Service Manual Models 6036, 6042, 8042, 10042 & 10054 6036 & 6042 S/N 0160045066 & After including 0160042742, 0160042747 & 0160042755 8042, 10042 & 10054 S/N 0160045250 & After including 0160042754, 0160042762, 0160042877, 0160042911, 0160043185, 0160043220 & 0160043244 excluding 0160045255 31200796 Revised October 10, 2014 An Oshkosh Corporation Company
EFFECTIVITY PAGE September 28, 2012 - A - Original Issue Of Manual March 17, 2014 - B - Revise pages 2-2 thru 2-12, 2-17, 2-18, 5-8, 7-8, 8-6, 8-8, 8-10, 8-11, 8-20, 8-22, 9-4, 9-31 thru 9-40. October 10, 2014 - C - Revise pages 1-4, 4-6, 7-2, 7-13, 7-14.
READ THIS FIRST Modifications Modifications to this machine may affect compliance with Industry Standards and/or Governmental Regulations. Any modification must be approved by JLG. Machine Configuration Two configurations of each machine are included in this manual. Determine if machine is equipped with Ultra Low Sulfur Fuel Decal (1) as indicated below.
SECTION CONTENTS Section Subject Section 1 Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 1.2 1.3 1.4 1.5 1.6 1.7 Page 1-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation & Safety Manual . . . . . . . .
Section Subject Page Section 5 Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5-1 Axle, Drive Shaft and Wheel Component Terminology (6036). . . . . . . . . . . . . . . . . . . . Axle, Drive Shaft and Wheel Component Terminology (6042). . . . . . . . . . . . . . . . . . . . Axle, Drive Shaft and Wheel Component Terminology (8042). . . . . . . . . . . . . . . . . . . .
Section Subject Section 9 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12 9.13 Page 9-1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information . . . . . . . . . . . . . . .
Section iv Subject Page 6036, 6042, 8042, 10042, 10054
Section 1 Safety Practices Contents PARAGRAPH 1.1 1.2 1.3 1.4 1.5 1.6 1.7 TITLE Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Practices 1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS This service manual provides general directions for accomplishing service and repair procedures. Following the procedures in this manual will help assure safety and equipment reliability. Place Do Not Operate Tags on the ignition key switch and the steering wheel before attempting to perform any service or maintenance. Remove key and disconnect battery leads.
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.
Safety Practices 1.6.4 Operational Hazards ENGINE: Stop the engine before performing any service unless specifically instructed otherwise. VENTILATION: Avoid prolonged engine operation in enclosed areas without adequate ventilation. SOFT SURFACES AND SLOPES: NEVER work on a machine that is parked on a soft surface or slope. The machine must be on a hard level surface, with the wheels blocked before performing any service.
Section 2 General Information and Specifications Contents PARAGRAPH 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 TITLE Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . .
General Information and Specifications 2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION 2.2 THREAD LOCKING COMPOUND JLG P/N Loctite® ND Industries Description 0100011 242TM Vibra-TITETM121 Medium Strength (Blue) 1001095650 243TM Vibra-TITETM122 Medium Strength (Blue) 0100019 271TM Vibra-TITETM140 High Strength (Red) 0100071 262TM Vibra-TITETM131 Medium - High Strength (Red) Note: Loctite® 243TM can be substituted in place of Loctite® 242TM.
General Information and Specifications 2.3 TORQUE CHARTS 2.3.1 SAE Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Tensile Stress Area Clamp Load Torque (Dry) Torque Lubricated Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 0.1120 0.00604 380 8 0.9 6 0.7 48 0.1120 0.00661 420 9 1.0 7 0.8 32 0.1380 0.00909 580 16 1.8 12 1.4 40 0.1380 0.01015 610 18 2.0 13 1.
General Information and Specifications 2.3.1 SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Tensile Stress Clamp Load Area Torque (Dry or Loctite® 263) K=0.20 Torque (Loctite® 242TM or 271TM or Vibra-TITETM 111 or 140) K=0.18 IN-LB [N.m] Torque (Loctite® 262TM or Vibra-TITETM 131) K=0.15 IN-LB [N.m] Size TPI Bolt Dia In Sq In 4 40 0.1120 0.00604 48 0.1120 0.00661 6 32 0.1380 0.00909 40 0.1380 0.
General Information and Specifications 2.3.1 SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque (Dry) K=0.17 Tensile Stress Clamp Load Area Torque (Loctite® 242TM or 271TM or Vibra-TITETM 111 or 140) K=0.16 IN-LB [N.m] Torque (Loctite® 262TM or Vibra-TITETM 131) K=0.15 IN-LB [N.m] Size TPI Bolt Dia In Sq In LB IN-LB [N.m] 4 40 0.1120 0.00604 380 7 0.8 48 0.1120 0.00661 420 8 0.9 32 0.1380 0.
General Information and Specifications 2.3.1 SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Tensile Stress Clamp Load Area Torque (Dry or Loctite® 263) K=0.17 Torque (Loctite® 242TM or 271TM or Vibra-TITETM 111 or 140) K=0.16 IN-LB [N.m] Torque (Loctite® 262TM or Vibra-TITETM 131) K=0.15 IN-LB [N.m] Size TPI Bolt Dia In Sq In 4 40 0.1120 0.00604 48 0.1120 0.00661 6 32 0.1380 0.00909 40 0.1380 0.
General Information and Specifications 2.3.1 SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SOCKET HEAD CAP SCREWS Tensile Stress Clamp Load Area See Note 4 Size TPI Bolt Dia In Sq In 4 40 0.1120 0.00604 48 0.1120 0.00661 6 32 0.1380 0.00909 40 0.1380 0.01015 8 32 0.1640 0.01400 36 0.1640 0.01474 10 24 0.1900 0.01750 32 0.1900 0.02000 1/4 20 0.2500 28 0.2500 5/16 3/8 7/16 1/2 Torque (Dry) K=0.
General Information and Specifications 2.3.1 SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* SOCKET HEAD CAP SCREWS Tensile Stress Clamp Load Area See Note 4 Size TPI Bolt Dia In Sq In 4 40 0.1120 0.00604 48 0.1120 0.00661 6 32 0.1380 0.00909 40 0.1380 0.01015 8 32 0.1640 0.01400 36 0.1640 0.01474 10 24 0.1900 0.01750 32 0.1900 0.02000 1/4 20 0.2500 28 0.2500 Torque (Dry) K=0.
General Information and Specifications 2.3.2 Metric Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Tensile Stress Clamp Load Area See Note 4 Torque (Dry or Loctite® 263TM) Torque (Lub) Torque (Loctite® 262TM or 271TM or Vibra-TITETM 131) Torque (Loctite® 242TM or 271TM or Vibra-TITETM 111 or 141) [N.m] [N.m] Size Pitch Sq mm KN [N.m] 3 0.5 5.03 2.19 1.3 1.0 1.2 1.4 3.5 0.6 6.78 2.95 2.1 1.
General Information and Specifications 2.3.2 Metric Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 10.9 METRIC (HEX HEAD) BOLTS, CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5* Size Pitch 3 0.5 Clamp Load See Note 4 Torque (Dry or Loctite® 263TM) K=0.20 Torque (Lub or Loctite® 242TM or 271TM or Vibra-TITETM 111 or 140) K=0.18 Torque (Loctite® 262TM or Vibra-TITETM 131) K=0.15 Sq mm KN [N.m] [N.m] [N.m] 5.03 3.
General Information and Specifications 2.3.2 Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Tensile Stress Area Clamp Load See Note 4 Torque (Dry or Loctite® 263TM) K=0.17 Torque (Lub or Loctite® 242TM or 271TM or Vibra-TITETM 111 or 140) K=0.16 Torque (Loctite® 262TM or Vibra-TITETM 131) K=0.15 Size Pitch Sq mm KN [N.m] [N.m] [N.m] 3 0.5 5.03 2.19 1.1 1.1 1.0 3.5 0.6 6.78 2.95 1.
General Information and Specifications 2.3.2 Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS, CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE* Size Pitch 3 0.5 Clamp Load See Note 4 Torque (Dry or Loctite® 263TM) K=0.17 Torque (Lub or Loctite® 242TM or 271TM or Vibra-TITETM 111 or 140) K=0.18 Torque (Loctite® 262TM or Vibra-TITETM 131) K=0.15 Sq mm KN [N.m] [N.m] [N.m] 5.03 3.
General Information and Specifications 2.3.3 Hydraulic Hose Torque Chart O-Ring Face Seal & JIC Torque Chart Size ORFS JIC Flats Method 4 13 lb-ft (18 Nm) 13 lb-ft (18 Nm) 1.5 to 1.75 6 23 lb-ft (31 Nm) 23 lb-ft (31 Nm) 1 to 1.5 8 40 lb-ft (54 Nm) 40 lb-ft (54 Nm) 1.5 to 1.75 10 60 lb-ft (81 Nm) 60 lb-ft (81 Nm) 1.5 to 1.75 12 74 lb-ft (100 Nm) 85 lb-ft (115 Nm) 1.0 to 1.5 16 115 lb-ft (156 Nm) 115 lb-ft (156 Nm) 0.75 to 1.0 20 170 lb-ft (230 Nm) 170 lb-ft (230 Nm) 0.
General Information and Specifications 2.4 2.4.1 SPECIFICATIONS Travel Speeds 6036 & 6042 8042 10042 & 10054 First Gear 3.3 mph (5,3 km/hr) 3.4 mph (5,5 km/hr) 3.5 mph (5,6 km/hr) Second Gear 5.5 mph (8,9 km/hr) 5.6 mph (9,0 km/hr) 5.8 mph (9,3 km/hr) Third Gear 13.8 mph (22 km/hr) 14.1 mph (23 km/hr) 14.5 mph (23 km/hr) Fourth Gear 19.1 mph (31 km/hr) 19.9 mph (32 km/hr) 20.5 mph (33 km/hr) 2.4.
General Information and Specifications 2.4.3 Electrical System Battery Type, Rating 12 BCI, Negative (-) Ground, Maintenance Free Quantity 3.3 Liter—1, 4.5 Liter - 2 Cold Cranking Amps 3.3 Liter—950 CCA @ 0° F (-18° C) If equipped for ULS 3.3 Liter—700 CCA @ 0° F (-18° C) if equipped for LS Reserve Capacity 205 Minutes @ 80° F (27° C) If equipped for ULS 180 Minutes @ 80° F (27° C) if equipped for LS Group/Series Group 31 Alternator 12V, 120 Amps 2.4.
General Information and Specifications 2.4.5 Tires Note: Standard wheel lug nut torque is 430–470 lb-ft (583–637 Nm). Note: Pressure for foam filled tires are for initial fill ONLY. a. 6036 Size Tire Type Minimum Ply/ Star Rating 13.0 x 24 G-2/L-2 Bias Ply Traction 12 Ply 13.0 x 24 Solid Tires 15.5 x 25 G-2/L-2 Bias Ply Traction 12 Ply 370/75x28 DuraForce 14 Ply Size Tire Type Minimum Ply/ Star Rating 13.0 x 24 G-2/L-2 Bias Ply Traction 12 Ply 13.0 x 24 Solid Tires 15.
General Information and Specifications 2.
General Information and Specifications If Equipped for LS Compartment or System Engine Crankcase Transmission and Transfer Case Axle Differential and Wheel End Hydraulic System Boom Wear Pad Grease Cylinder and Axle Grease Boom Chain Lubricant Engine Coolant Fuel 2-18 Type and Classification API CI-4 Multigrade Viscosities SAE 0W-30 SAE 5W-30 SAE 10W-30 SAE 15W-40 10W-30 10W-30 10W-30 32 Mobilfluid 424 MobilFluid 424 MobilFluid 424 MobilFluid DTE-13 Exxon Univis HVI 26 Mystik Tetrimoly NLGI Grade 2
General Information and Specifications 2.6 FLUID AND LUBRICANT CAPACITIES Engine Crankcase Oil Capacity w/Filter Change 7.6 quart (7,2 liter) Fuel Tank Capacity 35.6 gallon (135 liter) Cooling System System Capacity If equipped for ULS 3.8 gallon (14,4 liter) If equipped for LS 4.
General Information and Specifications 2.7 2.7.
General Information and Specifications 2.7.2 50, 250 & 1st 500 Hour EVERY 50 Check Boom Wear Pads Check Washer Fluid Level (if equipped) Check Battery Lubrication Schedule EVERY 250 Change Engine Oil and Filter* Check Axle Oil Level Check Wheel End Oil Levels Change Air Filter Elements Check Boom Chain Lubrication Schedule 1st 500 Change Axle Oil Change Wheel End Oil OH4800 Note: Engine oil and filter service interval can be extended. See Engine Manual for details.
General Information and Specifications 2.7.
General Information and Specifications 2.7.4 2000 Hour EVERY 1500 Change Crankcase Vent Filter (if equipped for ULS) EVERY 2000 Change Engine Coolant Engine Valve Lash Adjustment OH4961 Note: Valve Lash adjustment for QSB 3.3 engine ONLY. See Engine Manual for details.
General Information and Specifications 2.8 2.8.1 LUBRICATION SCHEDULES 50 Hour a.
General Information and Specifications EVERY 50 OH4162 6036, 6042, 8042, 10042, 10054 2-25
General Information and Specifications b.
General Information and Specifications 2.8.2 250 Hour a.
General Information and Specifications b.
General Information and Specifications 2.8.
General Information and Specifications This Page Intentionally Left Blank 2-30 6036, 6042, 8042, 10042, 10054
Section 3 Boom Contents PARAGRAPH 3.1 3.2 3.3 3.4 3.5 3.6 3.7 TITLE Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom System - Three Section (6036, 6042, 8042 & 10042) . . . . . . . . . . . . . . . . . 3.3.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Assembly Maintenance . .
Boom 3.8 3.9 3.10 3.11 3-2 Quick Attach Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.1 Quick Attach Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.2 Quick Attach Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.1 Wear Pad Inspection . . . . . .
Boom 3.1 BOOM SYSTEM COMPONENT TERMINOLOGY The following illustrations identify the components that are referred to throughout this section.
Boom 3.2 SAFETY INFORMATION WARNING DO NOT service the machine without following all safety precautions as outlined in the “Safety Practices” section of this manual. 3.3 3.3.1 BOOM SYSTEM - THREE SECTION (6036, 6042, 8042 & 10042) Boom System Operation The three section boom assembly consists of first, second and third boom section assemblies with double top boom extend chains and a single retract chain. Boom extension and retraction is accomplished via hydraulic power and chain movement.
Boom 3.4.2 Third Boom Section Removal 1. Remove any attachment from quick attach assembly. 1 2 Note: If replacing the third section boom, remove the quick attach from the third section. Refer to Section 3.8.1, “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.
Boom 6 4 7 MH0912 14. At the rear of the boom, measure the amount of threads protruding beyond each locknut (4) and record the measurement for reassembly. Remove the two locknuts and flat washers holding both extend chain clevis’ to the anchor plate on the first boom section. 5 MH2551 Note: Record the location of the shoulder bolt (6) to ensure correct installation. 16. At the rear of the boom, locate the retract chain (7) on the right side of the boom.
Boom 3.4.3 Second Boom Section Removal 1. At the front of the first boom section, remove the top, bottom and side wear pads to the inside of the boom. Label and tag each set of wear pads being removed. 2. Remove the capscrews and lockwashers holding the center wear pad spacer mount to the front of the first boom section. Label and tag each set of wear pads being removed. Reassemble the capscrews, lockwashers and flat washers to hold the lower wear pad in place for second boom section removal. 7.
Boom 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. 14 15. Remove the remaining wear pads. Label and tag each set of wear pads being removed. 16. Inspect all wear pads for wear. Refer to Section 3.9, “Boom Wear Pads.” MH1131 4. Label, disconnect and cap the hydraulic hoses from the bulkhead fittings on the mounting plate (14). Remove the tubes from the bulkhead fittings. 5.
Boom 8. Label, disconnect and cap the hydraulic hoses attached to both compensation cylinders (17). Cap all fittings to keep dirt and debris from entering the hydraulic system. 15. Lower the base end of the Extend/Retract cylinder and remove the rod end of the cylinder from the retainer at the front of the boom. Place the Extend/ Retract cylinder on a clean, flat surface. 9. Support the compensation cylinder on the right side of the machine. Remove the rod end pins securing the cylinder in position.
Boom 6. Using a suitable hoist and slings, lift the boom assembly and position the boom on the frame. Align the mounting plates on the frame between the mounting hubs on each side of the boom assembly. Lower the boom assembly until the holes in the boom assembly and the mounting plates align. 7. On the end of the boom pivot pin, closest to the capscrew hole, mark the capscrew mounting hole location. Coat the entire pin with anti-seize compound. 8.
Boom 16. Uncap and connect the hydraulic hoses and attach to their appropriate cylinder locations. 3.4.6 Second Boom Section Installation 17. Install the Extend and Retract and Auxiliary (if equipped) tube assemblies to their appropriate bulkhead fittings. Secure with tube clamps. 6 18. Uncap and connect the previously labeled Attachment Tilt and Auxiliary (if equipped) hydraulic hoses to their appropriate bulkhead fittings. MH1481 1.
Boom 6. Before installing the second boom section into the first boom section, place a string (heavy enough to pull the Attachment Tilt and Auxiliary hydraulic hoses) down the inside of the boom. Allow the string to hang out the rear of the boom. Pull the other end out the opening on the left side of the boom where the hoses will exit the boom. Position the strings all the way to the left side of the first boom section. 7.
Boom 5. Install the top, bottom and side wear pads to the rear of the third boom section. If the machine is equipped with Auxiliary hydraulics, the top left wear pad is already installed. 11 12 MH1651 6. Lay the two extend chains (11) on the top of the third boom section with the threaded clevis ends toward the rear of the boom. Coat the threads on each clevis with multi-purpose grease and insert the clevis’ through the holes in the anchor plate. Install a washer and locknut onto each clevis.
Boom 18. Insert the shoulder bolt from the top down and secure in place with a locknut. 15 14 3.4.8 Boom Installation 1. Park the machine on a hard, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Using suitable slings, balance the boom assembly, lift and guide the boom assembly into place. Align the frame pivot bores with the boom assembly pivot bores.
Boom 3.5 3.5.1 BOOM SYSTEM - FOUR SECTION (10054) Boom System Operation The four section boom consists of the fourth, third, second and first boom assemblies with double intermediate boom extend chains, a single inner boom extend chain, a single inner boom retract chain and a single intermediate boom retract chain.
Boom 1 17 2 MH1691 MH1791 10. Label and remove the hydraulic hoses from the hose reel (17). 18 16. At the front of the boom, disconnect the fourth boom section extend chain clevis (1) from the anchor plates on the third boom section. Pull the extend chain clevis from between the plates and lay over the front of the fourth boom section (2). 17. Remove the extend chain sheave. 19 MH1781 18. Remove the top and side wear pads on the inside of the third boom section.
Boom 23. Remove the two capscrews and lockwashers holding the hose carrier support (7) and the lower wear pad to the third boom section. 24. Pull the hose carrier support with hose carrier attached toward the rear of the boom. Reinstall the capscrews and lockwashers to hold the wear pad in place. DO NOT fully tighten the capscrews. 4 25. Remove the hose carrier support from the hose carrier.
Boom 9 11 MH1901 30. Inside the boom section, remove the hardware securing the hose carrier (9) to the bottom of the boom. 31. On each side of the boom, remove the hardware securing the rear of the hose carrier guide in place. MH1961 35. Remove the hose carrier assembly (11) from the boom by carefully pulling both the upper and lowers portions through the rear of the boom at the same time. 36. Carefully slide the hose channel assembly out of the rear of the boom. 3.6.
Boom 3.6.3 13 Second Boom Section Removal 1. At the front of the first boom section, remove the top, side and bottom wear pads. Label and tag each set of wear pads being removed. 14 4. Remove the locknuts (13) holding the threaded clevis of the extend chains to the anchor bracket on the rear of the third boom section. 5. Pull both extend chains out from the front of the boom. 6. At the rear of the third boom section, remove the retract chain sheave. 7. Remove the shoulder bolt.
Boom 7. Remove the remaining wear pads, shims and hardware. Label and tag each set of wear pads being removed. 5. Remove the retract chain by pulling it out the rear of the boom. 8. Inspect all wear pads for wear. Refer to Section 3.9, “Boom Wear Pads.” 18 MH1131 6. Label, disconnect and cap the Attachment Tilt and Auxiliary (if equipped) hydraulic hoses on the mounting plate (18). 7. Label, disconnect and cap the Attachment Tilt and Auxiliary (if equipped) hydraulic tubes from the bulkhead fittings.
Boom 11. Use a hoist and a sling to hold the left Compensation cylinder in position. Remove the lockbolt from the Compensation cylinder rod end mounting pin. Remove the locknut from the base end of Compensation cylinder. Lift the Compensation cylinder away from the machine. Repeat procedure for the right Compensation cylinder. 19. Remove the rubber bumper from the Extend/Retract cylinder retainer. Inspect the rubber bumper. If it is in good condition, the rubber bumper can be reused.
Boom 6 7 5 MH1391 MH1381 7. Shim the boom as required using the shims (5) to maintain a 0.10 in (2,5 mm) maximum gap (6) between the boom mounting hub and the self aligning bearing in the frame. If an additional shim is required to maintain the maximum gap, the extra shim MUST be inserted on the right side of the boom. 8. Align the rod end of the right Lift/Lower cylinder with the self-aligning bearing on the boom assembly. Coat the entire Lift/Lower cylinder pin with anti-seize compound.
Boom side. Align the hole in the pin retainer plate with the threaded hole in the left ear. Secure the pin. 2. Apply grease to the grease fitting in the pin. Spin the sheave by hand to ensure the sheave spins freely on the pin and to distribute grease evenly. 12 10 MH1461 17. Inside the rear of the boom, slide the threaded clevis end (10) of the retract chain down the right side of the boom. Guide the threaded part of the clevis out through the hole in the tab on the bottom of the boom.
Boom 3.6.7 Third Boom Installation 1. Install the bottom, side and top wear pads to the rear of the third boom section. 15 13 MH2211 8. Install the center wear pad mount (13) and wear pad to the bottom front of the first boom section. 9. Install the side and top wear pads to the front of the first boom section. 10. Install the double extend chain sheave to the front of the second boom section. 11. With the sling still in place, install the rod end of the Extend/Retract cylinder, pin and retaining ring.
Boom 7. Using a suitable sling, carefully slide the third boom section into the second boom section. Leave enough room at the front of the boom to install the remaining wear pads. 3.6.8 Fourth Boom Section Installation 0 6.0 ) 19 8 cm (49 8. Install the top and side wear pads to the inside of the second boom section. 9. Place the two extend chains up through the double sheave mounting bracket on the front of the second boom section. 10.
Boom 19 1 MH2411 5. Fold the hose carrier assembly in half, ensure the female ends (19) of the hoses are on the bottom, and carefully slide the folded hose carrier into the fourth boom section. 6. Line up the lower mounting holes in the hose carrier assembly with the holes in the bottom of the fourth boom section. Secure with the previously used hardware. MH2471 7.
Boom 22. Place the extend chain clevis between the mounting plates at the front of the second boom section. Coat the shoulder bolt (4) with anti-seize compound and insert through the plates and clevis. Secure the shoulder bolt in place with a locknut. Tighten securely, but the chain clevis should pivot freely. 2 MH1861 15. Reassemble the hose carrier support to the hose carrier on the right side. Install the hose carrier support (2) and lower wear pad with the previously used hardware. 16.
Boom 3.7 3.7.1 BOOM EXTEND AND RETRACT CHAINS Boom Chain Inspection WARNING 6 MH1451 29. At the front of the first boom section, assemble the hose assemblies and tube assemblies to the mounting plate (6). Note: Where the hose assemblies come out of the outer boom, lubricate the radius in the first boom section with soap and water to allow proper tensioning of hoses. 30. Install the quick attach and Attachment Tilt cylinder to the front of the boom. Refer to Section 3.8.2, “Quick Attach Installation.
Boom Following are some examples of dynamic shock loading which can impose abnormal loads above the endurance limit of a leaf chain. Edge Wear • High velocity movement of load, followed by sudden, abrupt stops. • Carrying loads in suspension over irregular surfaces such as railroad tracks, potholes, and rough terrain. • Attempting to “inch” loads which are beyond the rated capacity of the machine. The above load cycles and environmental conditions make it impossible to predict chain life.
Boom Cracked Plates Distorted or Battered Link Plates Inspect the chains very carefully, front and back as well as side to side, for any evidence of cracked plates. If any one crack is discovered, the chain should be replaced in its entirety. 85 It is important, however to determine the cause of the crack before installing a new chain so the condition does not repeat itself.
Boom 3.7.3 Expose Chains for Inspection c. Extend Chains 1. Park the machine on a firm, level surface. Place the transmission control lever in (N) NEUTRAL, engage the park brake switch and raise the boom to a horizontal (level) position. 2. Fully extend the boom and shut the engine OFF. The extend chains will be visible for inspection with the machine in this state.
Boom 3.7.5 Boom Chain Tension Check 3.7.6 1. Make sure the attachment is attached to the boom head before doing the tension check. 2. Park the machine on level ground. Place the transmission control lever in (N) NEUTRAL, engage the parking brake switch and level the boom. Boom Chain Tension Adjustment (6036, 6042, 8042 & 10042) Note: Always perform Section 3.7.5, “Boom Chain Tension Check” before adjusting the boom chain tension. 2 3. Slowly, fully extend the boom and retract it about halfway.
Boom a. Component/Assembly Verification 9 5 8 7 OH1091 OA0513 3. If there is no adjustment left on the extend chains, tighten the retract chain locknut (5) at the front on the underside of the outer boom. 4. Recheck chain tension. Refer to Section 3.7.5, “Boom Chain Tension Check.” 6 The third (7) to second (8) boom section separation should be checked when assembling new boom sections or chains, or when the rear retract chain clevis has been moved forward on the anchor plate.
Boom 3.7.7 Boom Chain Tension Adjustment (10054) a. Outer Boom Chains Tension Adjustment Note: Always perform Section 3.7.5, “Boom Chain Tension Check.” before adjusting the boom extend chain tension. 10 12 OH0552 OA0493 11 2. Tighten or loosen the two extend chain adjustment locknuts (11) located at the rear of the boom. Be sure each of the locknuts are adjusted equally so that each extend chain maintains the same tension.
Boom If the distance is less than 8.5 in (216 mm) or greater than 11 in (279 mm): 1. Verify that the retract chain clevis is not mounted in the last hole in the anchor plate. 14 2. Make sure that the chain system is properly tensioned. Refer to Section 3.7.5, “Boom Chain Tension Check.”. 18 MA9451 5. Further chain adjustment can be achieved by loosening all three chain locknuts and moving the rear retract chain clevis (14) from the original mounting hole in the anchor plate to the next hole.
Boom c. Inner Boom Chain Tension Adjustment Note: Always perform the Section 3.7.5, “Boom Chain Tension Check,” before adjusting the fourth boom section extend chain tension. 19 2 OH0661 2. If there is no adjustment left on the extend chains, tighten the retract chain locknut (2) on the bottom of the second boom section several turns. OA0493 3. Recheck chain tension. Refer to Section 3.7.5, “Boom Chain Tension Check.” 1 3 MH1781 1.
Boom 3.7.8 d. Component/Assembly Verification The fourth to third boom section separation should be checked when assembling new boom sections or chains, or when the rear retract chain clevis has been moved forward on the anchor plate. 6 Extend Chains Removal and Replacement (6036, 6042, 8042 & 10042) 1. Park the machine on level ground. Place the transmission control lever in (N) NEUTRAL, engage the parking brake switch, level the boom and shut the engine OFF. 2.
Boom 9 10 11 MH6510 8. At the rear of the boom, attach one end of a wire to the threaded clevis (9) on the right side extend chain using a threaded eye or a flat washer tack welded to a capscrew. The outside diameter of the eye or flat washer must be smaller than the diameter of the threads on the clevis. 9. Have an assistant pull the chain from the front of the boom while guiding the wires into the boom from the rear. Remove the wire from the clevis, but not from inside the boom. 10.
Boom 3.7.9 Retract Chain Removal and Replacement (6036, 6042, 8042 & 10042) 1. Park the machine on level ground. Place the transmission control lever in (N) NEUTRAL, engage the parking brake switch, level the boom and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. washer must be smaller than the diameter of the threads on the clevis.
Boom 14. From the rear of the boom, have an assistant push the threaded clevis end of the chain under the chain sheave and down between the second and first boom sections. Pull the front clevis using the string or wire. Keep the chain to the right side of the boom, push the threaded clevis down to the tab at the front underside of the first boom section. 15. Have an assistant guide the threaded end of the clevis through the hole in the tab. 16. Remove the string or wire from the end of the clevis. 17.
Boom 8. Inspect the capscrews for signs of wear or damage. Replace with new capscrews if damaged or worn. 9. At the front of the second boom section, remove the capscrew and lockwasher holding the extend chain sheave pin to the sheave mount bracket. Remove the pin from the mount bracket and the extend chain sheave. Remove the extend chain sheave from the mount. 19 18 MH2601 MH6510 10.
Boom 24. At the rear of the boom, tighten the two locknuts on the chain clevis’ until the amount of threads protruding beyond each locknut is the same as the measurement recorded during removal of the extend chains. 2 25. Check and adjust the retract chain tension. Refer to Section 3.7.5, “Boom Chain Tension Check.” 26. Install the boom rear cover. 27. Properly connect the battery. 28. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. b.
Boom 12. Coat the threads of the threaded clevis with multipurpose grease. 13. Lay the new extend chain on top of the fourth boom section with the threaded clevis toward the front of the boom. 14. Attach the wire to the threaded clevis of the new extend chain with a threaded eye or a flat washer tack welded to a capscrew. The outside diameter of the eye or flat washer must be smaller than the diameter of the threads on the clevis. 21.
Boom 9. From the rear of the boom, pull the boom retract chain out of the rear of the boom. 10. Disconnect the string or wire from the retract chain clevis, and allow it to hang out the rear of the boom. 11. Coat the threads of the threaded clevis with multipurpose grease. 7 12. At the rear of the boom, attach the string or wire to the new retract chain threaded clevis end with a threaded eye or a flat washer tack welded to a capscrew.
Boom until all the tension on the retract chain is relieved. Shut the engine OFF. 18. Install the boom rear cover. 19. Properly connect the battery. 20. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. Note: Record the location of the shoulder bolt to ensure correct installation. 11 d. Fourth Boom Section Retract Chain Removal and Replacement 1. Park the machine on level ground.
Boom 13. Attach a wire to the end of the retract chain clevis (12) with a threaded eye or a flat washer tack welded to a capscrew. The outside diameter of the eye or flat washer must be smaller than the diameter of the threads on the clevis. The wire must be long enough to pull the clevis and chain through the boom. The wire must be heavy enough to pull the weight of the entire chain back through the boom during the reassembly. 14.
Boom 26. Insert the shoulder bolt (17) through the plates and clevis and secure in place with a locknut. Tighten the locknut securely. 27. Pull the extend chain up and around the sheave at the front of the third boom section. 28. Place the extend chain clevis between the mounting plates at the front of the third boom section. Coat the shoulder bolt with anti-seize compound and insert through the plates and clevis. Secure the shoulder bolt in place with a locknut.
Boom 3.8 3.8.1 QUICK ATTACH ASSEMBLY Quick Attach Removal 1. Remove the lock bolt holding the Attachment Tilt cylinder rod end pin to the quick attach assembly. Remove the Attachment Tilt Cylinder pin. 2. Support the quick attach assembly. Remove the capscrew and locknut securing the quick attach pivot pin to the quick attach assembly. Remove the quick attach assembly. Record the location and quantity of the shim washers as the pin is being removed. 3.
Boom 3.10 FORKS 5 Forks should be cleaned and inspected prior to being attached to carriage. If the following criteria is not met, forks must be removed from service immediately. Daily Inspection 6 9 10 • Maintain a total boom section clearance (5) of 0.070 - 0.130 in (1,78 - 3,30 mm) both the horizontal and vertical directions. 7 8 5 4 14 A B 13 12 MY3620 • The length of the wear pad bolt depends on the number of shims, spacers and washers being used.
Boom 3.11 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that occur during operation of the boom. Problem 1. Boom will not extend or retract Cause Remedy 1. Broken hydraulic hose(s) or tube(s) and/or connections leaking. 1. Locate break, replace hose(s) or tube(s), tighten connections. 2. Extend/retract hydraulic system not operating properly. 2. Refer to Section 8.4, “Hydraulic Circuits.” 3. Faulty extend/retract cylinder. 3. Repair cylinder.
Boom Problem 6. Drooping chain, or jerky boom extend or retract functions. 7. Boom will not raise or lower. 8. Excessive Lift/Lower cylinder pivot pin noise and/or wear. 6036, 6042, 8042, 10042, 10054 Cause Remedy 1. Chain(s) tension not properly adjusted. 1. Adjust chain(s). 2. Chain(s) stretched or binding. 2. Replace chains as needed. Refer to Section 3.7, “Boom Extend and Retract Chains.” 3. Wear pads loose, contaminated, excessively worn or damaged. 3. Replace wear pad. Refer to Section 3.
Boom Problem 9. Rapid boom pad wear. Cause Remedy 1. Incorrect wear pad gap. 1. Check wear pad gaps and correct as needed. Refer to Section 3.9, “Boom Wear Pads.” 2. Rapid cycle times with heavy loads. 2. Reduce cycle times. 3. Contaminated, corroded or rusted wear pad sliding surfaces. 3. Remove contamination and/or corrosion from wear pad sliding surfaces and lubricate. If the surfaces cannot be reconditioned, replace the boom section(s). 4. Operating in extremely dusty/ abrasive conditions. 4.
Section 4 Cab and Covers Contents PARAGRAPH 4.1 4.2 4.3 4.4 4.5 TITLE Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab and Covers 4.1 OPERATOR CAB AND COVERS COMPONENT TERMINOLOGY To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the machine cab and covers. The following illustration identifies the components that are referred to throughout this section.
Cab and Covers WARNING DO NOT service the machine without following all safety precautions as outlined in the “Safety Practices” section of this manual. 4.2 4.2.1 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Remove the left, right and lower dash panels.
Cab and Covers 7. Install the travel select lever, connect the instrument panel harness connector, install the steering wheel assembly. Torque the steering wheel nut to 50 lb-ft (68 Nm). 8. Properly connect the battery. 9. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 10. Start the engine and check the operation of steering system. Check for hydraulic fluid leaks. Check the hydraulic fluid level in the tank and add fluid as required. 11.
Cab and Covers 4.3.3 Throttle Pedal a. Throttle Pedal Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake and turn the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Properly disconnect the battery. 4 MH6210 5 5. Remove the lower dash panel. 6.
Cab and Covers 4.3.4 Joystick Assemblies These removal and installation instructions apply to the boom control, attachment tilt/frame level and auxiliary hydraulic joysticks. 4 a. Joystick Assembly Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake and turn the engine OFF. 2.
Cab and Covers function. The boom should FRAME LEVEL RIGHT. • Move joystick handle to left, activating frame level function. The boom should FRAME LEVEL LEFT. Auxiliary Control Joystick • Move the joystick handle to the right, the auxiliary attachment should LOWER/OPEN. • Move the joystick handle to the left, the auxiliary attachment should RAISE/CLOSE. 6. Install console panel in the cab. c. Joystick Cable Adjustment A 4.3.5 Windshield Wiper Assembly Refer to Section 9.
Cab and Covers Note: The capscrew (8) at the lower rear position on each side of the heater will be secured with an insert nut (9). 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 (10). 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.
Cab and Covers 1 2 4 MA8501 MA8781 9. Working under the cab, loosen the clamp screw (1) and disconnect the heater control cable (2) from the heater control valve. Label, disconnect and cap the heater hoses. 10. Remove the heater access panel. Label, disconnect and cap the heater hoses and route them through the opening in the bottom of the cab. 15. Working under the cab, label, disconnect and cap the hydraulic hoses at the cab fittings (4).
Cab and Covers the cab and remove it from the frame. Readjust the position of the sling as needed to help balance the cab during removal. 22. 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. 23. Inspect the condition of the fittings, clamps, hydraulic hoses, etc. Replace parts as indicated by their condition. 24.
Cab and Covers 2 1 MA8781 13. Connect the heater control cable (2) to the heater control valve (1). 14. Fill the cooling system completely with coolant, allowing time for the coolant to fill the engine block. The cooling system capacity is listed in Section 2.5, “Fluid Specifications.” 15. Properly connect the battery. 16. Carefully examine all cab components, fasteners, etc., one last time before engine start-up. Rectify any faulty conditions. 17.
Cab and Covers This Page Intentionally Left Blank 4-12 6036, 6042, 8042, 10042, 10054
Section 5 Axles, Drive Shafts, Wheels and Tires Contents PARAGRAPH 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 TITLE Axle, Drive Shaft and Wheel Component Terminology (6036) . . . . . . . . . . . . . . Axle, Drive Shaft and Wheel Component Terminology (6042) . . . . . . . . . . . . . . Axle, Drive Shaft and Wheel Component Terminology (8042) . . . . . . . . . . . . . . Axle, Drive Shaft and Wheel Component Terminology (10042 & 10054) . . . . . . General Information . . . . . . . . . . . . . . . . .
Axles, Drive Shafts, Wheels and Tires 5.1 AXLE, DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGY (6036) 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.
Axles, Drive Shafts, Wheels and Tires 5.2 AXLE, DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGY (6042) To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the axles, drive shafts, wheels and tires. The following illustration identifies the components that are referred to throughout this section.
Axles, Drive Shafts, Wheels and Tires 5.3 AXLE, DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGY (8042) 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.
Axles, Drive Shafts, Wheels and Tires 5.4 AXLE, DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGY (10042 & 10054) To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the axles, drive shafts, wheels and tires. The following illustration identifies the components that are referred to throughout this section.
Axles, Drive Shafts, Wheels and Tires 5.5 GENERAL INFORMATION WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. Note: To help ensure optimum performance, the drive shaft assemblies are specially balanced as a unit at the factory. When servicing any flange yoke, slip yoke or drive shaft tube, order a complete assembly if components are bent or damaged. Refer to the appropriate parts manual for ordering information.
Axles, Drive Shafts, Wheels and Tires 5.6.4 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.
Axles, Drive Shafts, Wheels and Tires Rear Axle: Open the right and left side engine compartment doors to gain access to the rear hose connections and mounting bolts. and lower the machine onto the supports, allowing enough room for axle installation. Ensure that the machine will remain in place during axle installation. 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. 3.
Axles, Drive Shafts, Wheels and Tires 12. Remove the blocks from the front and rear of both tires on the other axle. Note: ALWAYS use new o-rings when servicing the machine. 4 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. 4 5 17.
Axles, Drive Shafts, Wheels and Tires 7 Keep the assembly supported and balanced during the installation procedure. 2. Place the same number and thickness of shims (8) on the pivot pin, as recorded during removal. 3. Position the outrigger assembly onto the machine, aligning the hole in the assembly on the axle pivot pin and the mounting plate under the axle flanges. 4. Install the two mount plates (7) onto the top of the axle and secure with the previously used hardware.
Axles, Drive Shafts, Wheels and Tires 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake, straighten all wheels and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 12.
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.
Axles, Drive Shafts, Wheels and Tires 5.7 AXLE ASSEMBLY AND DRIVE SHAFT TROUBLESHOOTING Problem 1. Excessive axle noise while driving. 2. Intermittent noise when traveling. 3. Vibration or intermittent noise when traveling. 6036, 6042, 8042, 10042, 10054 Cause Remedy 1. Oil level too low. 1. Fill oil to correct level. Refer to Section 2.5, “Fluid Specifications.” 2. Axle and/or wheel end housings filled with incorrect oil or oil level low. 2.
Axles, Drive Shafts, Wheels and Tires Problem 4. Oil leaking from axle (differential housing and/or axle housings). 5. Oil leaking from wheel end housing (planet carrier). 6. Oil leaking from steering cylinder. 5-14 Cause Remedy 1. Drain and/or inspection plugs loose and/or o-rings damaged or missing. 1. Replace o-rings as needed and tighten plugs to 96 lb-ft (130 Nm). 2. Hose fittings loose. 2. Tighten fittings. 3. Axle shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces.
Axles, Drive Shafts, Wheels and Tires Problem 7. Axle overheating. 8. High steering effort required. 9. Slow steering response. 10. Excessive noise when brakes are engaged. 11. Brakes will not engage. 12. Brakes will not hold the machine or braking power reduced. 6036, 6042, 8042, 10042, 10054 Cause Remedy 1. Oil level too high. 1. Fill oil to correct level with Mobilfluid 424® ISO 46. Refer to Section 2.5, “Fluid Specifications.” 2.
Axles, Drive Shafts, Wheels and Tires 5.8 DRIVE SHAFTS TO TRANSMISSION 5.8.1 Drive Shaft Inspection and Service Whenever servicing the machine, conduct a visual inspection of the drive shafts and cross and bearing assemblies (universal joints, or U-joints). A few moments spent doing this can help prevent further problems and down time later. Inspect areas where the drive shaft flange yokes and slip yokes mount to the drive shafts. Attempt to turn each drive shaft in both directions.
Axles, Drive Shafts, Wheels and Tires 5.9 WHEELS AND TIRES 5 WARNING Mismatched tire sizes, ply ratings or mixing of tire types (radial tires with bias-ply tires) may compromise machine stability and may cause machine to tip over. It is recommended that a replacement tire to be the same size, ply and brand as originally installed. Refer to the appropriate parts manual for ordering information.
Axles, Drive Shafts, Wheels and Tires 5.9.2 Installing Wheel and Tire Assembly onto Machine Note: The wheel and tire assemblies must be installed with the directional tread pattern “arrows” facing in the direction of forward travel. TREAD “ARROWS” MUST POINT FORWARD 5.10 BRAKES 5.10.1 Brake Disc Inspection A brake lining wear measurement on service brake (multi-disc brake) gives just limited information about the overall condition of the multi-disk package–without disassembly of the output.
Axles, Drive Shafts, Wheels and Tires 5.11 TOWING A DISABLED MACHINE Towing a disabled machine should only be attempted as a last resort, after exhausting all other options. Make every effort to repair the machine, and move it under its own power. Towing the machine improperly can result in damage to the machine drivetrain. Note: In the event the machine is disabled and cannot be moved under engine power, the situation must be properly evaluated and dealt with on an individual basis.
Axles, Drive Shafts, Wheels and Tires 8042, 10042 & 10054 FRONT OF MACHINE 5 6 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.
Section 6 Transmission Contents PARAGRAPH 6.1 6.2 6.3 6.4 6.5 TITLE Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Specifications and Maintenance Information. . . . . . . . . . . . . . . . Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.1 Transmission Removal . . . . . . . . .
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.
Transmission WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. 6.2 TRANSMISSION SERIAL NUMBER cleaning solution onto or near transmission shift solenoids and other electrical components. 6.4.1 Transmission Removal 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 lb (454 kg). 1.
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 5.8.3, “Drive Shaft Removal.” 12. Remove the hydraulic pump. Refer to Section 8.6.1, “Pump Replacement.” 2 4 16.
Transmission 27. Lift the transmission clear of the machine and lower it onto suitable supports or secure it to a stand built especially for the transmission or engine service. Secure the transmission so that it will not move or fall. 3 4 28. Remove any external transmission components as required, including the transmission temperature switch, and inlet and outlet cooler hose fittings. Cover all transmission openings. 29. Remove the transmission oil filter and dispose of properly.
Transmission 12. Uncap and connect the previously labeled transmission oil cooler inlet and out hoses at the transmission. 8 13. Install the hydraulic pump. Refer to Section 8.6.1, “Pump Replacement.” 14. Install the engine-to-transmission and transmissionto-axle drive shafts. Refer to Section 5.8.5, “Drive Shaft Installation.” 15. Clean the transmission oil filter mounting surface. 16. Apply a thin film of clean Mobilfluid 424® (ISO Grade 46) to the new transmission filter gasket.
Transmission 6.5 TRANSMISSION TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that may occur during operation of the transmission. Note: Contact the JLG Service Department if internal transmission repair is required during the warranty period. The transmission should be checked, serviced and repaired only by experienced service technicians who are aware of all safety instructions and particular component features. Problem 1.
Transmission Problem 2. Low or no pump flow or pressure. 3. Low clutch pressure. 4. Lack of power. 6-8 Cause Remedy 1. Low oil level. 1. Fill transmission to correct level with Mobilfluid 424® ISO Grade 46. Refer to Section 2.5, “Fluid Specifications.” 2. Transmission filled with incorrect oil, or oil contaminated. 2. Drain transmission and fill to correct level with Mobilfluid 424® ISO Grade 46. Refer Section 2.5, “Fluid Specifications.” 3. Pump suction pipe screen clogged. 3.
Transmission Problem 5. Transmission overheating (oil above 120° C (248° F)). 6. Grinding or “clunking” noise from transmission. 6036, 6042, 8042, 10042, 10054 Cause Remedy 1. Low oil level. 1. Fill transmission to correct level with Mobilfluid 424® ISO Grade 46. Refer to Section 2.5, “Fluid Specifications.” 2. Clogged radiator. 2. Remove debris from the radiator. 3. Transmission filled with incorrect oil, or oil contaminated. 3.
Transmission Problem 7. Oil leaking from transmission. 6-10 Cause Remedy 1. Oil leaking from vent (high oil level). 1. Remove drain plug and drain oil as needed, until oil is at correct level. Refer to Section 2.5, “Fluid Specifications.” Replace o-rings as needed and tighten plugs to 96 lb-ft (130 Nm). 2. Drain plug loose and/or o-rings damaged or missing. 2. Replace o-rings as needed and tighten plug to 26 lb-ft (35 Nm). 3. Hose fittings loose. 3. Tighten fittings. 4.
Section 7 Engine Contents PARAGRAPH 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 TITLE Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.2 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine 7.1 7.1.1 INTRODUCTION Disclaimer and Scope WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. WARNING 7.3 SPECIFICATIONS AND MAINTENANCE INFORMATION For engine, coolant and oil specifications, and maintenance information, refer to Section 2, “General Information and Specifications.
Engine IF EQUIPPED FOR ULS IF EQUIPPED FOR LS TURBOCHARGER TURBOCHARGER THERMOSTAT OIL FILTER ALTERNATOR OIL FILTER ALTERNATOR THERMOSTAT FUEL FILTER STARTER FUEL INJECTOR PUMP MAQ0480 STARTER FUEL INJECTOR PUMP FUEL FILTER MAQ0490 6036, 6042, 8042, 10042, 10054 7-3
Engine 7.4 ENGINE COOLING SYSTEM IF EQUIPPED FOR ULS 6 1 7.4.1 Coolant System Pressure Cap 2 If equipped for ULS, the surge tank cap is designed to use a 17 psi (120 kPa) cap. 4 If equipped for LS, the radiator cap is designed to use 13 psi (90 kPa) cap. An incorrect or malfunctioning cap can result in the loss of coolant and a hot-running engine. 7.4.
Engine If equipped for LS, label and disconnect all hoses and tubes attached to radiator (2), charge air cooler (3) and oil cooler (4). 10. Working at rear of machine, remove capscrews and lockwashers securing radiator assembly. 11. Remove radiator assembly through rear of machine. b. Radiator/Oil Cooler Installation 1. If equipped for ULS, secure radiator (2), charge air cooler (3), oil cooler (4), and fuel cooler (5) to machine frame with previously used hardware. Reinstall surge tank (6). 2.
Engine Note: Have a dry chemical (Class B) fire extinguisher near the work area. 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. 9 tank. Dispose of the old tank according to local regulations concerning hazardous materials disposal. c.
Engine f. Fuel/Hydraulic Oil Tank Installation 1. Attach tank to a suitable lifting device at lift point. 2. Place tank carriage bolts into slotted holes in 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.
Engine 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. IF EQUIPPED FOR ULS 11 10 When replacing the muffler, also replace the tail pipe. Before assembling components, use exhaust system sealer at all slip joint connections.
Engine 10. Lift right side and slip bolts up and through slots on the right side of frame. 11. Place mounting plate on level surface and replace muffler, clamps and tailpipe. Note position of muffler for re-installation purposes. 7.7.2 Exhaust System Installation - LS 15 Note: Install muffler in proper direction. Note: Keep all clamps loosened until entire exhaust system is in place. 1. Install muffler and tailpipe on muffler mounting plate (12) using proper clamps in proper position. 2.
Engine The following steps may be required to achieve distance (C) (Expanded web). • Loosen the turbocharger clamp to allow rotation of the top exhaust pipe (11). Do Not remove clamp. • Pull up and out on exhaust pipe (11) to allow for a straight line and expansion of the flex pipe. • Tighten the turbocharger clamp while holding the exhaust pipe (11) in place. • If the flex pipe is in a “S” shape, loosen the band clamp (17) securing the muffler.
Engine 7.8 AIR CLEANER ASSEMBLY 6. Remove air intake hose and pre-cleaner (16). CAUTION NEVER run the engine with only the inner safety element installed. Note: Refer to the appropriate Operation & Safety Manual for your machine for the correct element change procedure. 7.8.1 17 Air Cleaner Assembly Removal - ULS 18 1.
Engine 7.8.3 Air Cleaner Assembly Removal - LS 1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake, and shut the engine OFF. 2. Place a Do Not Operate Tag on both ignition key switch and steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow system fluids to cool. 4. Properly disconnect the battery. 22 23 24 7.9 7.9.
Engine 14. Remove the exhaust pipe and muffler system. Refer to Section 7.7.1, “Exhaust System Removal.” 2. Install the engine mounting brackets. Torque to 93-100 lb-ft (126-135 Nm). 3. Place the engine on a flat, level surface. 4. Position a fork truck behind the engine, and drive forward, placing the forks underneath the rear engine mount and front right and left engine mount brackets. Lift the engine and slowly drive it into the back of the machine.
Engine 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. 4 Note: During the full throttle check: 3 • 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. MH6360 22.
Engine 4. Install the access cover plate over the drive shaft and assemble the drive shaft flange to the coupler using new hardware. Torque to 48 lb-ft (65 Nm). 5. 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. 6.
Engine This Page Intentionally Left Blank 7-16 6036, 6042, 8042, 10042, 10054
Section 8 Hydraulic System Contents PARAGRAPH 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 TITLE Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.1 Pressure Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System 8.1 HYDRAULIC COMPONENT TERMINOLOGY To understand the safety, operation and service information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the hydraulic components of the machine. The following illustration identifies the components that are referred to throughout this section.
Hydraulic System 8042, 10042 & 10054 LIFT/LOWER CYLINDERS COMPENSATION CYLINDERS ATTACHMENT TILT CYLINDER EXTEND/ RETRACT CYLINDER EXTEND LOCKOUT VALVE (10054 MAIN PUMP HYDRAULIC FLUID RESERVOIR STEER SELECT VALVE FRAME LEVEL CYLINDER STABILIZER CYLINDER SECONDARY FUNCTION SERVICE BRAKE STEERING VALVE VALVE OUTRIGGER CYLINDERS (10042 & 10054 ONLY) MAIN CONTROL VALVE STEERING CYLINDER (FRONT) STEERING CYLINDER (REAR) OUTRIGGER VALVE (10042 & 10054 ONLY) MH3441 6036, 6042, 8042, 10042, 10054 8
Hydraulic System 8.2 SAFETY INFORMATION WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. Petroleum-based hydraulic fluids are used in this machine. Temperature of hydraulic fluid increases during operation of various hydraulic functions. A heated petroleum-based hydraulic fluid presents a fire hazard, especially when an ignition source is present.
Hydraulic System 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. Test port is located at top right corner of main control valve. Install a pressure gauge capable of measuring at least 10% more pressure than that which circuit being checked operates under. 3. Start the engine. Operate machine functions several times to allow hydraulic oil to reach operating temperature.
Hydraulic System c.
Hydraulic System Test Site Hydraulic Pump Flow Test To check flow readings, a flow meter capable of measuring 60 gpm (3,8 liter/sec) and a load valve capable of 6000 psi (413,4 bar) will be required. — 2000 psi (137,8 bar) load @ Engine Speed of 2475–2525 rpm—Flow rate should be 28–32 GPM (1,8–2,0 liter/sec) 1 Test Valve Adj.
Hydraulic System d. Pressure Specifications (6042) ATTACHMENT TILT CYLINDER FRONT AXLE FRAME SWAY CYLINDER FTR FTB AUXILIARY HYDRAULICS Ø .040 E FRONT STEERING CYLINDER Ø .047 R MAIN CONTROL VALVE T Ø .089 BRAKE VALVE Ø .089 T P LS Ø .029 8 SHUTTLE VALVE UNLOADER VALVE Ø .
Hydraulic System Test Location Hydraulic Pump Flow Test To check flow readings, a flow meter capable of measuring 60 gpm (3,8 liter/sec) and a load valve capable of 6000 psi (413,4 bar) will be required. — 2000 psi (137,8 bar) load @ Engine Speed of 2475–2525 rpm—Flow rate should be 34–40 GPM (2,1–2,5 liter/sec) 1 Test Valve Adj.
Hydraulic System e.
Hydraulic System Test Location 1 Hydraulic Pump Flow Test To check flow readings, a flow meter capable of measuring 60 gpm (3,8 liter/sec) and a load valve capable of 6000 psi (413,4 bar) will be required. — 2000 psi (137,8 bar) load @ Engine Speed of 2475–2525 rpm—Flow rate should be 48.9 GPM (3 liter/sec) Test Adjust.
8-12 15.9 GPM LOW IDLE 1050 RPM 37.9 GPM RATED SPEED 2500 RPM 41.7 GPM HIGH IDLE 2750 RPM 3.5 IN 3 4000 PSI HOIST CYLINDER - 5.00 X 2.75 X 39.
6036, 6042, 8042, 10042, 10054 37.9 GPM RATED SPEED 2500 RPM 41.7 GPM HIGH IDLE 2750 RPM 15.9 GPM LOW IDLE 1050 RPM 3.5 IN 3 4000 PSI HOIST CYLINDER - 5.00 X 2.75 X 44.36 4000 PSI HOIST CYLINDER - 5.00 X 2.75 X 44.36 65 PSI PRESSURE PORT SHUTTLE IN LOAD SENSE OUT TANK 10um TANK 25 PSI BYPASS TO TANK 2750 PSI 3500 PSI 4000 PSI 250 PSI 60um HOIST B 10um A T 12A V 3 P 1 11 2A B 4A 100 PSI 2B .03 EXTEND FTR A G1 .06 4B INLET PRESSURE PORT 11 G2 TANK G3 .
8-14 4000 PSI HOIST CYLINDER - 6.00 x 3.00 x 42.41 4000 PSI HOIST CYLINDER - 6.00 x 3.00 x 42.41 10um 25 PSI LOW IDLE 18.3 GPM HI IDLE 44.9 GPM RATED 41.6 GPM SHUTTLE IN 65 PSI TANK B A T V 12A HIGH HYD. OIL TEMP 3 3.84 IN/REV LOW IDLE-1100 RPM HIGH IDLE-2700 RPM RATED-2500 RPM HOIST 3000 PSI 4000 PSI EXTEND CYLINDER - 5.00 x 3.00 x 131.25 3 B G1 INLET A 11 2A 195 F 60 um 10 um 400 PSI STAND BY 3100 PSI 100 PSI 4A 2B .03 EXTEND P 1 FTR 11 6 GPM MAX .
6036, 6042, 8042, 10042, 10054 4000 PSI HOIST CYLINDER - 6.00 x 3.00 x 42.41 4000 PSI HOIST CYLINDER - 6.00 x 3.00 x 42.41 10um 25 PSI LOW IDLE 18.3 GPM HI IDLE 44.9 GPM RATED 41.6 GPM SHUTTLE IN 65 PSI TANK B A T V 12A 125 PCI HIGH HYD. OIL TEMP 3 3.84 IN/REV LOW IDLE-1100 RPM HIGH IDLE-2700 RPM RATED-2500 RPM HOIST 3000 PSI 4000 PSI EXTEND CYLINDER - 5.00 x 3.00 x 131.25 3 P B 4A INLET A 11 2A G1 195 F 60~am 10~am 575 PSI STAND BY 3300 PSI 100 PSI 2B .
8-16 E B2 R.H. A2 R OUTRIGGER CYLINDER 5.00 X 3.00 X 13.31 .156 OUTRIGGER VALVE E L.H. A1 B1 4000 PSI R LS HOIST CYLINDER - 6.00 x 3.00 x 42.41 4000 PSI HOIST CYLINDER - 6.00 x 3.00 x 42.41 LS P T 10um 25 PSI LOW IDLE 18.3 GPM HI IDLE 44.9 GPM RATED 41.6 GPM SHUTTLE IN 65 PSI TANK B A T V T HIGH HYD. OIL TEMP P 1 FTR 100 PSI 4A 2B .03 11 2A G1 EXTEND B 195 F 60 um 11 G2 6 GPM MAX .
6036, 6042, 8042, 10042, 10054 E B2 R.H. R OUTRIGGER CYLINDER 5.00 X 3.00 X 13.31 A2 .156 OUTRIGGER VALVE E L.H. A1 B1 4000 PSI HOIST CYLINDER - 6.00 x 3.00 x 42.41 R LS LS P T 10um 25 PSI LOW IDLE 18.3 GPM HI IDLE 44.9 GPM RATED 41.6 GPM SHUTTLE IN 65 PSI TANK B 125 PCI A T 12A V HIGH HYD. OIL TEMP 3 3.84 IN/REV LOW IDLE-1100 RPM HIGH IDLE-2700 RPM RATED-2500 RPM HOIST 3000 PSI 4000 PSI EXTEND CYLINDER - 5.00 x 3.00 x 131.
8-18 E B2 R.H. R OUTRIGGER CYLINDER 5.00 X 3.00 X 13.31 A2 .156 OUTRIGGER VALVE E L.H. A1 B1 4000 PSI R LS HOIST CYLINDER - 6.00 x 3.00 x 42.41 4000 PSI HOIST CYLINDER - 6.00 x 3.00 x 42.41 LS P T 10um 25 PSI LOW IDLE 18.3 GPM HI IDLE 44.9 GPM RATED 41.6 GPM SHUTTLE IN 65 PSI TANK B A T T HIGH HYD. OIL TEMP P 1 FTR 100 PSI 4A 2B .03 11 2A G1 EXTEND B 195 F 60 um 11 G2 6 GPM MAX .
6036, 6042, 8042, 10042, 10054 E B2 R.H. R OUTRIGGER CYLINDER 5.00 X 3.00 X 13.31 A2 .156 OUTRIGGER VALVE E L.H. A1 B1 4000 PSI HOIST CYLINDER - 6.00 x 3.00 x 42.41 4000 PSI HOIST CYLINDER - 6.00 x 3.00 x 42.41 R LS LS P T 10um 25 PSI LOW IDLE 18.3 GPM HI IDLE 44.9 GPM RATED 41.6 GPM SHUTTLE IN 65 PSI TANK B 125 PSI A T T P 1 FTR 4A 100 PSI 2B .03 11 2A EXTEND B G1 195 F 60~am 11 G2 6 GPM MAX .
Hydraulic System 8.5 HYDRAULIC RESERVOIR 5. Open the filler cap on the hydraulic oil reservoir. Remove the drain plug on the side of the hydraulic oil reservoir. 1 2 6. Transfer the used hydraulic oil into a suitable covered container, and label as “Used Oil”. Dispose of used oil at an approved recycling facility. Clean and reinstall the drain plug. 7. Wipe up any hydraulic fluid spillage in, on, near and around the machine and the work area. 8.5.2 Hydraulic Oil Reservoir Filling 1.
Hydraulic System 7. Install the four previously removed nuts securing the hydraulic filter assembly to the hydraulic reservoir. Torque the nuts to 75 lb-in (8.5 Nm). 8. Wipe up any hydraulic fluid spillage in, on, near and around the machine and the work area. 8.5.4 Hydraulic Oil Reservoir Replacement The hydraulic reservoir and the fuel tank are one unit and are removed together. Refer to Section 7.6.2, “Fuel/ Hydraulic Oil Tank,” for information on hydraulic reservoir/fuel tank replacement. 8.
Hydraulic System d. Load Sense Relief Adjustment EATON PUMP 6 REXROTH PUMP 6 4 4 5 7 5 7 MAQ1130 MAQ1090 SAUER PUMP 6 4 5 1. With park brake on and engine at high idle (2650 rpm), fully retract boom hoist cylinder and hold. Check main pump maximum pressure tap (4). Measurement range 3400–3500 psi (234,241 bar) 2. Adjust main pump maximum pressure (7) as necessary. (load sense relief (6) may need to be turned up two turns to achieve pressure first) 3.
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. 9 The main control valve assembly consists of individual working sections with their own valve assemblies, each providing a specific hydraulic function. 10 a. Main Control Valve Removal 1.
Hydraulic System Disassemble each Valve Section Assemble the Main Control Valve. 1. Carefully separate the load sense outlet section from the next section. 1. Place all three tie rods with the nuts through the end main control valve section. 2. Remove the o-rings from between the two sections. 2. Stand the end main control valve section on end. 3. Carefully separate each remaining sections, being careful not to lose the load sense shuttle ball. 4.
Hydraulic System f. Main Control Valve Installation 1. Install the main control valve onto the frame, aligning the bolts with the holes in the end sections of the main control valve. Slide the main control valve into position, and tighten the bolts. 2. Prime the main control valve by filling the inlet openings with fresh, filtered hydraulic oil from a clean container, before attaching the hoses. 3. Use new oiled o-rings as required. Uncap and connect all previously labeled hoses, clamps, etc.
Hydraulic System 8.7.3 Service Brake Valve a. Service Brake Valve Removal 2. Use new oiled o-rings as required. Uncap and connect the previously labeled hoses to the service brake 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. 3.
Hydraulic System 8.7.7 Steer Select Valve 8042, 10042, 10054 2 4 MAQ1110 2. Remove the plastic cap from the brake bleeder (2). Attach one end of a length of transparent tubing over the brake bleeder. Place the other end of this tubing in a suitable transparent container that is partially filled with hydraulic oil. The end of the tubing must be below the oil level in the container. 3. DO NOT open the brake bleeder without holding the tubing firmly on the bleeder. There is pressure at the brakes.
Hydraulic System 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 the components with a suitable cleaner before inspection. 5. Inspect the solenoid cartridges for proper operation.
Hydraulic System 3. Temporarily block up or support the raised boom. 4. Open the rear door. Allow the system fluids to cool. 5. Properly disconnect the battery. 6. Label, disconnect and cap 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.
Hydraulic System 2. Remove the solenoid valve assemblies (2) from the outrigger valve by removing the four capscrews (3). Discard the four o-rings. 3. Remove shuttle cartridges (4) from outrigger valve. 4. Clean all components with a suitable cleaner before inspection. 5. Inspect the solenoid cartridges for proper operation. Check by shifting the spool to ensure that it is functioning properly. Check that the spring is intact. Inspect the cartridge interior for contamination. 6.
Hydraulic System 7. Label, disconnect and cap hydraulic hoses and electrical plugs connected to extend lockout valve. 8. Remove nut and bolt securing 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 7 3. Connect all the previously labeled hydraulic hoses, fittings, solenoid wire terminal leads, etc.
Hydraulic System 4. Label, disconnect and cap or plug hydraulic hoses in relation to the cylinder. Note: Protect the finish of the rod at all times. Damage to the surface of the rod can cause seal failure. 5. Attach a suitable sling to an appropriate lifting device and to the cylinder. Make sure the device used can actually support the cylinder. 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.
Hydraulic System brass wire brush. Wipe clean with Loctite Cleaner prior to reassembly. d. Cylinder Inspection 1. Inspect internal surfaces and all parts for wear, damage, etc. If the inner surface of the cylinder barrel does not display a smooth finish, or is scored or damaged in any way, replace the barrel. 2. Remove light scratches on the piston, head gland, rod or inner surface of the cylinder barrel with a 400600 grit emery cloth.
Hydraulic System 8.8.2 Cylinder Pressure Checking Attach 4000 psi (276 bar) gauge to test port on hydraulic pump to check system pressure. For more information, refer Section 8.3.1, “Pressure Checks and Adjustments.” Note: If a hydraulic cylinder pressure is greater than main control valve pressure, increase main control valve pressure by adjusting the main relief. Generally, one half turn clockwise will be adequate to check an individual circuit.
Hydraulic System 8.8.4 Cylinder Torque Specifications a. Lift/Lower Cylinder Model Nut Valve Locking Collar 6036, 6042 1750-2000 lb-ft (2373-2712 Nm) 30-35 lb-ft (41-47 Nm) 300-400 lb-ft (407-542 Nm) 8042, 10042, 10054 1735-1885 lb-ft (2352-2556 Nm) 30-35 lb-ft (41-47 Nm) 300-400 lb-ft (407-542 Nm) b.
Hydraulic System f. Compensation Cylinder Model Head Locknut Set Screw 6036 250-300 lb-ft (339-407 Nm) 675-750 lb-ft (915-1017 Nm) N/A 6042 300-350 lb-ft (407-475 Nm) 650-700 lb-ft (881-949 Nm) 3-4 lb-ft (4-5 Nm) 8042, 10042, 10054 300-400 lb-ft (407-542 Nm) 900-1050 lb-ft (1220-1424 Nm) N/A g.
Section 9 Electrical System Contents PARAGRAPH 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12 9.13 TITLE Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1.1 General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . .
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.
Electrical System 9.2 SPECIFICATIONS 9.4 Electrical system specifications are listed in Section 2, “General Information and Specifications.” 9.3 SAFETY INFORMATION WARNING FUSES AND RELAYS 9.4.1 Engine Compartment Starter relay (1), one 250 amp fuse (2) 200 amp relay (3) for cold start grid heater and starter lockout relay (4) (if equipped) are located inside engine compartment in protective case next to battery.
Electrical System 9.4.2 Cab Harness Fuses and Relays 6036, 6042, 8042 & 10042 10054 11 13 12 14 2 11 13 12 14 24 26 25 27 10 28 2 15 3 6 15 16 6 3 16 17 7 4 18 17 7 4 10 19 18 5 5 29 20 19 8 22 8 23 20 30 21 MAQ0350 21 No. Volt/ Amp 2 12 Volt 3 MAQ0341 No. Volt/ Amp Headlight Switch 23 7.
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 THROTTLE SENSOR # 2 APS GROUND 1 YEL (18) APS SIGNAL 1 VIO (18) APS SUPPLY 1 ORG (18) P14 HTR TAIL 1 8 APS SIGNAL 2 BLK (18) APS GROUND 2 WHT (18) APS SUPPLY 2 RED (18) 8 A B C 8 HTR ORG (12) 8 THROTTLE SENSOR # 1 Electrical Schematic (if equipped for ULS) 3 2 1 SN334 9.5.
RIGHT OUTRIGGER SWITCH LEFT OUTRIGGER SWITCH 1 2 3 4 5 6 7 8 SW217 1 2 3 4 5 6 7 8 SW216 2A BLK (16) 60D YEL/GRN (16) 63 BRN/YEL (16) 60C YEL/GRN (16) 64 GRY/VIO (16) 2B BLK (16) 60B YEL/GRN (16) 61 RED/GRY (16) 60A YEL/GRN (16) 62 VIO/WHT (16) FUSE HARNESS, WIRING, OUTRIGGERS SPL 60 60E YEL/GRN (16) 60E YEL/GRN (16) SPL 2 20 BLK (14) CAB GDN STUD LEFT OUTRIGGER VALVE DOWN 1 2 HV228 64 GRY/VIO (16) 2D BLK (16) 63 BRN/YEL (16) 2E BLK (16) LEFT OUTRIFFER VALVE (UP) 1 2 HV229 9-6 2G BLK (16)
9-7 PARK BRAKE SWITCH TO 152B IN CAB TO 41B IN CAB CAB HARNESS HARNESS, LOGIC 3 RED (14) 3C RED (14) 2 BLK (14) 2J BLK (14) 7 TAN (16) 35 BRN/GRN (16) 45B DBL (16) 52 DBL/RED (16) 51B BLU/WHT (16) 45A DBL/ORG (16) 45B DBL (16) PARK BRAKE WIRING WITH OUTRIGGER HARNESS CAB GND STUD TO 107B IN CAB MAQ0630 FUSEBLOCK PWR 6036, 6042, 8042, 10042, 10054 SPL 3 3B RED (14) 3A RED (14) SPL 2A 70B ORG/BLK (16) 70C ORG/BLK (16) RIGHT DOWN OUTRIGGER VALVES RIGHT UP 61 RED/GRY (16) 2G BLK (16) 50B
6036, 6042, 8042, 10042, 10054 1 CAB GND STUD 1 DIAGNOSTIC FUSE 10A DIAGNOSTIC 1 1 IGN BLU (18) IGNA BLU (18) FUSE A 2 1 HDLIGHTS PWR TAIL 34 RED/BLK (16) 34A RED (16) FUSE B 2 1 155 GRN/RED (16) 2MM BLK (12) 2LL BLK (12) PWR RED (16) PWR2 RED (16) IGN BLU (18) GND BLK (16) PWR RED (16) CANH YEL (18) CANL GRN (18) 21C RED (16) A 23 GRN (16) B LB162 154 BLU/WHT (16) 2 1 ROAD LIGHT HARN ROAD LIGHT TAILS 1 5A TURN SIGNAL 5A A B C D E F G H J LIGHTS FUSE HIGH BEAM 27B RED (12) 27F
ENG_BULK1_15M TRANS GND ENG_BULK2_15F T312 2G BLK (16) X1 A B C D E F G H J K L M N O P Q R S T U V W X D304 103A BLU (16) A 101A BRN (16) B 102 PNK (16) C D E 2DD BLK (16) F D305 1 FUEL SENDER T87 1 T88 2A BLK (16) 17 GRY (16) A B HV111 HV313 A B 9 GRN (16) 2B BLK (16) 8 GRN (16) 2C BLK (16) 18 GRN (16) S 105 S 101 S 103 S 102 S 104 APS SUPPLY 2 RED (18) APS GROUND 2 WHT (18) APS SIGNAL 2 BLK (18) APS GROUND 1 BLK (18) APS SUPPLY 1 BLK (18) APS SIGNAL 1 BLK (18) S 150 X44 CNH1 YEL
A B C D E F G H J K L M N O P Q R S T U V W X CHG ORN (16) HTR TAIL S7 APS SUPPLY 1 ORG (18) APS SIGNAL 1 VIO (18) APS GROUND 1 YEL (18) 8 8 HARNESS, DASH/THROTTLE HTR/HRN/CHARGE FUSE THROTTLE SENSOR # 2 P14 APS SIGNAL 2 BLK (18) APS SUPPLY 2 RED (18) APS GROUND 2 WHT (18) HRT ORG (12) 1 CHG2 ORG (12) 1 8 APS SIGNAL 2 BLK (18) APS GROUND 2 WHT (18) APS SUPPLY 2 RED (18) A B C 9-10 8 APS GROUND 1 YEL (18) APS SIGNAL 1 VIO (18) APS SUPPLY 1 ORG (18) THROTTLE SENSOR # 1 9.5.
RIGHT OUTRIGGER SWITCH LEFT OUTRIGGER SWITCH 1 2 3 4 5 6 7 8 SW217 1 2 3 4 5 6 7 8 SW216 2A BLK (16) 60D YEL/GRN (16) 63 BRN/YEL (16) 60C YEL/GRN (16) 64 GRY/VIO (16) 2B BLK (16) 60B YEL/GRN (16) 61 RED/GRY (16) 60A YEL/GRN (16) 62 VIO/WHT (16) FUSE HARNESS, WIRING, OUTRIGGERS SPL 60 60E YEL/GRN (16) 60E YEL/GRN (16) SPL 2 20 BLK (14) CAB GDN STUD LEFT OUTRIGGER VALVE DOWN 1 2 HV228 64 GRY/VIO (16) 2D BLK (16) 63 BRN/YEL (16) 2E BLK (16) LEFT OUTRIFFER VALVE (UP) 1 2 HV229 6036, 6042, 804
6036, 6042, 8042, 10042, 10054 TO 152B IN CAB CAB HARNESS TO 41B IN CAB CAB GND STUD TO 107B IN CAB FUSEBLOCK PWR PARK BRAKE SWITCH MAQ0680 HARNESS, LOGIC 3 RED (14) 3C RED (14) 2 BLK (14) 2J BLK (14) 7 TAN (16) 35 BRN/GRN (16) 45B DBL (16) 52 DBL/RED (16) 51B BLU/WHT (16) 45A DBL/ORG (16) 45B DBL (16) SPL 3 3B RED (14) 3A RED (14) SPL 2A PARK BRAKE WIRING FOR MACHINES WITH OUTRIGGER HARNESS 70B ORG/BLK (16) 70C ORG/BLK (16) RIGHT DOWN OUTRIGGER VALVES RIGHT UP 61 RED/GRY (16) 2G BLK
9-13 1 DIAGNOSTIC FUSE 10A DIAGNOSTIC 1 1 FUSE A 2 1 HDLIGHTS PWR TAIL 34 RED/BLK (16) 34A RED (16) IGN BLU (18) IGNA BLU (18) FUSE B 2 1 155 GRN/RED (16) 2LL BLK (12) 2MM BLK (12) PWR RED (16) PWR2 RED (16) 154 BLU/WHT (16) 2 1 IGN BLU (18) GND BLK (16) PWR RED (16) CANH YEL (18) CANL GRN (18) 21C RED (16) A 23 GRN (16) B LB162 HIGH BEAM CAB GND STUD 1 ROAD LIGHT HARN ROAD LIGHT TAILS 1 5A TURN SIGNAL 5A A B C D E F G H J LIGHTS FUSE 3 6L GRN (18) 2 38H YEL (18) 1 CAN TERMINATI
ENG_BULK1_15M ENG_BULK2_15F T312 2G BLK (16) ECM_BULK_23S X2 A B C D E F G H J K L M N O P Q R S T X1U V W X 103A BLU (16) A 101A BRN (16) B 102 PNK (16) C D E 2DD BLK (16) F D305 D E 2D BLK (16) F D304 1 T87 1 T88 HV313 A B A B HV111 2A BLK (16) 8 GRN (16) 2C BLK (16) 9 GRN (16) 2B BLK (16) S 105 S 101 S 103 S 102 S 104 CHG ORN (16) APS SUPP 2 RED (18) APS GND 2 WHT (18) APS SIG 2 BLK (18) APS GND 1 BLK (18) ASP SUPP 1 BLK (18) APS SIG 1 BLK (18) 18 GRN (16) 17 GRY (16) 104B(S1) YE
Electrical System 9.6 9.6.1 ENGINE START CIRCUIT 1. The main fuse may be blown, requiring replacement. Check for the cause of the blown fuse. 2. There may be a defect in the ignition key switch, ignition wiring or starter solenoid. Starter 3. Check battery condition. Clean the battery posts and the connectors at each end of the battery cables. IF EQUIPPED FOR ULS 4. Check for broken wiring and damaged insulation on the wiring. Replace all broken or damaged wiring. 5.
Electrical System 6. Support starter and remove fasteners securing starter to engine. Remove negative (-) ground cable from its starter mounting bolt. 9.7 CHARGING CIRCUIT IF EQUIPPED FOR ULS 2 7. Remove the starter from the machine. d. Starter Installation 1. Position starter in its mounting on flywheel housing. Position ground cable over correct starter mounting bolt. Secure starter with previously used hardware. 2. Connect positive (+) battery cable to upper solenoid stud.
Electrical System 4. Run the engine and check the alternator for noise. A loose drive pulley, loose mounting hardware, worn or dirty internal alternator bearings, a defective stator or defective diodes can cause noise. Replace a worn or defective alternator. 9.7.1 Alternator a. Alternator Removal alignment. (Refer to the appropriate Operation & Safety Manual.) 4. Connect the previously labeled wire leads to the alternator. 5. Properly connect the battery. 6.
Electrical System 9.8 WINDOW WIPER/WASHER WINDSHIELD WIPER MOTOR 9.8.1 12. Remove the metal hex jam nut and metal washer from the motor shaft. 13. Remove the motor mounting bolts, panto adapter and gasket from the motor shaft. Windshield Wiper Motor a. Removal Note: It may be necessary to remove several hydraulic hoses from behind the dash in order to remove and install the wiper motor housing. (Refer to Section 4.3.1, “Steering Column and Steering Valve.”) 1.
Electrical System 9. Turn ignition key switch to the RUN position, and operate windshield wiper in both LOW and HIGH speeds to ensure proper operation and that correct wiper travel is achieved. 10. If previously removed, install hydraulic hoses under the dash. (Refer to Section 4.3.1, “Steering Column and Steering Valve.”) 11. Install the previously removed dash panels. 8. Unclip the plastic motor cover (6) and remove. 9. From the top of the cab, remove the nut from the wiper motor shaft. 10.
Electrical System 9.8.3 Windshield Washer Reservoir c. Installation and Testing 1. Connect windshield washer hoses to reservoir. 2. Connect the cab wiring harness connectors to the reservoir connectors. 3. Install the reservoir tank onto the welded studs. 7 4. Install the lock washers and nuts and secure. 5. Fill the washer fluid reservoir with washer fluid. 6. Properly connect the battery. 7. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 8.
Electrical System 7. Remove the screws and backing locknuts from the cab heater and fan control panel. 8. Pull the control panel out from the dash panel, and if removing variable speed fan control, remove the cab harness connector. 9. If removing the temperature control knob, disconnect the cable connector and remove control knob. 10. Remove the locknut from the suspect control shaft. 9.10 9.10.1 SOLENOIDS, SENSORS AND SENDERS Coolant Level Switch (if equipped for ULS) a.
Electrical System 3. Properly connect the battery. 4. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 5. Start engine. Allow it to reach operating temperature and observe the operator instrument cluster for warning indication. If switch is not defective, 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.
Electrical System 9.10.3 Transmission Solenoid Valves 5. Open the rear door. Allow the system fluids to cool. 6. Remove the transmission covers. 11 7. Unplug the transmission temperature sender connector from the wiring harness connector. 8. The sender is threaded into the transmission housing. Remove the sender. b. Transmission Temperature Sender Inspection and Replacement 10 Inspect the sender and the wiring harness connector terminals for continuity.
Electrical System 9.10.5 Service Brake Switch b. Service Brake Switch Installation 1. Ensure that there is only one thread showing above the locknut on the shaft of the switch body. 12 13 2. Insert switch body through the top of the service brake switch bracket. 3. Thread the switch dust cover onto the switch body until finger tight against the service brake switch bracket. 4. Use a wrench and fully tighten the locknut against the service brake switch bracket.
Electrical System 8. Using the switch dust cover and the locknut in combination, position the brake switch so the StabilTRAK dash light comes ON at the 150 ±50 psi (10,3 ±3,4 bar) brake pressure. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 9. Repeat steps 6 through 8 until the Stabil-TRAK dash light comes ON at 150 ±50 psi (10,3 ±3,4 bar) brake pressure. 4. Properly disconnect the battery. 10.
Electrical System 9.10.7 Boom Extend Interlock Sensor (10054 only) 7. Loosen the inside locknut (17) on the sensor (18). 8. Slide the sensor out of the bracket and remove. The boom extend interlock sensor is located on the left side of the machine, on the outer boom frame and just behind the cab. The boom extend interlock sensor prohibits the last boom section from extending unless both outriggers are down and pressure is applied to the ground surface. a. Boom Extend Interlock Sensor Removal 1.
Electrical System 9.10.8 9.11 Outrigger Pressure Switches (10054 Only) DISPLAY MONITOR AND GAUGES 9.11.1 a. Removal 1. Park the vehicle on a firm, level surface. Level the vehicle, ground the attachment, place the travel select lever in the (N) NEUTRAL position, place the neutral lock lever in the (N) NEUTRAL LOCK position and engage the parking brake switch. 2. Raise both outriggers fully, and shut the engine OFF. 3. Open the rear door. Allow the system fluids to cool. 4.
Electrical System 9.12 DASH SWITCHES c. Inspection and Replacement Note: For information on the front windshield wiper, rear window wiper and washer systems, refer to Section 9.8, “Window Wiper/Washer Windshield Wiper Motor.” 9.12.1 To determine the proper operation of the ignition key switch, test the terminals on the back of the switch for continuity with an ohmmeter.
Electrical System 9.12.2 Dash Switches c. Inspection and Replacement a. Switch Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the rear door. Allow the system fluids to cool. 4.
Electrical System 9.13 TROUBLESHOOTING 9.13.1 Fault Detection Faults are detected while key switch is in RUN position, during operation of machine itself. If a fault becomes active (currently detected) at this time, a fault is logged in memory and a snapshot of engine parameters is logged. In addition, certain faults may illuminate warning lamp (amber) or stop lamp (red) depending upon severity of the active fault. Fault codes will display in the instrument cluster display (9).
Electrical System 9.13.
Electrical System Fault Code SPN Code FMI Code LAMP Area Description 141 100 4 Amber Engine Oil Pressure Oil Pressure Sensor Circuit—Voltage Below Normal, or Shorted to Low Source 143 100 18 Amber Engine Oil Pressure Oil Pressure Low—Data Valid but Below Normal Operational Range—Moderately Severe Level 415 100 1 Red Engine Oil Pressure Oil Pressure Low – Data Valid but Below Normal Operational Range - Most Severe Level 435 100 2 Amber Engine Oil Pressure Oil Pressure Sensor Circ
Electrical System Fault Code SPN Code FMI Code LAMP Area Description 153 105 3 Amber Intake Manifold #1 Temp Intake Manifold Air Temperature Sensor Circuit—Voltage Above Normal, or Shorted to High Source 154 105 4 Amber Intake Manifold #1 Temp Intake Manifold Air Temperature Sensor Circuit—Voltage Below Normal, or Shorted to Low Source 155 105 0 Red Intake Manifold #1 Temp Intake Manifold Air Temperature High—Data Valid but Above Normal Operational Range—Most Severe Level 488 105 1
Electrical System Fault Code SPN Code FMI Code LAMP 422 111 2 Amber Coolant Level Coolant Level - Data Erratic, Intermittent, or Incorrect 2448 111 17 Amber/ Blinking Coolant Level 449 157 0 Red 451 157 3 Amber Injector Injector Metering Rail #1 Pressure Sensor Circuit—Voltage Metering Rail Above Normal, or Shorted to High Source 1 Pressure 452 157 4 Amber Injector Injector Metering Rail #1 Pressure Sensor Circuit—Voltage Metering Rail Below Normal, or Shorted to Low Source 1 Pre
Electrical System Fault Code SPN Code FMI Code LAMP Area Description 489 191 18 Amber Transmission Transmission Output Shaft Speed—Data Valid but Below Output Shaft Normal Operational Range—Moderately Severe Level Speed 3328 191 9 Amber 2375 412 3 Diagnostic Description Transmission Output Shaft Speed—Abnormal update rate Amber Exhaust Gas Recirculation (EGR) Temperature Exhaust Gas Recirculation (EGR) Temperature Sensor Circuit— Voltage Above Normal, or Shorted to High Source Exhaust
Electrical System Fault Code SPN Code FMI Code LAMP Area Description 1117 627 2 None Power Supply Power Lost With Ignition On—Data Erratic, Intermittent, or Incorrect 343 629 12 Amber Controller #1 Engine Control Module Warning internal hardware failure - Bad Intelligent Device or Component 2311 633 31 Amber Fuel Control Valve #1 Fueling Actuator #1 Circuit Error—Condition Exists 285 639 9 Amber SAE J1939 Datalink SAE J1939 Multiplexing PGN Timeout Error—Abnormal Update Rate 28
Electrical System Fault Code SPN Code FMI Code 2195 703 14 731 723 7 Amber Engine Speed/Position #2 Mechanical Misalignment Between Engine Speed Camshaft and Crankshaft Sensors—Mechanical System Sensor #2 Not Responding Properly or Out of Adjustment 778 723 2 Amber Engine Speed Engine Speed Sensor (Camshaft) Error—Data Erratic, Sensor #2 Intermittent, or Incorrect 2322 723 2 None Engine Speed Engine Speed /Position Sensor #2—Data Erratic, Intermittent, Sensor #2 or Incorrect 2555 729
Electrical System Fault Code SPN Code FMI Code LAMP Area Description 271 1347 4 Amber Fuel Pump Pressurizing Assembly #1 High Fuel Pressure Solenoid Valve Circuit—Voltage Below Normal, or Shorted to Low Source 272 1347 3 Amber Fuel Pump Pressurizing Assembly #1 High Fuel Pressure Solenoid Valve Circuit—Voltage Above Normal, or Shorted to High Source 497 1377 2 Amber Switch Circuit Multiple Unit Synchronization Switch Circuit—Data Erratic, Intermittent, or Incorrect 649 1378 31 Amb
Electrical System Fault Code SPN Code FMI Code LAMP Area Description Diagnostic Description 386 3509 3 Amber 5 Volts DC Supply Sensor Supply Voltage #1 Circuit – Voltage Above Normal, or Shorted to High Source 187 3510 4 Amber 5 Volts DC Supply Sensor Supply Voltage #2 Circuit—Voltage Below Normal, or Shorted to Low Source 227 3510 3 Amber 5 Volts DC Supply Sensor Supply Voltage #2 Circuit—Voltage Above Normal, or Shorted to High Source 238 3511 4 Amber System Diagnostic code #
Electrical System Fault Code SPN Code FMI Code LAMP 3921 5421 7 Amber Engine Turbocharger Wastegate Actuator—Mechanical system not responding or out of adjustment 3922 5421 5 Amber Engine Turbocharger Wastegate Actuator—Current below normal or open circuit 3923 5421 6 Amber Engine Turbocharger Wastegate Actuator—Current above normal or grounded circuit 3927 5421 11 Amber Engine Turbocharger Wastegate Actuator—Root Cause Not Known 3928 5421 11 Amber Engine Turbocharger Wastegate
Section 10 Stabil-TRAK™ System and Boom Interlock System Contents PARAGRAPH 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10 TITLE PAGE Stabil-TRAK™ System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 Boom Extend Interlock System Component Terminology (10054 Only) . . . . . . 10-4 Stabil-TRAK™ Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 Stabil-TRAK™ Operation . . . . . . . . . . . . . . . . . . . . . . . . .
Stabil-TRAK™ System and Boom Interlock System 10.11 10.12 10-2 Stabil-TRAK™ Hydraulic Circuit Operation and Troubleshooting . . . . . . . . . . . 10-25 10.11.1 Stabil-TRAK™ Cylinder Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26 10.11.2 Hydraulic Circuit Operation - FREE PIVOT Mode, Rod Oil Out . . . . . . . . 10-28 10.11.3 Hydraulic Troubleshooting - FREE PIVOT Mode, Rod Oil Out . . . . . . . . . 10-29 10.11.4 Hydraulic Circuit Operation - FREE PIVOT Mode, Base Oil Out .
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™ System and Boom Interlock System 10.2 BOOM EXTEND INTERLOCK SYSTEM COMPONENT TERMINOLOGY (10054 ONLY) To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the boom extend interlock system. The following illustration identifies the components that are referred to throughout this section.
Stabil-TRAK™ System and Boom Interlock System 10.3 STABIL-TRAK™ DESCRIPTION The stabilizing system operates via an interface between: Patented rear axle lock or Stabil-TRAK™system works to stabilize vehicle under various conditions. Appropriate Operation and Safety Manual contains basic Stabil-TRAK™information; a copy of Operation and Safety Manual should always be available in the storage compartment located in the cab .
Stabil-TRAK™ System and Boom Interlock System 10.4 STABIL-TRAK™ OPERATION 10.4.1 H 7 G F E D C Understanding Stabil-TRAK™ System The following is a description of modes in the patented Stabil-TRAK™system. The vehicle may operate in any one of the following modes. 5 8 8 B A 7 5 6 6 OH0603 OH0703 a. Free Pivot Mode Boom below 40° (5), Stabil-TRAK™system is in FREE PIVOT MODE (6). Rear axle is allowed to pivot freely. Frame level control will function normally with or without outriggers down.
Stabil-TRAK™ System and Boom Interlock System 10.4.2 10.4.3 Stabil-TRAK™ Solenoid Valves There are five Stabil-TRAK™solenoid valves installed in the Stabil-TRAK™manifold, attached to the stabilizer cylinder above the left side of the rear axle. If a solenoid valve is suspected of malfunctioning, disconnect the coil wiring lead and test the coil for proper resistance (7-9 ohms) and for proper voltage from the harness (12 VDC). Replace the solenoid coil if open or shorted to ground.
Stabil-TRAK™ System and Boom Interlock System 10.4.4 Relay Testing 10.4.5 If after checking the electrical system, a relay is suspect, test the relay as follows: 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake, straighten all wheels and shut the engine OFF. 2.
Stabil-TRAK™ System and Boom Interlock System 10.5 b. 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, straighten all wheels and shut the engine OFF. 2. Lower the outriggers onto firm terrain, and shut the engine OFF. 3. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 4.
Stabil-TRAK™ System and Boom Interlock System 10.6 BOOM EXTEND INTERLOCK SYSTEM OPERATION (10054 ONLY) The ultimate purpose of this system is to add an extra measure of stability, allowing the boom to be extended to its maximum limits. The boom extend interlock system may operate in one of the two following modes: 10.6.1 6 H G F E D C 8 B Extend Interlock Mode A EXTEND INTERLOCK MODE, limits boom extension (4) to a point after letter “E” has appeared on side of boom and before letter “F” appears.
Stabil-TRAK™ System and Boom Interlock System 10.7 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 10.7.2, “Stabil-TRAK™ System Test Procedures.” 10.7.1 10.7.
Stabil-TRAK™ System and Boom Interlock System Stabil-TRAK System Test Procedures Step 1 a. Place the vehicle on a level surface with 0° level. b. Have the boom fully retracted and horizontal. c. Place an 8in (203 mm) wood or cement block in front of the front left tire. d. Enter the vehicle. e. Fasten the seat belt. FREE PIVOT MODE f. Turn the key to the RUN position. g. Check to be sure the Stabil-TRAK™light is OFF. OH2500 Step 2 a. Start the engine. b. Turn the parking brake switch OFF. c.
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 level the vehicle no more than 5° to the left. LOCKED MODE d. Frame level the vehicle back to 0°. e. Frame level the vehicle no more than 5° to the right. Note: Observe that frame level will be slower than normal during this test. f.
Stabil-TRAK™ System and Boom Interlock System 10.8 STABIL-TRAK™ BOOM INTERLOCK ELECTRICAL CIRCUIT OPERATION AND TROUBLESHOOTING (6042/8042/10042) Note: Before using the 6042, 8042 and 10042 StabilTRAK System Troubleshooting chart and diagrams, complete the Section 10.7.2, “Stabil-TRAK™ System Test Procedures,” to determine what part of the system is not functioning properly.
6036, 6042, 8042, 10042, 10054 C O E DE = = = = = = = LEGEND SHIFTER ZF TRANSMISSION Secondary Function Manifold Park Brake Solenoids 1 2 3 4 5 6 7 8 9 107B 45A2 B+ GEAR GEAR GEAR GEAR 2HH B+ FORWARD REVERSE NEUTRAL 111 De-energized Energized Open Closed Active Circuit (Heavy Line) Inline Harness Connection Component/Bulkhead Connection REVERSE R N F E E 2E PB A 41A 107A 2HH 1 O 3C 7.
10-16 C O E DE = = = = = = = 1 2 3 B+ FORWARD REVERSE NEUTRAL GEAR GEAR GEAR De-energized Energized Open Closed Active Circuit (Heavy Line) Inline Harness Connection Component/Bulkhead Connection LEGEND SHIFTER ZF TRANSMISSION 4 B+ GEAR 113 104 102A 112 101 105 103 150 153 102 102B 30 87 153A 87A 2EE 85 86 153 45 O 112 113B Park Brake Disengage Relay E 30 31 87 113 112 112A 113 113A 2FF 85 86 111 111 35 157 7 106 87 O 45 Boom Angle Sensor 35
6036, 6042, 8042, 10042, 10054 C O E DE = = = = = = = 107A LEGEND SHIFTER ZF TRANSMISSION R N F 2E Secondary Function Manifold Park Brake Solenoids DE PB A 2HH 1 1 2 3 4 5 6 7 8 9 107B 45A2 B+ GEAR GEAR GEAR GEAR 2HH B+ FORWARD REVERSE NEUTRAL 111 C De-energized Energized Open Closed Active Circuit (Heavy Line) Inline Harness Connection Component/Bulkhead Connection REVERSE 2 Park Brake Switch To Fuel Shutoff 3C 7.
Stabil-TRAK™ System and Boom Interlock System 10.9 STABIL-TRAK™ BOOM INTERLOCK ELECTRICAL CIRCUIT OPERATION AND TROUBLESHOOTING (10054) Note: Before using the 10054 Stabil-TRAK System Troubleshooting chart and diagrams, complete Section 10.7.2, “Stabil-TRAK™ System Test Procedures,” and Section 10.10, “Boom/Outrigger Interlock System Test,”, to determine what part of the system is not functioning properly.
Stabil-TRAK™ System and Boom Interlock System Note: If an outrigger is raised or a pressure switch is defective, boom on the 10054 will not extend beyond the 42 Series extension limit. Definitions: Boom Retracted = Less than 42 Series extension limit DE = De-energized E = Energized C = Closed O = Open 42 Series Exte ns io PB = Park Brake n Boom Extended = Boom at 42 Series extension limit or greater (See Figure at Right).
10-20 C O E = = = = = = = REVERSE FORWARD R N F 2K2 1 2 3 4 5 6 7 8 B+ B+ FORWARD REVERSE NEUTRAL GEAR GEAR GEAR GEAR 45A2 107B 9 LEGEND SHIFTER ZF TRANSMISSION E 51D Secondary Function Manifold Park PB A Brake Solenoids 51B DE 2HH To Fuel Shutoff 3C 45 113 104 102A 112 101 105 103 150 153 7.
6036, 6042, 8042, 10042, 10054 C O E DE = = = = = = = R B+ FORWARD REVERSE NEUTRAL GEAR GEAR GEAR 103 113 104 102A 112 101 105 De-energized Energized Open Closed Active Circuit (Heavy Line) Inline Harness Connection Component/Bulkhead Connection LEGEND 1 2 3 4 5 6 7 102 112 113B 113 113 113A 111 112 30 30 87A 114A 87 104 2H 150B 101B 105B 102B 103B 104B 150 150 2J 101 101 7 6 5 4 2 3 1 7 104 102 103 105 102 DE 45 105 103 B BLK BLU -
10-22 C O E = = = = = = = REVERSE 2K2 1 2 3 4 5 6 7 8 B+ 3C 45 113 104 102A 112 101 105 103 150 153 7.5A 45 30 87 112 113B Park Brake Disengage Relay DE 111 111 113 113 113A To Back-Up Alarm 112 70C Back-Up Alarm Relay 24A To Horn 10A 31 87 24 30 87A 2BB 85 86 70B 45A 7.
Stabil-TRAK™ System and Boom Interlock System 10.10 BOOM/OUTRIGGER INTERLOCK SYSTEM TEST Before performing the following Boom/Outrigger Interlock System Test, perform Section 10.7, “Stabil-TRAK™ System Test,” to determine if the Stabil-TRAK™system is working properly. If necessary, repair Stabil-TRAK™ system before testing boom/outrigger interlock system. 10.10.
Stabil-TRAK™ System and Boom Interlock System Boom/Outrigger Interlock System Test Procedures BOOM EXTEND MODE 1 Step 1 a. Place the vehicle with no load on a hard, level surface such as blacktop or concrete. b. Fasten your seat belt. Step 2 BOOM EXTEND MODE 2 a. With 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.
Stabil-TRAK™ System and Boom Interlock System 10.11 STABIL-TRAK™ HYDRAULIC CIRCUIT OPERATION AND TROUBLESHOOTING The function of the Stabil-TRAK™system varies under different operating conditions. The basic modes include the FREE PIVOT MODE, SLOW PIVOT MODE and LOCKED MODE. The hydraulic operation and troubleshooting information for each of these modes will be described on the following pages.
Stabil-TRAK™ System and Boom Interlock System 10.11.1 Stabil-TRAK™ Cylinder Oil Flow In the FREE PIVOT and SLOW PIVOT MODES, oil flow from the stabilizer cylinder will be in one of two directions; ROD OIL OUT or BASE OIL OUT. ROD OIL OUT flow will occur when the left side of the rear axle is lower than the right side (left wheel in a pothole, or the right wheel passing over an obstruction), causing the cylinder to extend (1).
Stabil-TRAK™ System and Boom Interlock System This Page Intentionally Left Blank 6036, 6042, 8042, 10042, 10054 10-27
Stabil-TRAK™ System and Boom Interlock System P IN T T AUX MAIN CONTROL VALVE FRAME SWAY ATTACH TILT FRAME LEVEL CYLINDER LFT/LWR Hydraulic Circuit Operation - FREE PIVOT Mode, Rod Oil Out EXT/RET 10.11.2 BYPASS CHECK VALVE TM STABIL-TRAK CYLINDER G3 G2 FTR 3 V DE 2A .030 DIA. C PBG PSG G 2B P 3 1 12B E 2 4B 4A 12A DE DE E .060 DIA. .060 DIA.
Stabil-TRAK™ System and Boom Interlock System 10.11.3 Hydraulic Troubleshooting - FREE PIVOT Mode, Rod Oil Out Conditions: • Ignition ON, engine running • Boom angle is below 40° • Travel select lever in (F) FORWARD or (R) REVERSE When frame leveling right, left front tire comes off the ground Check electrical wiring. Not OK Refer to Section 10.8, “Stabil-TRAK™ Boom Interlock Electrical Circuit Operation and Troubleshooting (6042/ 8042/10042),” or Section 10.
Stabil-TRAK™ System and Boom Interlock System P IN T T AUX MAIN CONTROL VALVE FRAME SWAY ATTACH TILT FRAME LEVEL CYLINDER LFT/LWR Hydraulic Circuit Operation - FREE PIVOT Mode, Base Oil Out EXT/RET 10.11.4 BYPASS CHECK VALVE TM STABIL-TRAK CYLINDER G3 G2 FTR V 3 DE 2A .030 DIA. C PBG PSG G 2B P 2 1 12B E 4B 4A 12A DE DE E .060 DIA. .060 DIA.
Stabil-TRAK™ System and Boom Interlock System 10.11.5 Hydraulic Troubleshooting - FREE PIVOT Mode, Base Oil Out Conditions: • Ignition ON, engine running With boom below 40°, when frame leveling to left, the right front tire comes off the ground. • Boom angle is below 40° • Travel select lever in (F) FORWARD or (R) REVERSE Check electrical wiring. Not OK Refer to Section 10.8, “Stabil-TRAK™ Boom Interlock Electrical Circuit Operation and Troubleshooting (6042/ 8042/10042),” or Section 10.
Stabil-TRAK™ System and Boom Interlock System P IN T T STABIL-TRAK CYLINDER AUX MAIN CONTROL VALVE FRAME SWAY ATTACH TILT FRAME LEVEL CYLINDER LFT/LWR Hydraulic Circuit Operation - SLOW PIVOT Mode, Rod Oil Out EXT/RET 10.11.6 BYPASS CHECK VALVE TM G3 G2 FTR 3 V DE 2A .030 DIA. C PBG PSG G 2B T PLT P PS HYDRAULIC RESERVOIR PB 1 12B 4B 4A 12A DE E E DE 2 .060 DIA. 3 5 .060 DIA.
Stabil-TRAK™ System and Boom Interlock System 10.11.7 Hydraulic Troubleshooting - SLOW PIVOT Mode, Rod Oil Out Conditions: • Ignition ON, engine running • Boom angle is above 40° • Travel select lever in (F) FORWARD or (R) REVERSE While traveling, ride feels spongy (riding on 3 wheels). Check electrical wiring. Not OK Refer to Section 10.8, “Stabil-TRAK™ Boom Interlock Electrical Circuit Operation and Troubleshooting (6042/ 8042/10042),” or Section 10.
Stabil-TRAK™ System and Boom Interlock System P IN T T STABIL-TRAK CYLINDER AUX MAIN CONTROL VALVE FRAME SWAY ATTACH TILT FRAME LEVEL CYLINDER LFT/LWR Hydraulic Circuit Operation - SLOW PIVOT Mode, Base Oil Out EXT/RET 10.11.8 BYPASS CHECK VALVE TM G3 G2 FTR V 3 DE 2A .030 DIA. C PBG PSG G 2B P PS 1 12B 4B 4A 12A DE E E DE .060 DIA. 4 5 2 .060 DIA.
Stabil-TRAK™ System and Boom Interlock System 10.11.9 Hydraulic Troubleshooting - SLOW PIVOT Mode, Base Oil Out Conditions: • Ignition ON, engine running • Boom angle is above 40° • Travel select lever in (F) FORWARD or (R) REVERSE • Park brake OFF • Service brake DISENGAGED While traveling, ride feels spongy (riding on 3 wheels). Check electrical wiring. Not OK Refer to Section 10.8, “Stabil-TRAK™ Boom Interlock Electrical Circuit Operation and Troubleshooting (6042/ 8042/10042),” or Section 10.
Stabil-TRAK™ System and Boom Interlock System 10.11.10 Hydraulic Circuit Operation LOCKED MODE a. Conditions: • Boom angle is above 40° • Park brake ON, or service brake ENGAGED, or travel select lever in (N) NEUTRAL b. Operation: When the conditions are met, solenoids 4A, 4B, 12A and 12B are de-energized and solenoid 3 is energized. In the LOCKED MODE, oil is prevented from flowing through the Stabil-TRAK™manifold due to check valves in solenoid-operated valves 4A (1), 4B (2), 12A (3), and 12B (4). 10.11.
Stabil-TRAK™ System and Boom Interlock System 10.11.12 Hydraulic Troubleshooting - LOCKED MODE, Will Not Frame Level Right P IN T 11 STABIL-TRAK CYLINDER 10 TM G3 G2 FTR 7 6 3 2A 9 E C 5 PBG PSG G 3 8 PS 12B 4B 4A 12A DE DE DE DE 2 .060 DIA. HYDRAULIC RESERVOIR PB SECONDARY FUNCTION MANIFOLD 1 4 T PLT P .060 DIA. BYPASS CHECK VALVE V .030 DIA.
Stabil-TRAK™ System and Boom Interlock System 10.11.13 Hydraulic Circuit Operation LOCKED MODE, Frame Level Left Oil from rod end of the frame level cylinder flows through the check valve (3) opened by incoming pilot pressure oil, to the FTR port of the Stabil-TRAK™manifold. a. Conditions Oil entering at port FTR flows through solenoid valve 3 (4) through check valve 2B (5), to the rod end of the StabilTRAK™cylinder (6).
Stabil-TRAK™ System and Boom Interlock System P IN T 2 STABIL-TRAK CYLINDER 4 3 TM G3 G2 FTR 7 V 3 E .030 DIA. C PBG PSG G 2B 11 6 4B DE DE 9 .060 DIA. 12 10 .060 DIA. 4A 12A DE DE T PLT P 12B BYPASS CHECK VALVE 8 2A 5 AUX T FRAME SWAY ATTACH TILT MAIN CONTROL VALVE 1 LFT/LWR FRAME LEVEL CYLINDER EXT/RET 10.11.
Stabil-TRAK™ System and Boom Interlock System 10.12 BOOM EXTEND SYSTEM HYDRAULIC CIRCUIT OPERATION AND TROUBLESHOOTING The function of the boom extend interlock system varies under different operating conditions. The basic modes include the EXTEND INTERLOCK MODE and OUTRIGGER INTERLOCK MODE. Hydraulic operation and troubleshooting information for each of these modes will be described on the following pages. 10.12.
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Stabil-TRAK™ System and Boom Interlock System 10.12.2 Hydraulic Circuit Operation Extend Interlock Mode valve (5), causing it to close. This prevents oil flow to the extend/retract cylinder (6), preventing the boom from being extended further. Operation: When the outriggers in the RAISED position, the outrigger pressure switches (1 and 2) are open. As the boom is extended past the boom extend switch, the switch opens, de-energizing the boom lockout solenoid (3).
Stabil-TRAK™ System and Boom Interlock System BOOM LOCKOUT VALVE EXTEND/RETRACT CYLINDER 8 5 C1 6 7 3 T 4 DE V1 P T OUTRIGGER VALVE AUX FRAME SWAY ATTACH TILT P BYPASS CHECK VALVE IN T LFT/LWR EXT/RET 9 T MAIN CONTROL VALVE HYDRAULIC RESERVOIR LS B2 A2 E A1 R 10 B1 E R PUMP HYDRAULIC OIL COOLER BYPASS CHECK VALVE 2 1 R.H. Pressure Return Suction Load Sense 6036, 6042, 8042, 10042, 10054 OUTRIGGER CYLINDER L.H.
Stabil-TRAK™ System and Boom Interlock System 10.12.4 Hydraulic Circuit Operation Outrigger Interlock Mode As the boom extends past the boom extend switch, the switch opens. The boom extend lockout solenoid valve (3), remains energized by the circuit provided by the outrigger pressure switches. Operation: When the outriggers are lowered onto firm terrain, pressure within the outrigger cylinders close the outrigger pressure switches (1 and 2), energizing the boom extend lockout solenoid valve (3). 10.12.
Stabil-TRAK™ System and Boom Interlock System BOOM LOCKOUT VALVE EXTEND/RETRACT CYLINDER 5 4 C1 E 3 T V1 P T MAIN CONTROL VALVE AUX FRAME SWAY ATTACH TILT P IN T LFT/LWR T EXT/RET OUTRIGGER VALVE BYPASS CHECK VALVE HYDRAULIC RESERVOIR LS B2 A2 E A1 R B1 E R PUMP HYDRAULIC OIL COOLER BYPASS CHECK VALVE 1 2 R.H. Pressure Return Suction Load Sense 6036, 6042, 8042, 10042, 10054 OUTRIGGER CYLINDER L.H.
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31200796 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 2 65811111 Fax: +61 2 65813058 JLG Latino Americana Ltda.
