Skytrak 6036 Service Manual Manuel d'utilisateur Page 1

An Oshkosh Corporation CompanyService ManualModels6036, 6042, 8042, 10042 & 100546036 & 6042S/N 0160045066 & After including 0160042742, 0

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 Coversfunction. The boom should FRAME LEVEL RIGHT.• Move joystick handle to left, activating frame level func

Cab and Covers4-8 6036, 6042, 8042, 10042, 10054Note: The capscrew (8) at the lower rear position on each side of the heater will be secured with an

4-96036, 6042, 8042, 10042, 10054Cab and Covers9. Working under the cab, loosen the clamp screw (1) and disconnect the heater control cable (2) from t

Cab and Covers4-10 6036, 6042, 8042, 10042, 10054the cab and remove it from the frame. Readjust the position of the sling as needed to help balance th

4-116036, 6042, 8042, 10042, 10054Cab and Covers13. Connect the heater control cable (2) to the heater control valve (1).14. Fill the cooling system c

Cab and Covers4-12 6036, 6042, 8042, 10042, 10054This Page Intentionally Left Blank

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)To understand the s

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

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

Axles, Drive Shafts, Wheels and Tires5-4 6036, 6042, 8042, 10042, 100545.3 AXLE, DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGY (8042)To understand the s

5-56036, 6042, 8042, 10042, 10054Axles, Drive Shafts, Wheels and Tires5.4 AXLE, DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGY (10042 & 10054)To unde

Axles, Drive Shafts, Wheels and Tires5-6 6036, 6042, 8042, 10042, 100545.5 GENERAL INFORMATIONNote: To help ensure optimum performance, the drive sha

5-76036, 6042, 8042, 10042, 10054Axles, Drive Shafts, Wheels and Tires5.6.4 Axle Maintenance CLEANING: Clean parts with machined or ground surfaces (s

Axles, Drive Shafts, Wheels and Tires5-8 6036, 6042, 8042, 10042, 10054Rear Axle: Open the right and left side engine compartment doors to gain access

5-96036, 6042, 8042, 10042, 10054Axles, Drive Shafts, Wheels and Tires12. Remove the blocks from the front and rear of both tires on the other axle.No

Axles, Drive Shafts, Wheels and Tires5-10 6036, 6042, 8042, 10042, 100548. Label, disconnect and cap the outrigger hydraulic hoses (6). Cap all fittin

5-116036, 6042, 8042, 10042, 10054Axles, Drive Shafts, Wheels and Tires1. Park the machine on a firm, level surface, level the machine, fully retract

Axles, Drive Shafts, Wheels and Tires5-12 6036, 6042, 8042, 10042, 10054removing it from beneath the machine. Place the axle on a suitable support or

5-136036, 6042, 8042, 10042, 10054Axles, Drive Shafts, Wheels and Tires5.7 AXLE ASSEMBLY AND DRIVE SHAFT TROUBLESHOOTINGProblem Cause Remedy1. Excessi

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 Tires5-14 6036, 6042, 8042, 10042, 100544. Oil leaking from axle (differential housing and/or axle housings).1. Drain

5-156036, 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 Tires5-16 6036, 6042, 8042, 10042, 100545.8 DRIVE SHAFTS5.8.1 Drive Shaft Inspection and ServiceWhenever servicing the

5-176036, 6042, 8042, 10042, 10054Axles, Drive Shafts, Wheels and Tires5.9 WHEELS AND TIRESIt is recommended that a replacement tire to be the same si

Axles, Drive Shafts, Wheels and Tires5-18 6036, 6042, 8042, 10042, 100545.9.2 Installing Wheel and Tire Assembly onto MachineNote: The wheel and tire

5-196036, 6042, 8042, 10042, 10054Axles, Drive Shafts, Wheels and Tires3. Using a feeler gauge, check thickness of lined/inner disc (6). If thickness

Axles, Drive Shafts, Wheels and Tires5-20 6036, 6042, 8042, 10042, 100545. Attach a remote portable hydraulic pressurizing unit to the parking brake g

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 NUMBERTransmission serial number plate (1) is located on pump side (front) of tra

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

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

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 ContentsPARAGRAPH TITLE PAGE7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine7-2 6036, 6042, 8042, 10042, 100547.1 INTRODUCTION7.1.1 Disclaimer and ScopeThese instructions are written for worldwide use. In territories whe

7-36036, 6042, 8042, 10042, 10054EngineMAQ0490TURBOCHARGEROIL FILTERALTERNATORTHERMOSTATSTARTERFUEL INJECTOR PUMPFUEL FILTERIF EQUIPPED FOR ULSMAQ0480

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

Engine7-4 6036, 6042, 8042, 10042, 100547.4 ENGINE COOLING SYSTEM7.4.1 Coolant System Pressure CapIf equipped for ULS, the surge tank cap is designed

7-56036, 6042, 8042, 10042, 10054EngineIf equipped for LS, label and disconnect all hoses and tubes attached to radiator (2), charge air cooler (3) an

Engine7-6 6036, 6042, 8042, 10042, 10054Note: Have a dry chemical (Class B) fire extinguisher near the work area.5. Remove the fuel/hydraulic oil tan

7-76036, 6042, 8042, 10042, 10054Enginef. Fuel/Hydraulic Oil Tank Installation1. Attach tank to a suitable lifting device at lift point.2. Place tank

Engine7-8 6036, 6042, 8042, 10042, 100547.7 ENGINE EXHAUST SYSTEMRattles and noise vibrations in the exhaust system are usually caused by misalignment

7-96036, 6042, 8042, 10042, 10054Engine10. Lift right side and slip bolts up and through slots on the right side of frame. 11. Place mounting plate on

Engine7-10 6036, 6042, 8042, 10042, 10054The following steps may be required to achieve distance (C) (Expanded web).• Loosen the turbocharger clamp to

7-116036, 6042, 8042, 10042, 10054Engine7.8 AIR CLEANER ASSEMBLYNote: Refer to the appropriate Operation & Safety Manual for your machine for the

Engine7-12 6036, 6042, 8042, 10042, 100547.8.3 Air Cleaner Assembly Removal - LS1. Park machine on a firm, level surface, level machine, fully retract

7-136036, 6042, 8042, 10042, 10054Engine14. Remove the exhaust pipe and muffler system. Refer to Section 7.7.1, “Exhaust System Removal.”15. At the fr

2-36036, 6042, 8042, 10042, 10054General Information and Specifications2.3 TORQUE CHARTS2.3.1 SAE Fastener Torque ChartValues for Zinc Yellow Chromate

Engine7-14 6036, 6042, 8042, 10042, 1005420. Check for leaks from the engine, main hydraulic pump and lines, transmission, hydraulic reservoir and fue

7-156036, 6042, 8042, 10042, 10054Engine4. Install the access cover plate over the drive shaft and assemble the drive shaft flange to the coupler usin

Engine7-16 6036, 6042, 8042, 10042, 10054This Page Intentionally Left Blank

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 LEVEL CYLINDERLIFT/LOWER CYLINDERSHYDRAULIC FLUID RESERVOIREXTEND/RETRACT CYLINDERMAIN CO

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

8-56036, 6042, 8042, 10042, 10054Hydraulic System1. Park the machine on a firm, level surface. Engage the park brake, place the travel select lever in

Hydraulic System8-6 6036, 6042, 8042, 10042, 10054c. Pressure Specifications (6036)MA6242FRONT STEERINGCYLINDERPOWERSTEERINGUNITRTPLBRAKEVALVETPLSREOP

8-76036, 6042, 8042, 10042, 10054Hydraulic SystemTest Site Hydraulic Pump Flow Test1To check flow readings, a flow meter capable of measuring 60 gpm (

General Information and Specifications2-4 6036, 6042, 8042, 10042, 100542.3.1 SAE Fastener Torque Chart (Continued)Values for Zinc Yellow Chromate Fas

Hydraulic System8-8 6036, 6042, 8042, 10042, 10054d. Pressure Specifications (6042)MA9242TSFVVLSGPLSVGSTABILIZERCYLINDERFRONT STEERINGCYLINDERREATTACH

8-96036, 6042, 8042, 10042, 10054Hydraulic SystemTest LocationHydraulic Pump Flow Test1To check flow readings, a flow meter capable of measuring 60 gp

Hydraulic System8-10 6036, 6042, 8042, 10042, 10054e. Pressure Specifications (8042, 10042 & 10054)MH6172REAR AXLERERIGHTSLAVECYLINDERREBAPTSTEERS

8-116036, 6042, 8042, 10042, 10054Hydraulic SystemTest LocationHydraulic Pump Flow Test1To check flow readings, a flow meter capable of measuring 60 g

Hydraulic System8-12 6036, 6042, 8042, 10042, 100548.4.2 Hydraulic Schematicsa. 6036UNLESS OTHERWISE SPECIFIED, ALLDIMENSIONS ARE IN INCHES.4000PSIHOI

8-136036, 6042, 8042, 10042, 10054Hydraulic Systemb. 6042UNLESS OTHERWISE SPECIFIED, ALLDIMENSIONS ARE IN INCHES.4000PSIHOIST CYLINDER - 5.00 X 2.75 X

Hydraulic System8-14 6036, 6042, 8042, 10042, 10054c. 8042 (if equipped for ULS).089.089.073.0890FEMALEDISCONNECTON L.H.SIDEOF BOOMMALEDISCONNECT ONR.

8-156036, 6042, 8042, 10042, 10054Hydraulic Systemd. 8042 (if equipped for LS).089.073.0890FEMALEDISCONNECTON L.H.SIDEOF BOOMMALEDISCONNECT ONR.H.SIDE

Hydraulic System8-16 6036, 6042, 8042, 10042, 10054e. 10042 (if equipped for ULS)STEERING SELECTORVALV EMANIFOLDREARFRONTabLRPTLRBARTP4WHEELSTEERCRABS

8-176036, 6042, 8042, 10042, 10054Hydraulic Systemf. 10042 (if equipped for LS).089.073.0890FEMALEDISCONNECTON L.H.SIDEOF BOOMMALEDISCONNECT ONR.H.SID

2-56036, 6042, 8042, 10042, 10054General Information and Specifications2.3.1 SAE Fastener Torque Chart (Continued)Values for Magni Coating Fasteners (

Hydraulic System8-18 6036, 6042, 8042, 10042, 10054g. 10054 (if equipped for ULS)STEERING SELECTORVALV EMANIFOLDREARFRONTabLRPTLRBARTP4WHEELSTEERCRABS

8-196036, 6042, 8042, 10042, 10054Hydraulic Systemh. 10054 (if equipped for LS)STEERING SELECTORVALV EMANIFOLDREARFRONTabLRPTLRBARTP4WHEELSTEERCRABSTE

Hydraulic System8-20 6036, 6042, 8042, 10042, 100548.5 HYDRAULIC RESERVOIRHydraulic reservoir (1) and fuel tank are one unit. They are located on the

8-216036, 6042, 8042, 10042, 10054Hydraulic System7. Install the four previously removed nuts securing the hydraulic filter assembly to the hydraulic

Hydraulic System8-22 6036, 6042, 8042, 10042, 10054d. Load Sense Relief Adjustment1. With park brake on and engine at high idle (2650 rpm), fully retr

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

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 System2. Remove the plastic cap from the brake bleeder (2). Attach one end of a length of transparent tubi

General Information and Specifications2-6 6036, 6042, 8042, 10042, 100542.3.1 SAE Fastener Torque Chart (Continued)Values for Magni Coating Fasteners

Hydraulic System8-28 6036, 6042, 8042, 10042, 10054b. Steer Select Manifold and Valve Disassembly, Cleaning, Inspection and Assembly1. Place the steer

8-296036, 6042, 8042, 10042, 10054Hydraulic System3. Temporarily block up or support the raised boom.4. Open the rear door. Allow the system fluids to

Hydraulic System8-30 6036, 6042, 8042, 10042, 100542. Remove the solenoid valve assemblies (2) from the outrigger valve by removing the four capscrews

8-316036, 6042, 8042, 10042, 10054Hydraulic System7. Label, disconnect and cap hydraulic hoses and electrical plugs connected to extend lockout valve.

Hydraulic System8-32 6036, 6042, 8042, 10042, 100544. Label, disconnect and cap or plug hydraulic hoses in relation to the cylinder.5. Attach a suitab

8-336036, 6042, 8042, 10042, 10054Hydraulic Systembrass wire brush. Wipe clean with Loctite Cleaner prior to reassembly.d. Cylinder Inspection1. Inspe

Hydraulic System8-34 6036, 6042, 8042, 10042, 100548.8.2 Cylinder Pressure CheckingAttach 4000 psi (276 bar) gauge to test port on hydraulic pump to c

8-356036, 6042, 8042, 10042, 10054Hydraulic System8.8.4 Cylinder Torque Specificationsa. Lift/Lower Cylinderb. Extend/Retract Cylinderc. Tilt Cylinder

Hydraulic System8-36 6036, 6042, 8042, 10042, 10054f. Compensation Cylinderg. Swing Carriage Cylinder (If Equipped)h. Side Tilt Carriage Cylinder (If

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

2-76036, 6042, 8042, 10042, 10054General Information and Specifications2.3.1 SAE Fastener Torque Chart (Continued)Values for Magni Coating Fasteners (

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 Relays232264710581112131415161718192021MAQ03502324252627282930236471058

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 Electrical Schematic (if equipped for ULS) (Continued)SW216SW217HV226HV227HV228HV22920 BLK (1

9-76036, 6042, 8042, 10042, 10054Electrical System9.5.1 Electrical Schematic (if equipped for ULS) (Continued)HV244HV245HV246HV247HV248HV249HV250HV251

Electrical System9-8 6036, 6042, 8042, 10042, 100549.5.1 Electrical Schematic (if equipped for ULS) (Continued)160 RED (12)160 RED (12)158 BLK (16)158

9-96036, 6042, 8042, 10042, 10054Electrical System9.5.1 Electrical Schematic (if equipped for ULS) (Continued)APS SUPPLY 1 BLK (18)APS SUPPLY 1 BLK (1

Electrical System9-10 6036, 6042, 8042, 10042, 100549.5.2 Electrical Schematic(if equipped for LS)APS SIGNAL 1 VIO (18)APS SIGNAL 1 VIO (18)APS SUPPLY

9-116036, 6042, 8042, 10042, 10054Electrical System9.5.2 Electrical Schematic (if equipped for LS) (Continued)SW216SW217HV226HV227HV228HV22920 BLK (14

General Information and Specifications2-8 6036, 6042, 8042, 10042, 100542.3.1 SAE Fastener Torque Chart (Continued)Values for Zinc Yellow Chromate Fas

Electrical System9-12 6036, 6042, 8042, 10042, 100549.5.2 Electrical Schematic (if equipped for LS) (Continued)HV244HV245HV246HV247HV248HV249HV250HV25

9-136036, 6042, 8042, 10042, 10054Electrical System9.5.2 Electrical Schematic (if equipped for LS) (Continued)160 RED (12)160 RED (12)158 BLK (16)158

Electrical System9-14 6036, 6042, 8042, 10042, 100549.5.2 Electrical Schematic (if equipped for LS) (Continued)ASP SUPP 1 BLK (18)ASP SUPP 1 BLK (18)A

9-156036, 6042, 8042, 10042, 10054Electrical System9.6 ENGINE START CIRCUIT9.6.1 StarterThe starter (1) is located on the left side of the engine.a. T

Electrical System9-16 6036, 6042, 8042, 10042, 100546. Support starter and remove fasteners securing starter to engine. Remove negative (-) ground cab

9-176036, 6042, 8042, 10042, 10054Electrical System4. Run the engine and check the alternator for noise. A loose drive pulley, loose mounting hardware

Electrical System9-18 6036, 6042, 8042, 10042, 100549.8 WINDOW WIPER/WASHER WINDSHIELD WIPER MOTOR9.8.1 Windshield Wiper Motora. RemovalNote: It may

9-196036, 6042, 8042, 10042, 10054Electrical System9. Turn ignition key switch to the RUN position, and operate windshield wiper in both LOW and HIGH

Electrical System9-20 6036, 6042, 8042, 10042, 100549.8.3 Windshield Washer ReservoirThe windshield washer motor and reservoir (7) is a unit and canno

9-216036, 6042, 8042, 10042, 10054Electrical System7. Remove the screws and backing locknuts from the cab heater and fan control panel.8. Pull the con

2-96036, 6042, 8042, 10042, 10054General Information and Specifications2.3.2 Metric Fastener Torque ChartValues for Zinc Yellow Chromate Fasteners (Re

Electrical System9-22 6036, 6042, 8042, 10042, 100543. Properly connect the battery.4. Remove the Do Not Operate Tags from both the ignition key switc

9-236036, 6042, 8042, 10042, 10054Electrical System9.10.3 Transmission Solenoid Valves Note: If the transmission is not shifting properly, the transm

Electrical System9-24 6036, 6042, 8042, 10042, 100549.10.5 Service Brake SwitchThe service brake switch (12) works in conjunction with the Stabil-TRAK

9-256036, 6042, 8042, 10042, 10054Electrical System8. Using the switch dust cover and the locknut in combination, position the brake switch so the Sta

Electrical System9-26 6036, 6042, 8042, 10042, 100549.10.7 Boom Extend Interlock Sensor(10054 only)The boom extend interlock sensor is located on the

9-276036, 6042, 8042, 10042, 10054Electrical System9.10.8 Outrigger Pressure Switches (10054 Only)a. Removal1. Park the vehicle on a firm, level surfa

Electrical System9-28 6036, 6042, 8042, 10042, 100549.12 DASH SWITCHESNote: For information on the front windshield wiper, rear window wiper and wash

9-296036, 6042, 8042, 10042, 10054Electrical System9.12.2 Dash Switchesa. Switch Removal1. Park the machine on a firm, level surface, level the machin

Electrical System9-30 6036, 6042, 8042, 10042, 100549.13 TROUBLESHOOTING9.13.1 Fault DetectionFaults are detected while key switch is in RUN position,

9-316036, 6042, 8042, 10042, 10054Electrical System9.13.3 Engine Fault Codes ChartFault CodeSPN CodeFMI CodeLAMPArea DescriptionDiagnostic Description

General Information and Specifications2-10 6036, 6042, 8042, 10042, 100542.3.2 Metric Fastener Torque Chart (Continued)Values for Zinc Yellow Chromate

Electrical System9-32 6036, 6042, 8042, 10042, 10054141 100 4 AmberEngine OilPressureOil Pressure Sensor Circuit—Voltage Below Normal, or Shorted to L

9-336036, 6042, 8042, 10042, 10054Electrical System153 105 3 AmberIntakeManifold #1TempIntake Manifold Air Temperature Sensor Circuit—Voltage Above No

Electrical System9-34 6036, 6042, 8042, 10042, 10054422 111 2 Amber Coolant Level Coolant Level - Data Erratic, Intermittent, or Incorrect2448 111 17A

9-356036, 6042, 8042, 10042, 10054Electrical System489 191 18 AmberTransmission Output Shaft SpeedTransmission Output Shaft Speed—Data Valid but Below

Electrical System9-36 6036, 6042, 8042, 10042, 100541117 627 2 None Power SupplyPower Lost With Ignition On—Data Erratic, Intermittent, or Incorrect34

9-376036, 6042, 8042, 10042, 10054Electrical System2195 703 14Auxiliary Equipment Sensor Input 3 Engine Protection Critical— Special Instructions731 7

Electrical System9-38 6036, 6042, 8042, 10042, 10054271 1347 4 AmberFuel Pump Pressurizing Assembly #1High Fuel Pressure Solenoid Valve Circuit—Voltag

9-396036, 6042, 8042, 10042, 10054Electrical System386 3509 3 Amber5 Volts DC SupplySensor Supply Voltage #1 Circuit – Voltage Above Normal, orShorted

Electrical System9-40 6036, 6042, 8042, 10042, 100543921 5421 7 AmberEngine Turbocharger Wastegate Actuator—Mechanical system not responding or out of

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

2-116036, 6042, 8042, 10042, 10054General Information and Specifications2.3.2 Metric Fastener Torque Chart (Continued)Values for Magni Coated Fastener

Stabil-TRAK™ System and Boom Interlock System10-2 6036, 6042, 8042, 10042, 1005410.11 Stabil-TRAK™ Hydraulic Circuit Operation and Troubleshooting .

10-36036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock System10.1 STABIL-TRAK™ SYSTEM COMPONENT TERMINOLOGYTo understand the safet

Stabil-TRAK™ System and Boom Interlock System10-4 6036, 6042, 8042, 10042, 1005410.2 BOOM EXTEND INTERLOCK SYSTEM COMPONENT TERMINOLOGY (10054 ONLY)T

10-56036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock System10.3 STABIL-TRAK™ DESCRIPTIONPatented rear axle lock or Stabil-TRAK™

Stabil-TRAK™ System and Boom Interlock System10-6 6036, 6042, 8042, 10042, 1005410.4 STABIL-TRAK™ OPERATION10.4.1 Understanding Stabil-TRAK™ System

10-76036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock System10.4.2 Stabil-TRAK™ Solenoid ValvesThere are five Stabil-TRAK™ soleno

Stabil-TRAK™ System and Boom Interlock System10-8 6036, 6042, 8042, 10042, 1005410.4.4 Relay TestingIf after checking the electrical system, a relay

10-96036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock Systemb. Removal1. Park the machine on a firm, level surface, level the mach

Stabil-TRAK™ System and Boom Interlock System10-10 6036, 6042, 8042, 10042, 1005410.6 BOOM EXTEND INTERLOCK SYSTEM OPERATION (10054 ONLY)The ultimate

10-116036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock System10.7 STABIL-TRAK™ SYSTEM TESTNote: The operator must know that the

General Information and Specifications2-12 6036, 6042, 8042, 10042, 100542.3.2 Metric Fastener Torque Chart (Continued)Values for Magni Coated Fastene

Stabil-TRAK™ System and Boom Interlock System10-12 6036, 6042, 8042, 10042, 10054Stabil-TRAK System Test ProceduresStep 1a. Place the vehicle on a le

10-136036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock SystemStep 7a. With the parking brake switch ON, move the travel select lev

Stabil-TRAK™ System and Boom Interlock System10-14 6036, 6042, 8042, 10042, 1005410.8 STABIL-TRAK™ BOOM INTERLOCK ELECTRICAL CIRCUIT OPERATION AND TR

10-156036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock System6042, 8042 and 10042 Stabil-TRAK™ Electrical CircuitFREE PIVOT ModeFR

Stabil-TRAK™ System and Boom Interlock System10-16 6036, 6042, 8042, 10042, 10054SLOW PIVOT MODE1.Ignition “ON”4.PB & SB Released6042, 8042 and 1

10-176036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock System6042, 8042 and 10042 Stabil-TRAK™ Electrical CircuitLOCKED MODELOCKED

Stabil-TRAK™ System and Boom Interlock System10-18 6036, 6042, 8042, 10042, 1005410.9 STABIL-TRAK™ BOOM INTERLOCK ELECTRICAL CIRCUIT OPERATION AND TR

10-196036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock SystemNote: If an outrigger is raised or a pressure switch is defective, b

Stabil-TRAK™ System and Boom Interlock System10-20 6036, 6042, 8042, 10042, 1005410054 Stabil-TRAK™ Electrical Circuit Boom Extend Mode 1MODE 11.Igni

10-216036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock SystemMODE 21.Ignition “ON”4.PB Released10054 Stabil-TRAK™ Electrical Circu

2-136036, 6042, 8042, 10042, 10054General Information and Specifications2.3.3 Hydraulic Hose Torque ChartNote: By definition the “Flats Method” will

Stabil-TRAK™ System and Boom Interlock System10-22 6036, 6042, 8042, 10042, 1005410054 Stabil-TRAK™ Electrical CircuitBoom Extend Mode 3MODE 31.Ignit

10-236036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock System10.10 BOOM/OUTRIGGER INTERLOCK SYSTEM TESTBefore performing the follo

Stabil-TRAK™ System and Boom Interlock System10-24 6036, 6042, 8042, 10042, 10054Boom/Outrigger Interlock System Test ProceduresStep 1a. Place the ve

10-256036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock System10.11 STABIL-TRAK™ HYDRAULIC CIRCUIT OPERATION AND TROUBLESHOOTINGThe

Stabil-TRAK™ System and Boom Interlock System10-26 6036, 6042, 8042, 10042, 1005410.11.1 Stabil-TRAK™ Cylinder Oil FlowIn the FREE PIVOT and SLOW PIV

10-276036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock SystemThis Page Intentionally Left Blank

Stabil-TRAK™ System and Boom Interlock System10-28 6036, 6042, 8042, 10042, 1005410.11.2 Hydraulic Circuit Operation - FREE PIVOT Mode, Rod Oil OutCo

10-296036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock System10.11.3 Hydraulic Troubleshooting - FREE PIVOT Mode, Rod Oil OutNotOK

Stabil-TRAK™ System and Boom Interlock System10-30 6036, 6042, 8042, 10042, 1005410.11.4 Hydraulic Circuit Operation - FREE PIVOT Mode, Base Oil OutC

10-316036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock System10.11.5 Hydraulic Troubleshooting - FREE PIVOT Mode, Base Oil OutCond

General Information and Specifications2-14 6036, 6042, 8042, 10042, 100542.4 SPECIFICATIONS2.4.1 Travel Speeds2.4.2 Hydraulic Cylinder PerformanceNote

Stabil-TRAK™ System and Boom Interlock System10-32 6036, 6042, 8042, 10042, 1005410.11.6 Hydraulic Circuit Operation - SLOW PIVOT Mode, Rod Oil OutCo

10-336036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock System10.11.7 Hydraulic Troubleshooting - SLOW PIVOT Mode, Rod Oil OutWhile

Stabil-TRAK™ System and Boom Interlock System10-34 6036, 6042, 8042, 10042, 1005410.11.8 Hydraulic Circuit Operation - SLOW PIVOT Mode, Base Oil OutC

10-356036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock System10.11.9 Hydraulic Troubleshooting - SLOW PIVOT Mode, Base Oil OutCond

Stabil-TRAK™ System and Boom Interlock System10-36 6036, 6042, 8042, 10042, 1005410.11.10 Hydraulic Circuit Operation - LOCKED MODEa. Conditions:• Bo

10-376036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock System10.11.12 Hydraulic Troubleshooting - LOCKED MODE, Will Not Frame Leve

Stabil-TRAK™ System and Boom Interlock System10-38 6036, 6042, 8042, 10042, 1005410.11.13 Hydraulic Circuit Operation - LOCKED MODE, Frame Level Left

10-396036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock System10.11.14 Hydraulic Troubleshooting - LOCKED MODE, Will Not Frame Leve

Stabil-TRAK™ System and Boom Interlock System10-40 6036, 6042, 8042, 10042, 1005410.12 BOOM EXTEND SYSTEM HYDRAULIC CIRCUIT OPERATION AND TROUBLESHOO

10-416036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock SystemThis Page Intentionally Left Blank

2-156036, 6042, 8042, 10042, 10054General Information and Specifications2.4.3 Electrical System2.4.4 Engine Performance Specifications BatteryType, Ra

Stabil-TRAK™ System and Boom Interlock System10-42 6036, 6042, 8042, 10042, 1005410.12.2 Hydraulic Circuit Operation - Extend Interlock ModeOperation

10-436036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock SystemERERINTTATTA CHTILTPFRAMESWAYEXT/RETLFT/LWRAUXBOOM LOCKOUT VALVEC1V1T

Stabil-TRAK™ System and Boom Interlock System10-44 6036, 6042, 8042, 10042, 1005410.12.4 Hydraulic Circuit Operation - Outrigger Interlock ModeOperat

10-456036, 6042, 8042, 10042, 10054Stabil-TRAK™ System and Boom Interlock SystemINTTATTA CHTILTPFRAMESWAYEXT/RETLFT/LWRAUXBOOM LOCKOUT VALVEC1V1TOUTR

Stabil-TRAK™ System and Boom Interlock System10-46 6036, 6042, 8042, 10042, 10054This Page Intentionally Left Blank

JLG Worldwide LocationsAn Oshkosh Corporation Companywww.jlg.comJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: +1-717-485-5161C

General Information and Specifications2-16 6036, 6042, 8042, 10042, 100542.4.5 TiresNote: Standard wheel lug nut torque is 430–470 lb-ft (583–637 Nm)

2-176036, 6042, 8042, 10042, 10054General Information and Specifications2.5 FLUID SPECIFICATIONSIf Equipped for ULSCompartment or System Type and Clas

EFFECTIVITY PAGE31200796 6036, 6042, 8042, 10042, 10054iSeptember 28, 2012 - A - Original Issue Of ManualMarch 17, 2014 - B - Revise pages 2-2 thru 2-

General Information and Specifications2-18 6036, 6042, 8042, 10042, 10054If Equipped for LSCompartment or System Type and Classification ViscositiesAm

2-196036, 6042, 8042, 10042, 10054General Information and Specifications2.6 FLUID AND LUBRICANT CAPACITIESEngine Crankcase OilCapacity w/Filter Change

General Information and Specifications2-20 6036, 6042, 8042, 10042, 100542.7 SERVICE AND MAINTENANCE SCHEDULES2.7.1 10 & 1st 50 HourChangeTransmis

2-216036, 6042, 8042, 10042, 10054General Information and Specifications2.7.2 50, 250 & 1st 500 Hour Note: Engine oil and filter service interval

General Information and Specifications2-22 6036, 6042, 8042, 10042, 100542.7.3 500 & 1000 Hour OH4970500EVERYChange FuelFiltersCheck WheelLug NutT

2-236036, 6042, 8042, 10042, 10054General Information and Specifications2.7.4 2000 HourNote: Valve Lash adjustment for QSB 3.3 engine ONLY. See Engin

General Information and Specifications2-24 6036, 6042, 8042, 10042, 100542.8 LUBRICATION SCHEDULES2.8.1 50 Houra. 6036, 6042, 8042 & 10042

2-256036, 6042, 8042, 10042, 10054General Information and SpecificationsOH416250EVERY

General Information and Specifications2-26 6036, 6042, 8042, 10042, 10054b. 10054OH424250EVERY

2-276036, 6042, 8042, 10042, 10054General Information and Specifications2.8.2 250 Houra. 6036 & 6042 OA1820EVERY2506042 ONLY

READ THIS FIRST 6036, 6042, 8042, 10042, 10054 31200796iiModificationsModifications to this machine may affect compliance with Industry Standards and/

General Information and Specifications2-28 6036, 6042, 8042, 10042, 10054b. 8042, 10042 & 10054OH4172EVERY250

2-296036, 6042, 8042, 10042, 10054General Information and Specifications2.8.3 1000 HourOH41811000EVERY

General Information and Specifications2-30 6036, 6042, 8042, 10042, 10054This Page Intentionally Left Blank

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

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 quick attach assembly.Note: If replacing the third

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, 10054Boom3.4.3 Second Boom Section Removal1. At the front of the first boom section, remove the top, bottom and side wear

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

Boom3-8 6036, 6042, 8042, 10042, 10054Reposition the slings as needed so the second boom section balances when removed from the first boom section. Se

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

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, 10054Boom16. Uncap and connect the hydraulic hoses and attach to their appropriate cylinder locations.17. Install the Ext

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

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

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 Compensation cylinder in position. Remove the lockbolt from the Com

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

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

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 Inspectionc. Extend Chains1. Park the machine on a firm, level surface. Place the transm

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

Section Subject Pageiv6036, 6042, 8042, 10042, 10054

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

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

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

Boom3-48 6036, 6042, 8042, 10042, 100543.8 QUICK ATTACH ASSEMBLY 3.8.1 Quick Attach Removal1. Remove the lock bolt holding the Attachment Tilt cylinde

3-496036, 6042, 8042, 10042, 10054Boom• Maintain a total boom section clearance (5) of 0.070 - 0.130 in (1,78 - 3,30 mm) both the horizontal and verti

Boom3-50 6036, 6042, 8042, 10042, 100543.11 TROUBLESHOOTINGThis section provides an easy reference guide covering the most common problems that occur

3-516036, 6042, 8042, 10042, 10054Boom6. Drooping chain, or jerky boom extend or retract functions.1. Chain(s) tension not properly adjusted. 1. Adjus

Boom3-52 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