Skytrak 8042 Service Manual User Manual

An Oshkosh Corporation CompanyService ManualModels6036, 6042, 8042, 10042 & 100546036S/N 0160039338 & After including 0160024571 & 0160037

Safety Practices1-2 6036, 6042, 8042, 10042, 100541.1 INTRODUCTIONThis service manual provides general directions for accomplishing service and repair

Cab and Covers4-6 6036, 6042, 8042, 10042, 100544.3.4 Joystick Assemblies These removal and installation instructions apply to the boom control, attac

4-76036, 6042, 8042, 10042, 10054Cab and Covers• Move the joystick handle to the left, activating the frame sway function. The boom should SWAY LEFT.A

Cab and Covers4-8 6036, 6042, 8042, 10042, 100547. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.Note: When

4-96036, 6042, 8042, 10042, 10054Cab and Covers12. Label and disconnect the two cab-to-wiring harness connectors (3). Push the connectors through the

Cab and Covers4-10 6036, 6042, 8042, 10042, 100547. Uncap and connect the previously labeled hydraulic hoses at the cab fittings (4).8. Route the joys

5-16036, 6042, 8042, 10042, 10054Section 5Axles, Drive Shafts, Wheels and TiresContentsPARAGRAPH TITLE PAGE5.1 Axle, Drive Shaft and Wheel Component T

Axles, Drive Shafts, Wheels and Tires5-2 6036, 6042, 8042, 10042, 100545.1 AXLE, DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGY (6036 & 6042)To under

5-36036, 6042, 8042, 10042, 10054Axles, Drive Shafts, Wheels and Tires5.2 AXLE, DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGY (8042, 10042 & 10054)T

Axles, Drive Shafts, Wheels and Tires5-4 6036, 6042, 8042, 10042, 100545.3 GENERAL INFORMATIONNote: To help ensure optimum performance, the drive sha

5-56036, 6042, 8042, 10042, 10054Axles, Drive Shafts, Wheels and Tires5.4.4 Axle MaintenanceCLEANING: Clean parts with machined or ground surfaces (su

1-36036, 6042, 8042, 10042, 10054Safety Practices1.6 SAFETY INSTRUCTIONSFollowing are general safety statements to consider before performing maintena

Axles, Drive Shafts, Wheels and Tires5-6 6036, 6042, 8042, 10042, 100547. Label, disconnect and cap the steering and brake lines at the axle. Cap all

5-76036, 6042, 8042, 10042, 10054Axles, Drive Shafts, Wheels and TiresNote: ALWAYS use new o-rings when servicing the machine.13. Install new o-rings

Axles, Drive Shafts, Wheels and Tires5-8 6036, 6042, 8042, 10042, 100548. Label, disconnect and cap the outrigger hydraulic hoses (6). Cap all fitting

5-96036, 6042, 8042, 10042, 10054Axles, Drive Shafts, Wheels and Tires1. Park the machine on a firm, level surface, level the machine, fully retract t

Axles, Drive Shafts, Wheels and Tires5-10 6036, 6042, 8042, 10042, 10054removing it from beneath the machine. Place the axle on a suitable support or

5-116036, 6042, 8042, 10042, 10054Axles, Drive Shafts, Wheels and Tires5.5 AXLE ASSEMBLY AND DRIVE SHAFT TROUBLESHOOTINGProblem Cause Remedy1. Excessi

Axles, Drive Shafts, Wheels and Tires5-12 6036, 6042, 8042, 10042, 100544. Oil leaking from axle (differential housing and/or axle housings).1. Drain

5-136036, 6042, 8042, 10042, 10054Axles, Drive Shafts, Wheels and Tires7. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level with M

Axles, Drive Shafts, Wheels and Tires5-14 6036, 6042, 8042, 10042, 100545.6 DRIVE SHAFTS5.6.1 Drive Shaft Inspection and ServiceWhenever servicing the

5-156036, 6042, 8042, 10042, 10054Axles, Drive Shafts, Wheels and Tires5.7 WHEELS AND TIRESIt is recommended that a replacement tire to be the same si

Safety Practices1-4 6036, 6042, 8042, 10042, 100541.6.4 Operational HazardsENGINE: Stop the engine before performing any service unless specifically i

Axles, Drive Shafts, Wheels and Tires5-16 6036, 6042, 8042, 10042, 100545.7.2 Installing Wheel and Tire Assembly onto MachineNote: The wheel and tire

5-176036, 6042, 8042, 10042, 10054Axles, Drive Shafts, Wheels and Tires4. Working through the level plug hole (2), carefully use a screwdriver to spre

Axles, Drive Shafts, Wheels and Tires5-18 6036, 6042, 8042, 10042, 100545.9 TOWING A DISABLED MACHINETowing a disabled machine should only be attempte

6-16036, 6042, 8042, 10042, 10054Section 6TransmissionContentsPARAGRAPH TITLE PAGE6.1 Transmission Assembly Component Terminology . . . . . . . . . .

Transmission6-2 6036, 6042, 8042, 10042, 100546.1 TRANSMISSION ASSEMBLY COMPONENT TERMINOLOGYTo understand the safety, operation and maintenance infor

6-36036, 6042, 8042, 10042, 10054Transmission6.2 TRANSMISSION SERIAL NUMBERThe transmission serial number plate (1) is located on the pump side (front

Transmission6-4 6036, 6042, 8042, 10042, 1005410. Transfer the used transmission oil into a suitable, covered container, and label the container as “U

6-56036, 6042, 8042, 10042, 10054Transmission27. Lift the transmission clear of the machine and lower it onto suitable supports or secure it to a stan

Transmission6-6 6036, 6042, 8042, 10042, 1005412. Uncap and connect the previously labeled transmission oil cooler inlet and out hoses at the transmis

6-76036, 6042, 8042, 10042, 10054Transmission6.5 TRANSMISSION TROUBLESHOOTINGThis section provides an easy reference guide covering the most common pr

2-16036, 6042, 8042, 10042, 10054Section 2General Information and SpecificationsContentsPARAGRAPH TITLE PAGE2.1 Replacement Parts and Warranty Informa

Transmission6-8 6036, 6042, 8042, 10042, 100542. Low or no pump flow or pressure.1. Low oil level. 1. Fill transmission to correct level with Mobilflu

6-96036, 6042, 8042, 10042, 10054Transmission5. Transmission overheating (oil above 120° C (248° F)).1. Low oil level. 1. Fill transmission to correct

Transmission6-10 6036, 6042, 8042, 10042, 100547. Oil leaking from transmission. 1. Oil leaking from vent (high oil level).1. Remove drain plug and dr

7-16036, 6042, 8042, 10042, 10054Section 7Engine - Cummins QSB3.3T/QSB4.5TContentsPARAGRAPH TITLE PAGE7.1 Introduction . . . . . . . . . . . . . . . .

Engine - Cummins QSB3.3T/QSB4.5T7-2 6036, 6042, 8042, 10042, 100547.1 INTRODUCTION7.1.1 Disclaimer and ScopeThese instructions are written for worldwi

7-36036, 6042, 8042, 10042, 10054Engine - Cummins QSB3.3T/QSB4.5T7.1.2 Component Terminology - Cummins - QSB3.3T/QSB4.5TTo understand the safety, oper

Engine - Cummins QSB3.3T/QSB4.5T7-4 6036, 6042, 8042, 10042, 100547.2 ENGINE SERIAL NUMBERThe Cummins QSB3.3T/QSB4.5T serial number is stamped on a pl

7-56036, 6042, 8042, 10042, 10054Engine - Cummins QSB3.3T/QSB4.5T2. Uncap and connect the all the previously labeled hoses and tubes to their appropri

Engine - Cummins QSB3.3T/QSB4.5T7-6 6036, 6042, 8042, 10042, 100547. Remove fuel tank drain plug (5), and drain fuel into an approved and suitable con

7-76036, 6042, 8042, 10042, 10054Engine - Cummins QSB3.3T/QSB4.5Tf. Fuel/Hydraulic Oil Tank Installation1. Attach the tank to a suitable lifting devic

General Information and Specifications2-2 6036, 6042, 8042, 10042, 100542.1 REPLACEMENT PARTS AND WARRANTY INFORMATIONBefore ordering parts or initiat

Engine - Cummins QSB3.3T/QSB4.5T7-8 6036, 6042, 8042, 10042, 100542. If previously removed, install the exhaust pipe (13).3. Install the exhaust pipe

7-96036, 6042, 8042, 10042, 10054Engine - Cummins QSB3.3T/QSB4.5T7.9 ENGINE REPLACEMENT 7.9.1 Engine RemovalNote: The radiator and oil cooler must be

Engine - Cummins QSB3.3T/QSB4.5T7-10 6036, 6042, 8042, 10042, 10054the help of an assistant, ensure that the engine clears the harness during installa

7-116036, 6042, 8042, 10042, 10054Engine - Cummins QSB3.3T/QSB4.5Ta jack under the bell housing (use a wood block to support the engine) and carefully

Engine - Cummins QSB3.3T/QSB4.5T7-12 6036, 6042, 8042, 10042, 100547.11 TROUBLESHOOTING Trouble Possible Causes (see key, below)Low Cranking PowerWill

8-16036, 6042, 8042, 10042, 10054Section 8Hydraulic SystemContentsPARAGRAPH TITLE PAGE8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . .

Hydraulic System8-2 6036, 6042, 8042, 10042, 100548.1 HYDRAULIC COMPONENT TERMINOLOGYTo understand the safety, operation and service information prese

8-36036, 6042, 8042, 10042, 10054Hydraulic SystemMH3441FRAME SWAY CYLINDERLIFT/LOWER CYLINDERSHYDRAULIC FLUID RESERVOIREXTEND/RETRACT CYLINDERMAIN CON

Hydraulic System8-4 6036, 6042, 8042, 10042, 100548.2 SAFETY INFORMATIONPetroleum-based hydraulic fluids are used in this machine. The temperature of

8-56036, 6042, 8042, 10042, 10054Hydraulic System8.3.1 Pressure Checks and AdjustmentsWhen diagnosing trouble in the hydraulic system, use the hydraul

2-36036, 6042, 8042, 10042, 10054General Information and Specifications2.2 TORQUE CHARTS2.2.1 SAE Fastener Torque ChartMY3141Size TPI Bolt DiaTensileS

Hydraulic System8-6 6036, 6042, 8042, 10042, 100548.4.1 Hydraulic Pressuresa. Checking Pressure1. Start the machine and warm the hydraulic system to o

8-76036, 6042, 8042, 10042, 10054Hydraulic Systemc. Pressure Specifications (6036)MA6241FRONT STEERINGCYLINDERPOWERSTEERINGUNITRTPLBRAKEVALVETPLSREOPE

Hydraulic System8-8 6036, 6042, 8042, 10042, 10054Test LocationHydraulic Pump Flow Test1 To check flow readings, a flow meter capable of measuring 60

8-96036, 6042, 8042, 10042, 10054Hydraulic System8 C Auxiliary Hydraulics3000 psi (207 bar)With engine at low idle, move auxiliary control lever left

Hydraulic System8-10 6036, 6042, 8042, 10042, 10054d. Pressure Specifications (6042)MA9241TSFVVLSGPLSVGSTABILIZERCYLINDERFRONT STEERINGCYLINDERREATTAC

8-116036, 6042, 8042, 10042, 10054Hydraulic SystemTest LocationHydraulic Pump Flow Test1 To check flow readings, a flow meter capable of measuring 60

Hydraulic System8-12 6036, 6042, 8042, 10042, 100547 PBG D Secondary Function Manifold500-600 psi(34-41 bar)With engine at idle, park brake released a

8-136036, 6042, 8042, 10042, 10054Hydraulic Systeme. Pressure Specifications (8042, 10042 &l 10054)MH6170REAR AXLERERIGHTSLAVECYLINDERREBAPTSTEER

Hydraulic System8-14 6036, 6042, 8042, 10042, 10054Test LocationHydraulic Pump Flow Test1 To check flow readings, a flow meter capable of measuring 60

8-156036, 6042, 8042, 10042, 10054Hydraulic System8 N/A Brake Valve (Service Brake Pressure)minimum550 psi(38 bar)With engine at idle, depress and hol

General Information and Specifications2-4 6036, 6042, 8042, 10042, 100542.2.1 SAE Fastener Torque Chart (Continued)MY3151Size TPI Bolt DiaTensileStres

Hydraulic System8-16 6036, 6042, 8042, 10042, 100548.4.2 Hydraulic Schematicsa. Model 6036ABCDEFGH12345678GHEFCDAB87654321EXTENDCYLINDER-4.50X3.00X102

8-176036, 6042, 8042, 10042, 10054Hydraulic Systemb. Model 6042ABCDEFGH12345678GHEFCDAB87654321EXTENDCYLINDER-4.50X3.00X102.504000PSIHOIST CYLINDER-5.

Hydraulic System8-18 6036, 6042, 8042, 10042, 10054c. Model 8042MAQ0090AABCDEFGH12345678GHEFCDAB87654321STEERINGSELECTORVALV EMANIFOLDREARFRONTabLRPTL

8-196036, 6042, 8042, 10042, 10054Hydraulic Systemd. Model 10042ABCDEFGH12345678GHEFCDAB87654321STEERINGSELECTORVALV EMANIFOLDREARFRONTabLRPTLRBARTP4W

Hydraulic System8-20 6036, 6042, 8042, 10042, 10054e. Model 10054ABCDEFGH12345678GHEFCDAB87654321STEERINGSELECTORVALV EMANIFOLDREARFRONTabLRPTLRBARTP4

8-216036, 6042, 8042, 10042, 10054Hydraulic System8.5 HYDRAULIC RESERVOIRThe hydraulic reservoir (1) and the fuel tank are one unit. They are located

Hydraulic System8-22 6036, 6042, 8042, 10042, 100548.6 HYDRAULIC SYSTEM PUMPFor internal service instructions contact your local authorized service di

8-236036, 6042, 8042, 10042, 10054Hydraulic System8.7 VALVES AND MANIFOLDS8.7.1 Main Control ValveThe main control valve is mounted on the frame under

Hydraulic System8-24 6036, 6042, 8042, 10042, 10054Disassemble each Valve Section1. Carefully separate the load sense outlet section from the next sec

8-256036, 6042, 8042, 10042, 10054Hydraulic Systemf. Main Control Valve Installation1. Install the main control valve onto the frame, aligning the bol

2-56036, 6042, 8042, 10042, 10054General Information and Specifications2.2.1 SAE Fastener Torque Chart (Continued)MY3161Size TPI Bolt DiaTensileStress

Hydraulic System8-26 6036, 6042, 8042, 10042, 100548.7.3 Service Brake Valvea. Service Brake Valve Removal1. Park the machine on a firm, level surface

8-276036, 6042, 8042, 10042, 10054Hydraulic System8.7.4 Brake TestCarefully bleed the brake lines as soon as the brake valve is installed in the machi

Hydraulic System8-28 6036, 6042, 8042, 10042, 100548.7.6 Steer Select ValveThe machine can be used in the front-wheel, four-wheel or crab steering mod

8-296036, 6042, 8042, 10042, 10054Hydraulic System6. Start the engine and run at approximately 1/3-1/2 throttle for about one minute without moving th

Hydraulic System8-30 6036, 6042, 8042, 10042, 100548.7.8 Outrigger Valve (10042 & 10054 only)The outrigger valve allows the left and right outrigg

8-316036, 6042, 8042, 10042, 10054Hydraulic Systemc. Outrigger Valve Installation1. Insert the previously used bolts through the bottom of the outrigg

Hydraulic System8-32 6036, 6042, 8042, 10042, 10054functioning properly. Check that the spring is intact. Inspect the cartridge interior for contamina

8-336036, 6042, 8042, 10042, 10054Hydraulic Systemb. Cylinder Disassembly1. Clean the cylinder with a suitable cleaner before disassembly. Remove all

Hydraulic System8-34 6036, 6042, 8042, 10042, 10054d. Cylinder Inspection1. Inspect internal surfaces and all parts for wear, damage, etc. If the inne

8-356036, 6042, 8042, 10042, 10054Hydraulic System8.8.3 Steering CylindersThe steer cylinder is attached to each axle center housing.The steer cylinde

General Information and Specifications2-6 6036, 6042, 8042, 10042, 100542.2.1 SAE Fastener Torque Chart (Continued)Size TPI Bolt DiaTensileStress Area

Hydraulic System8-36 6036, 6042, 8042, 10042, 100548.8.4 Cylinder Torque Specificationsa. Lift/Lower Cylinderb. Extend/Retract Cylinderc. Tilt Cylinde

8-376036, 6042, 8042, 10042, 10054Hydraulic Systemf. Slave Cylinderg. Swing Carriage Cylinder (If Equipped)h. Side Tilt Carriage Cylinder (If Equipped

Hydraulic System8-38 6036, 6042, 8042, 10042, 10054This Page Intentionally Left Blank

9-16036, 6042, 8042, 10042, 10054Section 9Electrical SystemContentsPARAGRAPH TITLE PAGE9.1 Electrical Component Terminology. . . . . . . . . . . . . .

Electrical System9-2 6036, 6042, 8042, 10042, 100549.1 ELECTRICAL COMPONENT TERMINOLOGYTo understand the safety, operation, and service information pr

9-36036, 6042, 8042, 10042, 10054Electrical System9.2 SPECIFICATIONSElectrical system specifications are listed in Section 2, “General Information and

Electrical System9-4 6036, 6042, 8042, 10042, 100549.4.2 Cab Harness Fuses and Relays213964710581112131415161718192021MAQ03402322647105811121314151617

9-56036, 6042, 8042, 10042, 10054Electrical System9.5 ELECTRICAL SYSTEM SCHEMATICSThe following Ladder Diagrams may be used to further investigate ele

Electrical System9-6 6036, 6042, 8042, 10042, 100549.5.1 6036 & 6042 Electrical Schematic (Continued)1616_C15_C15151_C1511818_C17_C173861561551541

9-76036, 6042, 8042, 10042, 10054Electrical System9.5.1 6036 & 6042 Electrical Schematic (Continued)3_H4_H1_H2_HCONNECTS TOFUSEBLOCKPIGTAIL WIRE52

2-76036, 6042, 8042, 10042, 10054General Information and Specifications2.2.2 Mertic Fastener Torque ChartMY3171SizePITCHTensileStressAreaClampLoadTorq

Electrical System9-8 6036, 6042, 8042, 10042, 100549.5.2 8042, 10042 & 10054 Electrical Schematic12V_BUSSBARNEG_JUMPPOS_JUMPBATT_POSENG_GNDAG1AG24

9-96036, 6042, 8042, 10042, 10054Electrical System9.5.2 8042, 10042 & 10054 Electrical Schematic (Continued)16 A15 A151_C1511818_C17_C173861561551

Electrical System9-10 6036, 6042, 8042, 10042, 100549.5.2 8042, 10042 & 10054 Electrical Schematic (Continued)5_H3_H4_H1_H2_HCONNECTS TOFUSEBLOCKP

9-116036, 6042, 8042, 10042, 10054Electrical System9.5.2 8042, 10042 & 10054 Electrical Schematic (Continued)3A_WL3B_WL3C_WL3A1_WL1_WL1C_WL1B_WL1A

Electrical System9-12 6036, 6042, 8042, 10042, 100549.6 ENGINE START CIRCUIT9.6.1 StarterThe starter (1) is located on the left side of the engine.a.

9-136036, 6042, 8042, 10042, 10054Electrical System9.7 CHARGING CIRCUITBefore using a battery charger, an attempt can be made to recharge the battery

Electrical System9-14 6036, 6042, 8042, 10042, 100549.8 WINDOW WIPER/WASHER WINDSHIELD WIPER MOTOR9.8.1 Windshield Wiper Motora. RemovalNote: It may

9-156036, 6042, 8042, 10042, 10054Electrical System9. Turn ignition key switch to the RUN position, and operate windshield wiper in both LOW and HIGH

Electrical System9-16 6036, 6042, 8042, 10042, 100549.8.3 Windshield Washer ReservoirThe windshield washer motor and reservoir (7) is a unit and canno

9-176036, 6042, 8042, 10042, 10054Electrical System8. Pull the control panel out from the dash panel, and if removing variable speed fan control, remo

General Information and Specifications2-8 6036, 6042, 8042, 10042, 100542.2.2 Mertic Fastener Torque Chart (Continued)MY3181SizePITCHTensileStressArea

Electrical System9-18 6036, 6042, 8042, 10042, 100545. Start the engine. Allow it to reach operating temperature and observe the operator instrument c

9-196036, 6042, 8042, 10042, 10054Electrical System9.10.3 Transmission Solenoid Valves Note: If the transmission is not shifting properly, the transm

Electrical System9-20 6036, 6042, 8042, 10042, 100549.10.5 Service Brake SwitchThe service brake switch (12) works in conjunction with the Stabil-TRAK

9-216036, 6042, 8042, 10042, 10054Electrical System8. Using the switch dust cover and the locknut in combination, position the brake switch so the Sta

Electrical System9-22 6036, 6042, 8042, 10042, 100549.10.7 Boom Extend Interlock Sensor(10054 only)The boom extend interlock sensor is located on the

9-236036, 6042, 8042, 10042, 10054Electrical System9.10.8 Outrigger Pressure Switches (10054 Only)a. Removal1. Park the vehicle on a firm, level surfa

Electrical System9-24 6036, 6042, 8042, 10042, 100549.12 DASH SWITCHESNote: For information on the front windshield wiper, rear window wiper and wash

9-256036, 6042, 8042, 10042, 10054Electrical System9.12.2 Dash Switchesa. Switch Removal1. Park the machine on a firm, level surface, level the machin

Electrical System9-26 6036, 6042, 8042, 10042, 100549.13 TROUBLESHOOTING9.13.1 Fault DetectionFaults are detected while the key switch is in the RUN p

9-276036, 6042, 8042, 10042, 10054Electrical System9.13.4 Engine Fault Codes ChartFault Code SPN Code FMI Code Description0001 Exhaust Gas Pressure Se

2-96036, 6042, 8042, 10042, 10054General Information and Specifications2.2.2 Mertic Fastener Torque Chart (Continued)MY3191SizePITCHTensileStressAreaC

Electrical System9-28 6036, 6042, 8042, 10042, 10054245 647 4/4 Fan Control Circuit - Low253 98 1 Engine Oil Level268 94 2 Injector Metering Rail 1 Pr

9-296036, 6042, 8042, 10042, 10054Electrical System429 97 4/4 Water-In-Fuel Indicator Sensor Circuit - Low431 558 2/2 Accelerator Pedal or Lever Idle

Electrical System9-30 6036, 6042, 8042, 10042, 10054778 723 2 Engine Speed Sensor (Camshaft) Error - Erratic779 703 11 Auxiliary Equipment Sensor Inpu

9-316036, 6042, 8042, 10042, 10054Electrical System1682 3362 11/31 Catalyst Reagent Dosing Unit Input Lines1683 3449 3 Catalyst Tank Heater Circuit -

Electrical System9-32 6036, 6042, 8042, 10042, 100542348 27 13/13 EGR Valve Failed Automatic Calibration Procedure2349 2791 5/5 EGR Valve Control Circ

10-16036, 6042, 8042, 10042, 10054Section 10Stabil-TRAK™ System and Boom Interlock SystemContentsPARAGRAPH TITLE PAGE10.1 Stabil-TRAK System Component

Stabil-TRAK™ System and Boom Interlock System10-2 6036, 6042, 8042, 10042, 1005410.1 STABIL-TRAK SYSTEM COMPONENT TERMINOLOGYTo understand the safety

10-36036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock System10.2 BOOM EXTEND INTERLOCK SYSTEM COMPONENT TERMINOLOGY (10054 ONLY)To

Stabil-TRAK™ System and Boom Interlock System10-4 6036, 6042, 8042, 10042, 1005410.3 STABIL-TRAK DESCRIPTIONThe patented rear axle lock or Stabil-TRA

10-56036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock System10.4 STABIL-TRAK ELECTRICAL CIRCUIT OPERATION AND TROUBLESHOOTING (604

General Information and Specifications2-10 6036, 6042, 8042, 10042, 100542.2.3 Hydraulic Hose Torque ChartNote: By definition the “Flats Method“ will

Stabil-TRAK™ System and Boom Interlock System10-6 6036, 6042, 8042, 10042, 10054MH6390LowerTransmissionConnectorsUpperTransmissionConnectorsZF Transm

10-76036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock System10.5 STABIL-TRAK SYSTEM TESTNote: The operator must know that the Sta

Stabil-TRAK™ System and Boom Interlock System10-8 6036, 6042, 8042, 10042, 10054Stabil-TRAK System Test ProceduresStep 1a. Enter the machine.b. Faste

10-96036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock SystemStep 7a. With the parking brake switch ON, move the travel select leve

Stabil-TRAK™ System and Boom Interlock System10-10 6036, 6042, 8042, 10042, 1005410.6 STABIL-TRAK BOOM INTERLOCK ELECTRICAL CIRCUIT OPERATION AND TRO

10-116036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock SystemC = Closed O = OpenRightOutriggerUPSolenoidRightOutriggerDOWNSolenoid

Stabil-TRAK™ System and Boom Interlock System10-12 6036, 6042, 8042, 10042, 1005410.7 BOOM/OUTRIGGER INTERLOCK SYSTEM TEST (10054)Before performing t

10-136036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock SystemBoom/Outrigger Interlock System Test ProceduresStep 1a. Place the mac

Stabil-TRAK™ System and Boom Interlock System10-14 6036, 6042, 8042, 10042, 1005410.8 STABIL-TRAK HYDRAULIC CIRCUIT OPERATION AND TROUBLESHOOTINGThe

2-116036, 6042, 8042, 10042, 10054General Information and Specifications2.3 SPECIFICATIONS2.3.1 Travel Speeds2.3.2 Hydraulic Cylinder PerformanceNote:

JLG Worldwide LocationsAn Oshkosh Corporation Companywww.jlg.com31200353JLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 24

General Information and Specifications2-12 6036, 6042, 8042, 10042, 100542.3.3 Electrical System2.3.4 Engine Performance SpecificationsBatteryType, Ra

2-136036, 6042, 8042, 10042, 10054General Information and Specifications2.3.5 TiresNote: Standard wheel lug nut torque is 430 - 470 lb-ft (583 - 637

General Information and Specifications2-14 6036, 6042, 8042, 10042, 10054b. 6042Size Tire Type Minimum Ply/Star RatingFill Type Pressure13.0 x 24 G-2/

2-156036, 6042, 8042, 10042, 10054General Information and Specificationsc. 8042 d. 10042 & 10054Size Tire Type Minimum Ply/Star RatingFill Type Pr

General Information and Specifications2-16 6036, 6042, 8042, 10042, 100542.4 FLUID AND LUBRICANT CAPACITIESEngine Crankcase OilCapacity with Filter Ch

2-176036, 6042, 8042, 10042, 10054General Information and SpecificationsAxles8042 Before S/N 0160038967 including 016003897110042 Before S/N 016003836

EFFECTIVITY PAGE31200353 6036, 6042, 8042, 10042, 10054iFebruary 23, 2007 - A - Original Issue Of ManualNovember 2, 2010 - B - Revised pages 1-4, 2-3

General Information and Specifications2-18 6036, 6042, 8042, 10042, 100542.5 SERVICE AND MAINTENANCE SCHEDULES2.5.1 10 & 1st 50 HourOH4132ChangeTr

2-196036, 6042, 8042, 10042, 10054General Information and Specifications2.5.2 50, 250 & 1st 500 Hour Note: Engine oil and filter service interval

General Information and Specifications2-20 6036, 6042, 8042, 10042, 100542.5.3 500 & 1000 Hour OH4152500EVERYChange FuelFilter & StrainerCheck

2-216036, 6042, 8042, 10042, 10054General Information and Specifications2.5.4 2000 HourNote: Valve Lash adjustment for QSB 3.3 engine ONLY. See Engin

General Information and Specifications2-22 6036, 6042, 8042, 10042, 100542.6 LUBRICATION SCHEDULESa. 50 Hour (6036, 6042, 8042 & 10042)OH416250EVE

2-236036, 6042, 8042, 10042, 10054General Information and Specificationsb. 50 Hour (10054)OH424250EVERY

General Information and Specifications2-24 6036, 6042, 8042, 10042, 10054c. 250 Hour (6036 & 6042)OA1820EVERY2506042 ONLY

2-256036, 6042, 8042, 10042, 10054General Information and Specificationsd. 250 Hour (8042, 10042 & 10054)OH4172EVERY250

General Information and Specifications2-26 6036, 6042, 8042, 10042, 10054e. 1000 HourOH41811000EVERY

3-16036, 6042, 8042, 10042, 10054Section 3BoomContentsPARAGRAPH TITLE PAGE3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . .

EFFECTIVITY PAGE6036, 6042, 8042, 10042, 10054 31200353ii

Boom3-2 6036, 6042, 8042, 10042, 100543.8 Quick Attach Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-36036, 6042, 8042, 10042, 10054Boom3.1 BOOM SYSTEM COMPONENT TERMINOLOGYThe following illustrations identify the components that are referred to thr

Boom3-4 6036, 6042, 8042, 10042, 100543.2 SAFETY INFORMATION3.3 BOOM SYSTEM - THREE SECTION (6036, 6042, 8042 & 10042)3.3.1 Boom System OperationT

3-56036, 6042, 8042, 10042, 10054Boom3.4.2 Third Boom Section Removal1. Remove any attachment from the quick attach assembly. Refer to Section 3.8.1,

Boom3-6 6036, 6042, 8042, 10042, 1005414. At the rear of the boom, measure the amount of threads protruding beyond each locknut (4) and record the mea

3-76036, 6042, 8042, 10042, 10054Boom2. Remove the capscrews and lockwashers holding the center wear pad spacer mount to the front of the first boom s

Boom3-8 6036, 6042, 8042, 10042, 1005416. Inspect all wear pads for wear. Refer to Section 3.9, “Boom Wear Pads.”17. Remove the extend chain sheave (1

3-96036, 6042, 8042, 10042, 10054Boom8. Label, disconnect and cap the hydraulic hoses attached to both slave cylinders (17). Cap all fittings to keep

Boom3-10 6036, 6042, 8042, 10042, 100546. Using a suitable hoist and slings, lift the boom assembly and position the boom on the frame. Align the moun

3-116036, 6042, 8042, 10042, 10054Boom17. Install the Extend and Retract and Auxiliary (if equipped) tube assemblies to their appropriate bulkhead fit

SECTION CONTENTSSection Subject Page6036, 6042, 8042, 10042, 10054iSection 1Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom3-12 6036, 6042, 8042, 10042, 100546. Before installing the second boom section into the first boom section, place a string (heavy enough to pull

3-136036, 6042, 8042, 10042, 10054Boom5. Install the top, bottom and side wear pads to the rear of the third boom section. If the machine is equipped

Boom3-14 6036, 6042, 8042, 10042, 1005418. Insert the shoulder bolt from the top down and secure in place with a locknut.19. Assemble the two extend c

3-156036, 6042, 8042, 10042, 10054Boom3.5 BOOM SYSTEM - FOUR SECTION (10054)3.5.1 Boom System OperationThe four section boom consists of the fourth, t

Boom3-16 6036, 6042, 8042, 10042, 1005410. Label and remove the hydraulic hoses from the hose reel (17).11. At the rear of the boom, locate the fourth

3-176036, 6042, 8042, 10042, 10054Boom20. Inside the third boom section, remove the hose clamps and hose clamp support bracket (4). 21. Return to the

Boom3-18 6036, 6042, 8042, 10042, 1005430. Inside the boom section, remove the hardware securing the hose carrier (9) to the bottom of the boom.31. On

3-196036, 6042, 8042, 10042, 10054Boom4. Remove the locknuts (13) holding the threaded clevis of the extend chains to the anchor bracket on the rear o

Boom3-20 6036, 6042, 8042, 10042, 100547. Remove the remaining wear pads, shims and hardware. Label and tag each set of wear pads being removed.8. Ins

3-216036, 6042, 8042, 10042, 10054Boom11. Use a hoist and a sling to hold the left Slave cylinder in position. Remove the lockbolt from the Slave cyli

Section Subject Pageii6036, 6042, 8042, 10042, 10054Section 5Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom3-22 6036, 6042, 8042, 10042, 100547. Shim the boom as required using the shims (5) to maintain a 0.10 in (2,5 mm) maximum gap (6) between the boo

3-236036, 6042, 8042, 10042, 10054Boom17. Inside the rear of the boom, slide the threaded clevis end (10) of the retract chain down the right side of

Boom3-24 6036, 6042, 8042, 10042, 100548. Install the center wear pad mount (13) and wear pad to the bottom front of the first boom section.9. Install

3-256036, 6042, 8042, 10042, 10054Boom7. Using a suitable sling, carefully slide the third boom section into the second boom section. Leave enough roo

Boom3-26 6036, 6042, 8042, 10042, 100545. Fold the hose carrier assembly in half, ensure the female ends (19) of the hoses are on the bottom, and care

3-276036, 6042, 8042, 10042, 10054Boom15. Reassemble the hose carrier support to the hose carrier on the right side. Install the hose carrier support

Boom3-28 6036, 6042, 8042, 10042, 1005429. At the front of the first boom section, assemble the hose assemblies and tube assemblies to the mounting pl

3-296036, 6042, 8042, 10042, 10054BoomFollowing are some examples of dynamic shock loading which can impose abnormal loads above the endurance limit o

Boom3-30 6036, 6042, 8042, 10042, 10054Distorted or Battered Link PlatesDistorted or battered link plates (5) on a leaf chain can cause tight joints a

3-316036, 6042, 8042, 10042, 10054Boom3.7.3 Expose Chains for Inspectionf. Extend Chains1. Park the machine on a firm, level surface. Place the transm

Section Subject Pageiii6036, 6042, 8042, 10042, 10054Section 9Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom3-32 6036, 6042, 8042, 10042, 100543.7.5 Boom Chain Tension Check1. Make sure the attachment is attached to the boom head before doing the tension

3-336036, 6042, 8042, 10042, 10054Boom3. If there is no adjustment left on the extend chains, tighten the retract chain locknut (5) at the front on th

Boom3-34 6036, 6042, 8042, 10042, 100543.7.7 Boom Chain Tension Adjustment (10054)a. Outer Boom Chains Tension AdjustmentNote: Always perform Section

3-356036, 6042, 8042, 10042, 10054Boom5. Further chain adjustment can be achieved by loosening all three chain locknuts and moving the rear retract ch

Boom3-36 6036, 6042, 8042, 10042, 10054c. Inner Boom Chain Tension AdjustmentNote: Always perform the Section 3.7.5, “Boom Chain Tension Check,” befo

3-376036, 6042, 8042, 10042, 10054Boomd. Component/Assembly VerificationThe fourth to third boom section separation should be checked when assembling

Boom3-38 6036, 6042, 8042, 10042, 100548. At the rear of the boom, attach one end of a wire to the threaded clevis (9) on the right side extend chain

3-396036, 6042, 8042, 10042, 10054Boom3.7.9 Retract Chain Removal and Replacement (6036, 6042, 8042 & 10042)1. Park the machine on level ground. P

Boom3-40 6036, 6042, 8042, 10042, 1005414. From the rear of the boom, have an assistant push the threaded clevis end of the chain under the chain shea

3-416036, 6042, 8042, 10042, 10054Boom8. Inspect the capscrews for signs of wear or damage. Replace with new capscrews if damaged or worn.9. At the fr

Section Subject Pageiv6036, 6042, 8042, 10042, 10054

Boom3-42 6036, 6042, 8042, 10042, 1005424. At the rear of the boom, tighten the two locknuts on the chain clevis’ until the amount of threads protrudi

3-436036, 6042, 8042, 10042, 10054Boom12. Coat the threads of the threaded clevis with multi-purpose grease.13. Lay the new extend chain on top of the

Boom3-44 6036, 6042, 8042, 10042, 100545. At the front underside of the boom, locate the retract chain locknut (7). Record the amount of threads exten

3-456036, 6042, 8042, 10042, 10054Boom18. Install the boom rear cover.19. Properly connect the battery.20. Remove the Do Not Operate Tags from both th

Boom3-46 6036, 6042, 8042, 10042, 1005413. Attach a wire to the end of the retract chain clevis (12) with a threaded eye or a flat washer tack welded

3-476036, 6042, 8042, 10042, 10054Boom26. Insert the shoulder bolt (17) through the plates and clevis and secure in place with a locknut. Tighten the

Boom3-48 6036, 6042, 8042, 10042, 100543.8 QUICK ATTACH ASSEMBLY This machine is equipped with a quick attach assembly system for easy attachment chan

3-496036, 6042, 8042, 10042, 10054Boom3.9 BOOM WEAR PADSThe wear pads on this machine are flat rectangular wear pads with metal inserts.A total of 32

Boom3-50 6036, 6042, 8042, 10042, 100543.10 BOOM EXTEND AND RETRACT CHAINS3.10.1 Boom Chain Inspection Under normal operating conditions the boom chai

3-516036, 6042, 8042, 10042, 10054BoomEdge WearCheck the chain for wear on the link plate edges caused by running back and forth over the sheave. The

1-16036, 6042, 8042, 10042, 10054Section 1Safety PracticesContentsPARAGRAPH TITLE PAGE1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . .

Boom3-52 6036, 6042, 8042, 10042, 10054Cracked PlatesInspect the chains very carefully, front and back as well as side to side, for any evidence of cr

3-536036, 6042, 8042, 10042, 10054Boom3.10.4 Chain LubricationAfter inspection and before being returned to service, chains must be lubricated with My

Boom3-54 6036, 6042, 8042, 10042, 100543.12 TROUBLESHOOTINGThis section provides an easy reference guide covering the most common problems that occur

3-556036, 6042, 8042, 10042, 10054Boom6. Drooping chain, or jerky boom extend or retract functions.1. Chain(s) tension not properly adjusted. 1. Adjus

Boom3-56 6036, 6042, 8042, 10042, 100549. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and correct as needed. Refer to Secti

4-16036, 6042, 8042, 10042, 10054Section 4Cab and CoversContentsPARAGRAPH TITLE PAGE4.1 Operator Cab and Covers Component Terminology . . . . . . . .

Cab and Covers4-2 6036, 6042, 8042, 10042, 100544.1 OPERATOR CAB AND COVERS COMPONENT TERMINOLOGYTo understand the safety, operation and maintenance i

4-36036, 6042, 8042, 10042, 10054Cab and Covers4.2 OPERATOR CAB4.2.1 Cab Safety 4.2.2 Serial Number DecalThe cab serial number decal is located on the

Cab and Covers4-4 6036, 6042, 8042, 10042, 1005410. Remove the steering column (5), by pushing it down, and removing it through the lower dash panel o

4-56036, 6042, 8042, 10042, 10054Cab and Covers5. Remove the lower dash panel.6. Remove the two capscrews, four flat washers, two pivots and two nuts