the relief if necessary 2 Start the machine and loosen the jam nut on the relief Turn the relief clockwise to increase pressure or counter clockwise to decrease pressure Set to the correct pressure 3 Tighten the jam nut and recheck the pressure at full throttle If the reading is within specification shut the machine off install the safety cap and remove the gauge from the test port 4 f the proper pressure cannot be set use the accompanying hydraulic schematic and or the electrical schematic to help troubleshoot and correct the problem 8 6 6036 6042 8042 10042 10054 Hydraulic Sy
311. tings to keep dirt and debris from entering the hydraulic system 8 Label and disconnect the boom proximity sensor at the rear of the boom 9 Remove the pin from the rod end of the slave cylinder being careful not to drop the cylinder Lower the cylinder onto the frame rails 10 Remove the pin from the rod end of the lift lower cylinders Lower the cylinders onto the frame rails 11 Confirm that the boom assembly is balanced with the sling and remove the boom assembly pivot pin 12 Lift the boom assembly from the machine and lower onto suitable supports 6036 6042 8042 10042 10054 Boom C 3 4 2 1 Third Boom Section Removal Remove any attachment from the quick attach assembly Refer to Section 3 8 1 Disconnecting from an Attachment Note If replacing the third section boom remove the quick attach from the third section Refer to Section 3 8 3 Quick Attach Removal 2 Park the machine on a hard level surface level the machine fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the rear door Allow the system fluids to cool Move the Attachment Tilt joystick in both directions to relieve any trapped pressure in the Attachment Tilt system If
312. tino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil Phone 55 193 295 0407 Fax 55 193 295 1025 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong Phone 852 2639 5783 Fax 852 2639 5797 JLG Industries Scotland Wright Business Centre 1 Lonmay Road Queenslie Glasgow G33 4EL Scotland Phone 44 0 141 781 6700 Fax 44 0 141 773 1907 JLG Industries UK Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England Phone 44 0 161 654 1000 Fax 44 0 161 654 1001 JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI Italy Phone 39 029 359 5210 Fax 39 029 359 5845 Plataformas Elevadoras JLG Iberica S L Trapadella 2 P I Castellbisbal Sur 08755Castellbisbal Barcelona Spain Phone 34 93 772 4 700 Fax 34 93 771 1762 www jlg com JLG France SAS 2 1 de Baulieu 47400 Fauillet France Phone 33 0 5 53 88 31 70 Fax 33 0 5 53 88 31 79 JLG Europe B V Polaris Avenue 63 2132 JH Hoofddorp The Netherlands Phone 31 0 23 565 5665 Fax 31 0 23 557 2493 JLG Sverige AB Enkopingsvagen 150 Box 704 SE 176 27 Jarfalla Sweden Phone 46 0 850 659 500 Fax 46 0 850 659 534
313. tion 8 7 3 Service Brake Valve 8 N A Brake Valve 550 psi 38 bar With engine at idle depress and hold brake Service minimum pedal DO NOT turn steering wheel DO NOT Brake overstroke the brake pedal Check pressure If Pressure pressure is incorrect refer to Section 8 7 3 Service Brake Valve 9 G1 E Stabilizer 75 150 psi With engine at idle check the pressure on the Cylinder 5 2 10 3 bar 8 12 6036 6042 8042 10042 10054 Hydraulic System e Pressure Specifications 8042 10042 amp 1 10054 LEFT RIGHT OUTRIGGER OUTRIGGER CYLINDER CYLINDER ATTACHMENT TILT CYLINDER FRONT AXLE AUXILIARY COUPLERS FTR FTB FRAME SWAY CYLINDER FRONT STEERING CYLINDER MAIN CONTROL VALVE STEER SELECT VALVE HUTTLEI VALVE m ee em d LFT LWR EXT RET RP LT POWER STEERING UNIT fe ce E E HYDRAULIC RESERVOIR SECONDARY Q Q FUNCTION PBG MANIFOLD C PSG G p PS PB EXTEND RETRACT CYLINDER OUTRIGGER VALVE 10042 amp 10054 ONLY LEFT LIFT LOWER CYLINDER RIGHT LIFT LOWER CYLINDER STABILIZER CYLINDER FTR G LEFT SLAVE CYLINDER RIGHT SLAVE CYLINDER REAR STEERING CYLINDER REAR AXLE
314. tion the slings as needed so the third boom section balances when removed from the second boom section Set the boom section down on a hard level surface Support the boom as needed to prevent it from tipping over 18 At the rear of the third boom section remove the remaining wear pads shims and hardware Label and tag each set of wear pads being removed 19 Inspect all wear pads for wear Refer to Section 3 9 Boom Wear Pads 3 4 3 Second Boom Section Removal 1 Atthe front of the first boom section remove the top bottom and side wear pads to the inside of the boom Label and tag each set of wear pads being removed 6036 6042 8042 10042 10054 N M I Boom 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 MH1021 Atthe rear of the second boom section remove the capscrew and lockwasher holding the retract chain sheave pin 8 to the mounting plate inside the boom Remove the retract chain sheave pin from the mount and the retract chain sheave Remove the retract chain sheave from the second boom section Inspect the bushings inside the sheave Replace the bushings if there are any signs of wear Inspect the pin for wear or damage Replace the pin if showing signs of wear MH1501 At the rear of the second boom section remove the hose r
315. tioning properly and or a fault in the wiring harness Transmission control lever not functioning properly and or a fault in the wiring harness 3 Transmission valve body solenoids not functioning properly 4 Pilot operated shift valves not operating properly 5 Pump output pressure low 8 Coupling shafts or gear teeth damaged 6 Clutch piston o rings damaged 7 Clutch discs worn or damaged Fill transmission to correct level with Mobilfluid 424 ISO Grade 46 Refer to Section 2 4 Fluid and Lubricant Capacities Refer to Section 9 5 Electrical System Schematics Refer to Section 9 5 Electrical System Schematics Clean the valve spool and housing Replace return spring as needed Refer to Section 6 5 Transmission Troubleshooting Problem 2 Low or no pump flow or pressure Replace o rings Replace clutch discs Replace couplings 6036 6042 8042 10042 10054 6 7 Transmission Problem Cause Remedy 2 Low or no pump flow or pressure Low oil level Transmission filled with incorrect oil or oil contaminated Pump suction pipe screen clogged Central shaft damaged Pump worn or damaged Fill transmission to correct level with Mobilfluid 4249 ISO Grade 46 Refer to Section 2 4 Fluid and Lubricant Capacities Drain transmission and fill to
316. tions Make every effort to repair the machine and move it under its own power Towing the machine improperly can result in damage to the machine drivetrain Note In the event the machine is disabled and cannot be moved under engine power the situation must be properly evaluated and dealt with on an individual basis Contact your local JLG distributor for specific instructions for your particular situation If it is necessary to tow the machine a short distance to avoid a potentially hazardous situation such as being in an unsafe area on the worksite or on a roadway prepare the machine for towing as follows 1 Remove the load from the machine 2 Block all four wheels to help prevent the machine from moving after the parking brake is disabled 3 Remove the transmission covers 4 Position the towing vehicle in place Attach any chains needed to secure the disabled machine 6036 amp 6042 FRONT OF MACHINE OA1231 5 18 8042 10042 amp 10054 FRONT OF MACHINE OH1841 5 Attach a remote portable hydraulic pressurizing unit to the parking brake gauge port 5 on the secondary function manifold 6 mounted on the inside wall of the frame on the left side next to the transmission 6 Turn the key switch to the ON position release the park brake and have an operator seated in the seat 7 Pressurize the park brake with the pressurizing unit Close the pump needle valve on the pressurizing unit A C
317. to Section 2 5 Service and Maintenance Schedules and Section 2 6 Lubrication Schedules for detailed information Lubrication of chains on machines working consistently in extreme hot or cold conditions requires special consideration It is important that a reputable lubrication specialist or a JLG distributor be consulted for guidance 3 31 P Boom 3 7 5 Boom Chain Tension Check 1 Make sure the attachment is attached to the boom head before doing the tension check Park the machine on level ground Place the transmission control lever in NEUTRAL engage the parking brake switch and level the boom Slowly fully extend the boom and retract it about halfway Fully extend the boom then retract it 2 in 51 mm one inch per section Turn the engine OFF pu OA0493 4 Measure the sag 1 in each of the boom extend chains between the bottom of the extend chains and the top of the boom at their closest point Acceptable boom chain sag is between 1 5 in 38 mm and 2 5 in 64 mm for the 8042 amp 10042 and between 2 85 in 72 mm and 3 85 in 98 mm If the measurement is either less than or greater than the range given the boom chains need to be adjusted Continue with Section 3 7 6 Boom Chain Tension Adjustment 6036 6042 8042 amp 10042 or Section 3 7 7 Boom Chain Tension Adjustment 10054 to adjust the chain system Start the engine
318. to repair a chain Replace a stretched or damaged chain with a new part Always replace both the chain and the clevis 11 12 13 Coat the threads of the threaded clevis with multi purpose grease Lay the new extend chain on top of the first boom section with the threaded clevis toward the front of the boom Attach the wire to the threaded clevis of the new extend chain using a threaded eye or a flat washer tack welded to a capscrew The outside diameter of the eye or flat washer must be smaller than the diameter of the threads on the clevis 3 38 14 17 19 20 21 22 23 24 25 SH1852 Pull the extend chain forward and place over the right side of the chain sheave 10 Guide the wire and the threaded clevis under the chain sheave and between the top of the third boom section 11 and the second boom section 12 Have an assistant guide the extend chain into the front of the boom while pulling on the wire from the rear of the boom Guide the threaded clevis into the hole in the anchor plate Assemble the flat washer and locknut to the threaded clevis Thread the locknut until the threads are flush with the top of the nut Pull the anchor clevis up around the double chain sheave and position the clevis between the yoke plates Coat the capscrew with anti seize compound Insert the capscrew through the yoke plates and clevis and secure in place with a locknut Tighten s
319. tor The motor is not serviceable Replace motor if found to be defective c Inspection and Replacement Inspect the motor terminals for continuity Replace motor if continuity is not found d Installation and Testing 1 Install all required hardware to the motor assembly Align spacer and wiper motor bracket and apply masking tape in order to hold the two components together during installation 2 Align motor with the mounting holes and insert motor through cab 3 Have an assistant insert gasket panto adapter onto the motor shaft Insert bolts through front cab holes and thread into motor housing Tighten bolts 4 Install metal washer and metal hex jam nut Tighten metal hex jam nut Install rubber cap and knurled driver onto the motor shaft Note Align the wiper blade arm with the hex jam nut Tighten shaft to ensure wiper stroke covers window area and it does not swipe past the glass area 5 Install wiper blade arm at 90 from the motor shaft flat 6 Connect the cab harness connectors to windshield wiper motor connectors 7 Properly connect the battery 8 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 6036 6042 8042 10042 10054 Electrical System 10 11 12 9 8 2 a 1 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 tra
320. tor Pressure Cap For a 210 F 99 C system use a 13 psi 90 kPa radiator cap An incorrect or malfunctioning cap can result in the loss of coolant and a hot running engine 7 4 2 Before considering radiator or oil cooler replacement for other than obvious damage conduct a cooling system pressure test check the coolant specific gravity coolant level fan belt tension and dash panel temperature indicator Radiator Oil Cooler and Replacement f the engine runs hot check the temperature of the upper radiator hose f the hose is not hot the thermostat may be stuck in the closed position If the engine has overheated performance may suffer indicating other damage including a leaking cylinder head gasket cracked cylinder head or block and or other internal engine damage a Radiator Oil Cooler Removal 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the travel select lever in the NEUTRAL position engage the parking brake and shut the engine OFF 7 4 Place a Do Not Operate Tag both the ignition key switch and steering wheel stating that the machine should not be operated Open the side and rear engine doors Allow the system fluids to cool Disconnect the battery positive and negative cables from the appropriate battery terminals Remove the battery or batteries MAQ0290 Slowly turn the radiator cap 1 to the
321. truding beyond the locknut is the same as the measurement recorded during removal of the retract chain Check and adjust retract chain tension Refer to Section 3 7 5 Boom Chain Tension Check Install the boom rear cover Properly connect the battery Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 3 40 3 7 10 Extend Chains Removal and Replacement 10054 a Second and Third Boom Section Extend Chains Removal and Replacement Park the machine on level ground Place the transmission control lever in NEUTRAL engage the parking brake switch level the boom and shut the engine OFF Place a Do Not Operate Tag on both the ignition key Switch and the steering wheel stating that the machine should not be operated 3 Properly disconnect the battery 4 Remove the boom rear cover 16 MH1781 At the rear of the boom locate the extend chain locknuts 16 Record the amount of threads extending beyond the locknuts This measurement will be the starting point for adjustment of the extend chains after installation Remove and replace the boom extend chains one at a time Remove the right side locknut and flat washer holding the right side chain clevis to the anchor plate SH1811 7 Atthe front of the first boom section remove the capscrews 17 and locknuts holding the extend chain clevis to the yoke plates 6036 6042 8042 10042 10054
322. tures are below 32 F 0 C a blend of 1 diesel and 2 diesel fuels known as winterized 2 diesel may be used Note 1 diesel fuel may be used however fuel economy will be reduced 6036 6042 8042 10042 10054 Use a low sulfur content fuel with a cloud point the temperature at which wax crystals form in diesel fuel at least 10 below the lowest expected fuel temperature The viscosity of the fuel must be kept above 1 3 centistrokes to provide adequate fuel system lubrication 7 6 2 Fuel Hydraulic Oil Tank Note The fuel hydraulic oil tank is part of a one piece unit divided into a two compartment tank unit It is located on the right side of the machine across from the operator cab If it is determined that either the fuel of hydraulic oil tank must be removed both the fuel and hydraulic oil must be drained before tank removal Always dispose of hydraulic oil or fuel properly a Fuel Hydraulic Tank Removal 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the travel select lever in the NEUTRAL position engage the parking brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated 3 Open the rear door Allow the system fluids to cool 4 Properly disconnect the battery Note replacing the tank remove all internal and extern
323. uent inspections until replacement life can be predicted The boom chain s normal life expectancy can be expressed as a maximum percent of elongation This is generally 396 As the chain flexes back and forth over the sheave the bearing joints pins and inside link plates gradually incur wear due to articulation 3 10 2 1 Park the machine on a firm level surface raise the boom to a horizontal level position place the transmission control lever in NEUTRAL engage the park brake switch Inspection Guidelines 2 Fully extend the boom until the extend chain is taut Shut the engine off 3 The extend chains will be visible for inspection with the vehicle in this state 4 While doing the chain inspection check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain 5 Inspect the retract chains every 1000 hours of operation 6 Inspect the chains for the following conditions 6036 6042 8042 10042 10054 Boom C E i ei Edge Wear E SY L 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 an
324. urns and tighten the two extend chain locknuts 18 equally the same number of turns A minimum of one full thread on the clevis must protrude beyond the collar of the locknut 4 To decrease the separation distance Loosen the extend chain locknuts 18 at the rear of boom equally one or two turns and tighten the retract chain locknut 13 the same number of turns A minimum of one full thread on the clevis must protrude beyond the collar of the locknut Note If the third to second boom section separation distance cannot be achieved contact your local authorized service distributor 3 35 E 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 19 655 965 L4 LL X OA0493 MH1781 1 Adjust the fourth boom section extend chain If the chain sag measurement 19 is less than 2 85 in 72 mm tighten the extend chain adjustment locknut 1 If the chain sag measurement 19 is more than 3 85 in 98 mm loosen the extend chain adjustment locknut 1 3 36 OH0661 2 f 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 3 Recheck chain tension Refer to Section 3 7 5 Boom Chain Tension Check MH4
325. use Registration activates the warranty period and helps to assure that warranty claims are promptly processed To guarantee full warranty service verify that the distributor has returned the business reply card of the warranty registration form to JLG 2 2 6036 6042 8042 10042 10054 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 amp GRADE 2 NUTS Torque Tensile Torque Loctite 242 or 271 Stress Area Lubricated OR Vibra TITE 111 or 140 Torque Loctite 262 or Vibra TITE 131 Bolt Dia Sq In 0 00604 0 00661 420 32 0 1380 0 00909 580 40 0 1380 0 01015 32 0 1640 0 01400 900 36 0 1640 0 01474 940 0 01750 0 02000 0 2500 0 0318 20200 96 108 75 9 0 2500 0 0364 2320 120 In Sq In LB FT LB 0 3125 0 0524 3340 0 3125 0 0580 3700 19 0 3750 0 0775 4940 5600 35 55 a i EX e 0 3750 0 0878 0 4375 0 1063 0 4375 0 1187 0 1419 9050 0 5625 0 1820 11600 110 0 5625 0 2030 12950 0 6250 0 2260 14400 150 203 0 6250 0 2560 16300 230 1 0 7500 0 3340 21300 260 353 9 0 8750 0 4620 0 8750 0 5090 32400 470 1 0000 0 6060 12 1 0000 0 6630 42200 700 0 7630 12 1 1250 0 8560 47500 1 2500 0 9690 53800 1120 1 3750 1 3150 73000 2278 1708 1750 1506 2042 1 5000 1
326. ut 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 Using a suitable sling carefully slide the second boom section into the first boom section Leave enough room at the front of the boom to install the center wear pad 3 23 Ern Boom 10 11 12 13 14 MH2211 Install the center wear pad mount 13 and wear pad to the bottom front of the first boom section Install the side and top wear pads to the front of the first boom section Install the double extend chain sheave to the front of the second boom section With the sling still in place install the rod end of the Extend Retract cylinder pin and retaining ring Install the front bottom wear pads in the second boom section MH2171 On the left side of the first boom section reassemble the boom extend interlock sensor 14 with mounting bracket Secure in place with the previously used hardware Tighten securely Secure the boom extend interlock sensor wire to the Attachment Tilt tubes under the boom with new tie wraps 3 24 3 6 7 Install the bottom side and top wear pads to the rear Third Boom Installation of the third boom section MH2021 At the rear of the third boom section assemble the retract chain sheave 15 to the mounting ears on the left side of the boom Place the sheave bet
327. vel is achieved If previously removed install hydraulic hoses under the dash Refer to Section 4 3 1 Steering Column and Steering Valve Install the previously removed dash panels Close and secure the rear door Skylight Wiper Motor Removal 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 Place a Do Not Operate Tag on both the ignition key Switch and the steering wheel stating that the machine should not be operated Open the rare door Allow the system fluids to cool Properly disconnect the battery 8361 Remove the wiper arm 5 from the wiper motor shaft Disconnect the washer hose from the top hose fitting From inside the cab remove screws from top locknut plate 6036 6042 8042 10042 10054 8 Unclip the plastic motor cover 6 and remove 9 From the top of the cab remove the nut from the 10 11 b wiper motor shaft From inside the cab pull the wiper motor down and away from the roof Label and disconnect the cab harness connectors from the wiper motor Disassembly DO NOT disassemble the motor The motor is not serviceable Replace motor if found to be defective Inspection and Replacement Inspect the motor terminals for continuity Replace motor if continuity is not found d
328. viously removed from the machine position the driveshaft yoke on the axle according to the alignment marks made earlier If installing a new axle note the position of the driveshaft yoke at the transmission Align the driveshaft yoke on the axle in the same plane as the yoke on the transmission 9 Install the wheel and tire assemblies Refer to Section 5 7 2 Installing Wheel and Tire Assembly onto Machine 10 Carefully remove the jack hoist or overhead crane and sling supporting the axle 11 Carefully raise the machine using a suitable jack or hoist Remove the supports from beneath the frame and lower the machine to the ground 12 Remove the blocks from the front and rear of both tires on the other axle 6036 6042 8042 10042 10054 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 15 Check the hydraulic reservoir oil level 16 Properly connect the battery 17 Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel 18 Start the engine Turn the steering wheel several times lock to lock operate the frame tilt function several times in both directions and check the function of the brakes Check for hydraulic leaks and tighten or repair as necessary
329. ween the ears and insert the sheave pin from the right side Line up the hole in the pin retainer plate with the threaded hole in the right ear Secure the pin 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 Install the bottom front wear pads MH2301 Lay the two extend chains 16 on the top of the third boom section with the threaded clevis ends toward the rear of the boom Coat the threads on each clevis with multi purpose grease and insert the clevis through the holes in the anchor plate Install a washer and locknut onto each clevis Tighten the locknut enough so the threads are even with the top of the locknut Grease the sections of the boom in areas where the wear pads will slide 6036 6042 8042 10042 10054 Boom 10 11 12 13 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 Install the top and side wear pads to the inside of the second boom section Place the two extend chains up through the double sheave mounting bracket on the front of the second boom section Assemble the two extend chains to the mount if the yoke plates were removed from the extend chains Secure in place with a locknut Tighten the locknut securely but the yoke plate
330. worn or damaged 3 9 2 Wear Pad Installation and Lubrication Note Inspect all wear pads Replace as necessary The following wear pad procedure must be followed to insure the proper wear pad installation The wear pad inserts and mounting bolts MUST be clean from any grease oil or other contaminates before applying Loctite 242 and installing mounting bolts Apply Loctite 2427 to all wear pad mounting bolts W ze NS MAQ0420 A spacer 2 must be used before any shim 3 is used Ashim 3 must be inserted between the spacer 2 and wear pad support plate block or boom section 4 The number of shims can vary at each shim point The bottom wear pads must be shimmed equally on each side 6036 6042 8042 10042 10054 Maintain a total boom section clearance 5 of 0 070 0 130 in 1 78 3 30 mm both the horizontal and vertical directions i MY3620 The length of the wear pad bolt depends on the number of shims spacers and washers being used The thickness of each threaded wear pad insert is 0 562 in 14 27 mm A The bolt length should be determined by measuring the distance from the face of the insert to the face of the boom B including any spacer shim s and washer s Bolt thread engagement in the wear pad insert should be 0 235 0 315 in 5 98
331. xtinguisher 7 10 18 Start the engine and run to normal operating temperature then shut off the engine While the engine is cooling check for leaks 19 Allow the engine to cool Check the radiator coolant level and add coolant if needed Replace the radiator cap 20 Check for leaks from the engine main hydraulic pump and lines transmission hydraulic reservoir and fuel tank Check the levels of all fluids and lubricants Fill as required Note During the full throttle check DO NOT operate any hydraulic function DO NOT steer or apply any pressure to the steering wheel Keep the transmission in N NEUTRAL 21 Obtain and connect an appropriate engine analyzer or tachometer Check the engine rpm at full throttle 22 Purge the hydraulic system of air by operating all boom functions through their entire range of motion several times Check the hydraulic oil level 23 Check for proper operation of all components 24 Turn the engine OFF 25 Install the side and rear engine covers 7 10 ISOLATION COUPLER 7 10 1 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 NEUTRAL position engage the parking brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated Isolation Coupler Removal 3 Open the rea
332. xtremely important Before attempting to remove the axle thoroughly clean the machine Avoid spraying water or cleaning solution on the stabilizer solenoids and other electrical components If using a steam cleaner seal all openings before steam cleaning Note Clear the work area of all debris unnecessary personnel etc Allow sufficient space to raise the machine and to remove the axle 6036 6042 8042 10042 10054 Axles Drive Shafts Wheels and Tires hs 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 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 Open the rear door Allow the system fluids to cool Properly disconnect the battery Remove the fender assembly if equipped Models 10042 and 10054 Front Axle Only Remove outrigger assembly Refer to Section 5 4 6 a Outrigger Removal 10042 amp 10054 only o o 7 If the axle will be disassembled after removal place a suitable receptacle under the axle drain plug 1 Remove the drain plug and allow the axle oil to drain into the receptacle Transfer the used axle oil into a suitable covered container and label the container as Used Oil Dispose of used oil at an
333. y 12 Label and disconnect the two cab to wiring harness connectors 3 Push the connectors through the opening at the bottom of the cab 13 Remove the joystick assemblies from the cab Refer to Section 4 3 4 a Joystick Assembly Removal Route the joystick cables through the opening at the bottom of the cab MA8501 14 Working under the cab label disconnect and cap the hydraulic hoses at the cab fittings 4 Cap all fittings to keep dirt and debris from entering the hydraulic system 15 If necessary remove mirrors and other cab components that may become damaged during cab removal MA3331 16 Attach a clevis 5 to each of the cab lifting brackets Route a sling 16 with a minimum lifting capacity of 1000 Ib 453 kg to a hoist or overhead crane Center the sling to ensure even lifting 17 Remove the two upper cab to frame capscrews and two flat washers 18 Remove the two lower cab to frame capscrews and two flat washers 6036 6042 8042 10042 10054 19 20 21 22 23 4 5 Carefully begin to lift the cab Stop and check that all wiring hydraulic hoses and fasteners are disconnected and removed When all wiring hydraulic hoses and fasteners are disconnected or removed carefully and slowly lift the cab and remove it from the frame Readjust the position of the sling as
334. y Pressure High 2217 630 11 31 Engine Control Module Calibration Program Memory RAM Corruption 2249 157 1 Injector Metering Rail 1 Pressure Low 2265 1075 3 Electric Lift Pump for Engine Fuel Supply Circuit High 2266 1075 4 Electric Lift Pump for Engine Fuel Supply Circuit Low 2271 27 3 3 Exhaust Gas Recirculation EGR Valve Position Sensor Circuit High 2272 027 4 4 Exhaust Gas Recirculation EGR Valve Position Circuit Low 2273 411 3 3 EGR Valve Differential Pressure Sensor Circuit Shorted High 2274 411 4 4 EGR VAlve Differential Pressure Sensor Circuit Shorted Low 2292 16 Fuel Inlet Meter Device High 2293 18 Fuel Inlet Meter Device Flow Demand Low 2311 633 11 31 Fueling Actuator Number 1 Circuit Error 2321 190 2 Engine Crankshaft Speed Position Erratic 2322 723 2 Backup Engine Speed Position Sensor Number 2 Erratic 2345 103 10 10 Turbocharger Speed Invalid Rate of Change Detected 2346 2789 1 15 Exhaust Gas Temperature High 2347 611 0 15 Turbocharger Compressor Outlet Temperature High 6036 6042 8042 10042 10054 9 31 Electrical System Fault Code SPN Code FMI Code Description 2348 27 13 13 EGR Valve Failed Automatic Calibration Procedure 2349 2791 5 5 EGR Valve Control Circuit Low 2351 2791 4 4 EGR Valve Control Circuit Low 2352 2791 3 3 EGR Valve Cont
335. y 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 4 4 REMOVAL A WARNING The protection offered by this ROPS FOPS will be impaired if subjected to any modification or structural damage at which time replacement is necessary ROPS FOPS must be properly installed using fasteners of correct size and grade and torqued to their specified value Note To help ensure safety and optimum performance replace the cab if it is damaged Refer to the appropriate parts manual for ordering information Inspect the cab its welds and mounts If modification damage a cracked weld and or fatigued metal is discovered replace the cab Contact the local distributor with any questions about the suitability or condition of a cab Note Remove and label cab components as needed before removing the cab from the machine Label disconnect and cap hydraulic hoses Transfer cab parts to the replacement cab after the replacement cab is securely mounted on the machine 1 Park the machine on a firm level surface Allow sufficient overhead and side clearance for cab removal Level the machine fully retract the boom lower the boom place the travel select lever in the N NEUTRAL position engage the park brake and shut the en

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