Service Manual Model 6036 S/N 14834 & After 8990416 Revised February 11, 2005
EFFECTIVITY PAGE September, 2001 - Original issue. February 11, 2005 - B - Replaced all branding with JLG.
EFFECTIVITY PAGE Model 6036 Legacy
SECTION CONTENTS Section Subject Section 1 Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 Page 1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Owners/Operators Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Training Mechanics as Operators . . . . . . . . . .
Section Subject Page Section 5 Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 5.2 5.3 5.4 5.5 5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 9.14 9.15 Section 10 Index Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . .
Section Subject Page This Page Intentionally Left Blank iv Model 6036 Legacy
Section 1 Safety Practices Contents PARAGRAPH 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 Model 6036 Legacy TITLE Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Owners/Operators Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Training Mechanics as Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . .
Safety Practices 1.1 INTRODUCTION JLG products meet all applicable industry safety standards. JLG actively promotes safe practices in the use and maintenance of its products through training programs, instructional manuals and the pro-active efforts of all employees involved in engineering, design, manufacture, marketing and service. This manual is designed to provide service technicians with complete information on the maintenance and repair of the Sky Trak Model 6036 Legacy Telescopic Material Handler.
Safety Practices 1.3 TRAINING MECHANICS AS OPERATORS Because it is necessary to move the vehicle to service or maintain the vehicle, it is necessary that all mechanics are OSHA trained and certified as operators. A mechanic trained in the proper operation of the vehicle can better determine whether all functions are operating correctly. At the time of original purchase, the purchaser of this vehicle was instructed by the seller on its proper use.
Safety Practices 1.4.2 Hazard Statements Signal words and messages are used in conjunction with the safety alert symbol to create hazard statements. These hazard statements convey important information about safety. 1.5 ACCIDENT PREVENTION TAG USAGE Four types of hazard statements are used in this manual. Each statement indicates the existence and degree of relative risk of the hazard described within the statement that follows the signal word.
Safety Practices 1.6 SAFETY INSTRUCTIONS Following are general safety statements to consider before performing maintenance procedures on a vehicle. 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 hazard occurs. For all safety messages, carefully read, understand and follow the instructions before proceeding. 1.6.
Safety Practices 1.6.3 General Hazards SOLVENTS: Only use approved solvents, and solvents that are known to be safe for use. HOUSEKEEPING: Keep the work area and operator’s cab clean and remove all hazards (debris, oil, tools, etc.). FIRST AID: Immediately clean, dress and report all injuries (cuts, abrasions, burns, etc.), no matter how minor. Know the location of a first-aid kit, and know how to use it.
Safety Practices 1.8 HAZARD/EMERGENCY INFORMATION DECALS If a replacement decal is needed, refer to the owners/ operators manual and parts catalog for the latest parts numbers and ordering information, or, contact JLG directly at: Locations of vehicle hazard and other emergency information decals are shown below. As part of routine maintenance, check that ALL hazard and emergency information decals on the vehicle are present and readable. Keep all decals clean.
Safety Practices This Page Intentionally Left Blank 1.
Section 2 General Information and Specifications Contents PARAGRAPH 2.1 2.2 2.3 2.4 2.5 TITLE 6036 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.1 Service Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.2 The Owners/Operators Manual . . . . . . . . . . . .
General Information and Specifications 2.6 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.1 Axles (Differential Housings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.2 Axle Wheel Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.3 Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.
General Information and Specifications 2.1 6036 COMPONENT TERMINOLOGY To understand the safety, operation and maintenance information presented in this manual, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies on this vehicle. The following illustration identifies the components that are referred to throughout this manual.
General Information and Specifications 2.2 2.2.1 INTRODUCTION The vehicle serial number plate (Fig. 2-1, 1) is located at the front of the vehicle on the frame sway cylinder upright. Service Methods Appropriate service methods and proper repair procedures are essential for safe, reliable operation of this vehicle and the safety of the individual doing the work. This Service Manual provides general direction for accomplishing service and repair work with tested, effective techniques.
General Information and Specifications 2.3 2.3.1 TORQUES 3. Tighten the fitting to the proper torque according to the following chart: Fasteners SAE Size All fasteners (nuts, bolts, washers, etc.) are equal to SAE Grade 5 (PC8.8) and are plated, unless otherwise specified. 2.3.2 4 6 8 10 12 16 20 24 Bolts and Nuts Unless otherwise specified, the following values apply for Grade 5 (PC8.
General Information and Specifications 2.3.5 2.4 Flat-Face O-ring Fittings When the vehicle leaves the factory, it is equipped only with straight thread o-ring fittings. Customer-added accessories may differ; therefore, consult the manufacturer’s product literature for information. Improper assembly of this type of joint will result in a leaking joint. Undertightening will result in the joint loosening during normal use.
General Information and Specifications When this is known Multiply by To find VOLUME When this is known Multiply by To find AREA Teaspoons (tsp) 5 Milliliters (ml) Tablespoons (Tbsp) 15 Milliliters (ml) Square centimeters (cm2) 0,4 Square inches (in2) Cubic inches (in3) 16 Milliliters (ml) Square meters (m2) 1,1 Square yards (yd2) Fluid ounces (fl oz) 30 Milliliters (ml) Cups (c) 0.24 Liters Square kilometers (km2) Square miles (mi2) Pints (pt) 0.47 Liters Quarts (qt) 0.
General Information and Specifications 2.5 SPECIFICATIONS 2.5.1 Vehicle Dimensions (With Standard 12-ply 13.00-24 Tires) Description (Fig.
General Information and Specifications I UM V J N 0.0 Q P C S R F 0.0 24.0" K T L O D A B E H G MA8250 Figure 2-2 Vehicle Dimensions with Standard Tires Model 6036 Legacy 2.
General Information and Specifications 2.5.
General Information and Specifications 2.5.
General Information and Specifications 2.5.5 Hydraulic Cylinder Performance Specifications Note: Vehicle with no load, engine at full throttle, hydraulic oil above 130° F (54° C) minimum, engine at operating temperature. Function Approximate Times, in Seconds Boom Extend Less than 15 seconds Boom Retract Less than 15 seconds Boom Lift Retracted Less than 15 seconds Boom Lower Retracted Less than 10 seconds Attachment Tilt - UP 4-6 Attachment Tilt - DOWN 3.5-5.
General Information and Specifications 2.5.7 Engine Performance Specifications Note: Engine manufacturer's maximum “high idle” setting is lockwired and sealed. DO NOT disturb this setting. Engine Make/Model Cummins Turbo/4BT3.
General Information and Specifications 2.5.8 Fluid and Lubricant Capacities Engine Crankcase Oil: Capacity with Filter Change 11.0 qt (10,4 liters) Filter Capacity 1.0 qt (0,9 liters) Oil Type SAE 15W40 Diesel Engine Oil (Refer to Section 2.6.6, “Engine.”) Fuel Tank: Total Capacity 37.0 gal (140 liters) Usable Capacity 35.0 gal (132,5 liters) Type of Fuel Above 32° F (0° C) Standard No. 2 Diesel. (Refer to Section 2.6.6, “Engine.
General Information and Specifications 2.5.
General Information and Specifications 2.5.12 2.6 Tamper Proofing A tamper-proof means is in place on the following adjustable components prior to machine shipment. This can either be tamper-proof paint, or a steel tamper-proof cap. DO NOT attempt to defeat, bypass or alter any tamper-proof device. • Main Valve Port Relief Valves (5) Standard, or (7) Auxiliary Hydraulics • Steering Relief Valve (1) 2.6.1 Axles (Differential Housings) a.
General Information and Specifications 2.6.2 Axle Wheel Ends a. Axle Wheel-End Lubricants In general, use a Universal Tractor Fluid that meets the following specifications: Products known to meet these requirements include: • JOHN DEERE: JDM J20C (HY-GARD) • FORD/NEW HOLLAND: ESN-M2C134-D (Hydraulic Oil 134) Nominal viscosity at 104° F (40° C)....................... 55 cSt • MASSEY-FERGUSON: M-1141 (PERMANTRAN III) Minimum viscosity at 212° F (10° C) .................... 9.
General Information and Specifications 2.6.5 Hydraulic System a. Hydraulic Fluids The hydraulic system is factory-filled with ISO Grade 46 anti-wear hydraulic oil. When filling the hydraulic system, use an anti-wear hydraulic oil meeting ISO Grade 46 with -40° F (-40° C) pour point/ASTM viscosity SUS 215 at 100° F (38° C), or a 10W motor oil that meets the requirements of U.S. ordinance specification MIL-L-2104C.
General Information and Specifications 2.6.7 Drive Shaft Splines IMPORTANT: DO NOT disassemble any of the drive shafts (refer to Section 5, “Axles, Drive Shafts, Wheels and Tires” of this manual for information covering drive shafts and U-joints). 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.
General Information and Specifications 2.6.10 Paint Unless otherwise specified, paint components as indicated in the following sections. a. Orange Paint Durable, premium Sky Trak orange paint is available in both a convenient 16-ounce (480 ml) spray can for touchups, and in a production-size, one gallon (3,8 liters) container for extensive repainting. Consult the appropriate parts manual for the applicable part number and ordering information.
General Information and Specifications 2.8 REPLACEMENT ALWAYS use the correct tool when removing or replacing any part or performing any service. Some procedures may require the use of specialized tools. If needed, many of these tools can be obtained through Snap-on® tool distributors. Contact: Snap-on Incorporated P.O. Box 1410 Kenosha, WI 53141-1410 USA Phone: (262)-656-5200 Internet: http://www.snapon.com Snap-on® is a registered trademark of Snap-on Technologies, Inc.
General Information and Specifications 2.10.3 Bearing Installation 2.12 1. Always install bearings carefully to help avoid damaging their delicate surfaces. 2. Install bearings using one of the following methods: After Service Startup • PRESS FIT for installation on rotating parts such as shafts and gears Note: Refer to the appropriate Owners/Operators manual for engine cold start procedures. • PUSH FIT into static locations such as reduction gear housings 1.
General Information and Specifications 2.12.3 After Hydraulic Component Service 1. Check the torque of fasteners on replaced components. 2. Check that the hoses and tubes are properly attached, properly positioned and that all fittings are properly tightened. 3. Check torque on drive shaft yoke retaining bolts. Tighten these M12 bolts to 156 lb/ft (212 Nm). 4.
General Information and Specifications 2.12.7 After Tire and Wheel Service 1. Check air pressure. 2. Check wheel nut torque. Tighten to 450 lb/ft (610 Nm). 2.12.8 After Engine Service Consult the qualified service agent (manufacturer’s representative and/or service manual) for proper procedures before engine startup. 2.12.9 After Boom Service 1. Check wear pads. 2. Check chain tension adjustment. 3. Apply grease at all lubrication points (grease fittings).
Section 3 Boom Contents PARAGRAPH 3.1 3.2 3.3 3.4 3.5 Model 6036 Legacy TITLE Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.1 Boom System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.2 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom 3.1 BOOM 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 boom system. The following illustration identifies the components that are referred to throughout this section.
Boom WARNING: DO NOT service the vehicle without following all safety precautions as outlined in the “Safety Practices” section of this manual. Failure to follow the safety practices may result in death or serious injury. 3.2 3.2.1 BOOM SYSTEM Boom System Description The boom operates via an interchange among the hydraulic and mechanical systems.
Boom Note: This procedure will require a clear space of approximately 16 feet at the front and rear of the vehicle. 1 2. Park the vehicle on a hard, level surface. Move the boom to a horizontal (level) position. Extend (or retract) the boom until the boom is extended approximately two feet (610 mm). Move the quick attach to the horizontal position.
Boom 6. At the front of the intermediate boom (Fig. 3-4, 1), remove the capscrews (2), lockwashers (3) and flat washers (4) holding the side wear pads (5) and shims (6) to the inside of the intermediate boom. Label the wear pads and shims as “Left Top/Bottom” and “Right Top/Bottom.” Save the shims, capscrews, flat washers, lockwashers and wear pad inserts (7). WARNING: Hydraulic fluid leaking under pressure can penetrate the skin, cause infection, gangrene, and death or serious personal injury.
Boom 13. If your vehicle is equipped with optional auxiliary hydraulics, label and remove the two hoses (Fig. 3-6, 1) from the bulkhead fittings (2) inside the gooseneck (3). Plug the hose ends, and cap the bulkhead fittings to prevent dirt and debris from entering the hydraulic system. 14. Without optional auxiliary hydraulics: Inside the inner boom, remove the two capscrews (Fig.
Boom 15. With optional auxiliary hydraulics: Inside the inner boom, remove the two capscrews (Fig. 3-8, 1), two lockwashers (2) and two flat washers (3) holding the clamp cover (4) and stack clamps (5) to the floor of the inner boom. Remove the clamps from the inner boom. 3 1 4 2 3 2 5 1 2 MA6610 Figure 3-9 Pull the Attachment Tilt and Auxiliary Hydraulics Hoses from the Inner Boom Note: Record the location of the shoulder bolt (Fig. 3-10, 2) to ensure correct installation.
Boom 18. Remove the elastic locknut (Fig. 3-11, 1) and shoulder bolt (2) holding the two yoke plates (3) to disconnect the extend chain yoke (4) from the outer boom. Retain the shoulder bolt and discard the elastic locknut. Lay the chain assembly flat against the inner boom. 1 19. Inspect the yoke plates for wear or distortion. If any wear or distortion is detected, both plates must be replaced. If no wear is detected, the plates can remain assembled to the extend chain clevis’.
Boom 30. Remove the capscrews (Fig. 3-13, 9), lockwashers (10) and flat washers (11) holding the side wear pads (12) and shims (13) to the sides of the inner boom. Label the wear pads and shims as “Left Top/ Bottom” and “Right Top/Bottom.” Save the shims, capscrews, lockwashers, flat washers and wear pad inserts (14). 31. Remove the capscrews (Fig. 3-13, 15), lockwashers (16) and flat washers (17) holding the bottom wear pad (18) and spacer (19) to the bottom of the inner boom.
Boom 3. At the front of the outer boom (Fig. 3-16, 1), remove the capscrews (2), lockwashers (3) and flat washers (4) holding the side wear pads (5) and shims (6) to the inside of the outer boom. Label the wear pads as “Left Top/Bottom” and “Right Top/Bottom.” Save the capscrews, lockwashers, flat washers, shims and wear pad inserts (7).
Boom 6. Remove the capscrews (Fig. 3-19, 1), lockwashers (2) and flat washers (3) holding the hose reel side plate (4), lower left side wear pad (5) and shims (6) to the side of the intermediate boom. Save the capscrews, lockwashers, flat washers, shims and wear pad inserts (7). 7 b. After the hoses are removed from behind the lower retaining bolt (Fig. 3-20, 4), insert the shoulder bolt through the plates, inserting the spacers between the plates as the bolt is inserted.
Boom 9. Without optional auxiliary hydraulics: At the front of the outer boom, label and remove the attachment tilt hoses (Fig. 3-21, 1 and 2) from the tube assemblies (3 and 4). Cap the hose ends. 4 3 10. With optional auxiliary hydraulics: Label and remove the auxiliary hoses (Fig. 3-21, 5 and 6) from the tube assemblies (7 and 8). Cap the hose ends. 2 1 1 MA6740 2 6 Figure 3-22 Remove the Retract Chain Sheave 3 16. Support the front of the extend/retract cylinder (Fig. 3-23, 1). 4 5 3 7 4 17.
Boom Note: Use a hoist capable of lifting 5000 lbs (2268 kg) and two slings to remove the intermediate boom. 19. Place the slings around the intermediate boom. Pull the intermediate boom straight out of the outer boom. Reposition the slings as needed so the intermediate boom balances when removed from the outer boom. Set the intermediate boom down on blocks on a level, hard surface. 1 2 3 WARNING: NEVER weld or drill the boom.
Boom c. Remove the capscrews (Fig. 3-27, 1), lockwashers (2) and flat washers (3) holding the side wear pads (4) and shims (5) to the intermediate boom. Label the wear pads and shims as “Left Side Upper” and “Right Side Upper/Lower.” Save the capscrews, lockwashers, flat washers, shims and wear pad inserts (6). 3.3.3 Outer Boom Removal WARNING: Wear protective footwear with reinforced toe caps and slip-resistant soles.
Boom 8. Label the attachment tilt tube assemblies located under the boom. Remove the capscrews (Fig. 3-32, 1), lockwashers (2) and flat washers (3) holding the clamp covers (4), tube clamps (5) and attachment tilt tube assemblies (6) to the underside of the outer boom. Save the capscrews, clamps and clamp covers. Remove the tube assemblies from the boom. 9. Inspect the tubes (Fig. 3-32, 6) for kinks or crushed areas. Replace any damaged tubes. Proceed to Step 17.
Boom 12. Label and remove the attachment tilt retract hose (Fig. 3-34, 1) and the extend hose (2) from the attachment tilt tubes (3 and 4) at the bulkhead mounting plate (5). Plug the hose ends and cap the attachment tilt tubes. 13. Remove the bulkhead nuts (Fig. 3-34, 6) from the attachment tilt tubes. 3 10 4 9 2 8 5 6 2 7 1 1 6 5 4 3 MA6980 Figure 3-35 Remove the Auxiliary Hydraulic and Attachment Tilt Tubes MA6860 Figure 3-34 Disconnect the Attachment Tilt Hoses 14.
Boom 19. Label and disconnect the boom extend hose (Fig. 3-37, 1) and retract hose (2) from the tubes (3 and 4) at the mounting plate (5). Cap the hose ends. 20. Remove the bulkhead nuts (Fig. 3-37, 6) from the extend and retract tubes. 21. Remove the capscrew and flat washer (Fig. 3-37, 7) holding the clamp cover and tube clamps (8) to the extend and retract tubes to the side of the boom. Retain the capscrew, flat washer, covers and clamps. Remove the tubes from the boom. 3 5 4 7 23.
Boom Note: A hoist with a lifting capacity of 5000 lbs (2268 kg) and two slings are required to remove the outer boom. Note: Record the number, thickness and position of shims to ensure correct installation. 28. Place the slings around the outer boom. The slings should be placed far enough apart on the outer boom so the boom will balance when the boom lift/ lower cylinder mounting pins and pivot pins are removed in the following steps. 33. Remove the capscrews (Fig.
Boom 40. Inspect all wear pads (Fig. 3-42, 1) for wear. If the angle indicators (2) on the ends of the wear pads are visible, the wear pads can be reused. If the pads show uneven wear (front to back), they should be replaced. Replace pads as a set if worn or damaged. 2 2 1 44. At the front of the outer boom, remove the elastic locknut (Fig. 3-44, 1) holding the rubber bumper (2) to the extend cylinder retainer (3). Discard the elastic locknut. 45. Inspect the rubber bumper (Fig. 3-44, 2).
Boom 46. Remove the grease fittings (Fig. 3-45, 1) from the lift/lower cylinder mounts (2) and the slave cylinder mounts (3) on the outer boom. Save the grease fittings for reassembly. 47. Remove the self-aligning bearings (Fig. 3-45, 4) from the lift/lower cylinder mounts (2) and the slave cylinder mounts (3). Inspect the bearings. If the bearing rotates freely inside the outer race, the bearing can be reused. 3.3.
Boom 3. Assemble new or saved lift/lower cylinder bearings (Fig. 3-48, 1) into the lift/lower cylinder mounts (2) on each side of the boom assembly. Orient the fracture (3) in the outer race of each bearing at the 3 o’clock position. Press the bearings into position until the edge of the outer race (4) of each bearing is flush with the edge of the plate (5). 4. Assemble new or saved slave cylinder bearings (Fig. 3-48, 6) into the slave cylinder mounts (7) on each side of the boom assembly.
Boom Note: ALWAYS replace elastic-lined nuts with new elastic-lined nuts to help ensure proper fastening. 1 8. Lift the rod end of the extend/retract cylinder far enough to insert the threaded stud on the rubber bumper (Fig. 3-50, 1) into the hole in the extend/retract cylinder retainer. Secure the rubber bumper in place with a new 3/8-16 elastic locknut (2). Tighten securely. Lower the rod end of the extend/retract cylinder, and allow it to rest on the rubber bumper.
Boom Note: ALWAYS replace elastic-lined nuts with new elastic-lined nuts to help ensure proper fastening. 13. After the pivot pin and shims are in place, use a tapered punch to align the capscrew hole in the pin with the mounting holes in the hub. Insert the capscrew (Fig. 3-52, 5) through the hub and the pin. Secure the capscrew in place with a new 5/8-11 elastic locknut (6). Tighten the elastic locknut securely. 14. Repeat Step 13 to install the pivot pin on the other side of the boom. 3 15.
Boom 19. Use a hoist and sling to position the slave cylinder (Fig. 3-54, 1) onto the lower cylinder mount (2) located on the frame. The cylinder should be positioned with the port fittings (3) toward the outside. 20. Coat the lower pivot pin (Fig. 3-54, 4) with anti-seize compound. Insert the pin through the base end of the slave cylinder. Use a tapered punch to line up the capscrew hole in the pin with the mounting tabs on the cylinder.
Boom 33. Position the attachment tilt retract tube assembly (Fig. 3-58, 1) into the inner hole in the mounting plate (2). Secure the tube using the bulkhead nut (3). 34. Position the attachment tilt extend tube assembly (Fig. 3-58, 4) into the outer hole in the mounting plate (2). Secure the tube using the bulkhead nut (3). 4 3 Note: ALWAYS use new o-rings when servicing the vehicle. 1 35. Install new o-rings into the fittings. Lubricate o-rings with clean hydraulic oil. 2 36.
Boom 38. Install the attachment tilt tube assemblies (Fig. 3-59, 1) to the bottom of the outer boom. Install the tube clamp halves (2). Place one clamp half on each side of the attachment tilt tubes. Secure each set of clamp halves to the boom with a locking plate (3) and a stacking bolt (4). Tighten the stacking bolt securely to hold the upper tubes in place. 39. Place a lower clamp half (Fig. 3-59, 5) on each side of the auxiliary hydraulic tubes (6).
Boom 46. Position the right auxiliary hydraulic tube assembly (Fig. 3-61, 1) into the inner hole in the mounting plate (2). Secure the tube using the bulkhead nut (3). 47. Position the left auxiliary hydraulic tube assembly (Fig. 3-61, 4) into the outer hole in the mounting plate (2). Secure the tube using the bulkhead nut (3). Note: ALWAYS use new o-rings when servicing the vehicle. 48. Install new o-rings into the fittings. Lubricate o-rings with clean hydraulic oil. 49.
Boom 53. At the front of the outer boom, install the lower outside wear pads (Fig. 3-63, 1) and wear pad spacers (2). a. Place the wear pad inserts (Fig. 3-63, 3) into the cavities in the wear pad. Be sure the inserts are seated completely in the cavities. b. Place a wear pad (Fig. 3-63, 1) and a spacer (2) into the outer boom with the hole offset of the wear pad toward the middle of the boom. Align the holes in the spacer and wear pads with the holes in the bottom of the boom. c.
Boom 11 1 6 7 12 13 5 2 5 4 4 3 3 2 1 MA7290 Figure 3-64 Install the Retract Chain Sheave 3. Install the hose reel assembly, left side and bottom wear pads to the rear of the intermediate boom: Note: Shim ALL side wear pads as needed to maintain a total minimum gap of .07-.13" (1,8-3,3 mm) in the horizontal direction. a. Install the hose reel assembly (Fig. 3-65, 1) on the rear of the intermediate boom, with the left side plate to the outside of the boom wall. b.
Boom Note: Shim ALL upper rear wear pads as needed to maintain a total maximum gap of .06" (1,5 mm) at the rear of the pads and maintain a total minimum gap of .07-.13" (1,8-3,3 mm) in the vertical direction. 5. Install the wear pads to the top of the intermediate boom. Position the wear pads so the outside pads are offset to the outside and the center pad is offset to the right as seen in Fig. 3-67. a. Place the wear pad shims (Fig. 3-67, 1) onto the top of the boom.
Boom 3 4 5 6 2 4 5 1 1 MA7460 2 Figure 3-69 Install the Outer Boom Top Wear Pads 3 MA7450 Figure 3-68 Install the Outer Boom Side Wear Pads 10. Install the top wear pads to the inside of the outer boom: a. Place the wear pad inserts (Fig. 3-69, 1) into the cavities of the top wear pads (2). b. Apply Loctite® 242 threadlocker to the threads of the 3/8-16 x 1" capscrews (Fig. 3-69, 3).
Boom 13. Use a hoist and sling to lift the rod end of the extend cylinder (Fig. 3-71, 1) up. Align the rod end of the extend cylinder with the mounts (2) at the front of the intermediate boom. 14. Coat the extend cylinder rod end pin (Fig. 3-71, 3) with an anti-seize compound. Insert the rod end pin through the mounts and secure in place with the retaining rings (4). Be sure the retaining rings are seated securely in the grooves on the pin.
Boom 3.3.6 Inner Boom Installation WARNING: Wear protective footwear with reinforced toe caps and slip-resistant soles. Failure to comply can result in foot or other bodily injury from crushing, slipping or falling. WARNING: NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist. Failure to comply can result in death or serious personal injury.
Boom 3. Assemble the hose clamps to the floor of the inner boom. Keep the two hoses on the left and right sides as they come out of the rear of the inner boom: a. Place a 5/16" lockwasher (Fig. 3-75, 1) and flat washer (2) onto each 5/16-18 x 3-1/2" capscrew (3), and insert the capscrews through the clamp cover plate (4). b. Place a hose clamp half (Fig. 3-75, 5) onto the capscrews. Place the left attachment tilt hose (6) and a hose clamp half (5) onto the capscrews.
Boom 6. Assemble the hose clamps to the floor of the inner boom. Keep the four hoses in line (left to right) as they come out of the rear of the inner boom: 3 a. Place a 5/16" lockwasher (Fig. 3-77, 1) and 5/16" flat washer (2) onto each 5/16-18 x 5" capscrew (3), and insert the capscrews through the clamp cover plate (4). 4 6 b. Place a 3/4" diameter hose clamp half (Fig. 3-77, 5) onto the capscrews.
Boom Note: Shim ALL upper rear wear pads as needed to maintain a total maximum gap of .06" (1,5 mm) at the rear of the pads and maintain a total minimum gap of .07-.13" (1,8-3,3 mm) in the vertical direction. 1 2 3 4 Note: Shim ALL side wear pads as needed to maintain a total minimum gap of .07-.13" (1,8-3,3 mm) in the horizontal direction. 7. Install all wear pads on the rear of the inner boom: a. Place the wear pad inserts (Fig.
Boom 10. At the rear of the inner boom, place the male ends of the hoses (attachment tilt and optional auxiliary hydraulics) inside the inner boom. Be sure the hoses are coiled up and inside the boom completely. 13. Install the top wear pads on the inside of the intermediate boom: a. Place the wear pad inserts (Fig. 3-81, 1) into the cavities of the top wear pads (2). b. Apply Loctite® 242 threadlocker to the threads of the 3/8-16 x 1-1/2" capscrews (Fig. 3-81, 3).
Boom Note: Steps 15-17 apply to vehicles not equipped with auxiliary hydraulics. If the vehicle is equipped with auxiliary hydraulics, proceed to Step 18. 15. Assemble the hoses to the hose reel at the rear of the boom: IMPORTANT: Keep the hoses in the same order as they come from the hose clamps. DO NOT allow the hoses to cross. Note: Loosen the nuts and capscrews only enough to pull the hoses around the hose reel. a. Loosen, but DO NOT remove, the elastic locknuts (Fig.
Boom 18. Assemble the hoses to the hose reel assembly at the rear of the boom: IMPORTANT: Keep the hoses in the same order as they come from the hose clamps. DO NOT allow the hoses to cross. Note: Loosen the nuts enough to pull the hoses around the hose reel. a. Loosen, but DO NOT remove, the elastic locknuts (Fig. 3-84, 1, 2 and 3) on the upper retaining capscrew (4), lower retaining capscrew (5) and center hose reel shoulder bolt (6). b. Loosen, but DO NOT remove, the wear pad mounting capscrews (Fig.
Boom 22. At the front of the outer boom, connect the hose assemblies and tube assemblies to the mounting plate. Note: ALWAYS use new o-rings when servicing the vehicle. 23. Install new o-rings into the fittings. Lubricate o-rings with clean hydraulic oil. 24. Remove the plugs and caps from the hoses and fittings, and connect the attachment tilt (Fig. 3-86, 5) and auxiliary hydraulic (6) (if equipped) hoses to the fittings on the boom tube bulkhead bracket. 25. Lubricate the radius (Fig.
Boom 32. Place the retract chain (Fig. 3-88, 1) around the retract chain sheave on the right side of the boom. Stretch the chain forward and place the clevis between the two anchor plates (2). Align the hole in the clevis with the second hole from the rear of the anchor plates. 33. Insert the shoulder bolt (Fig. 3-88, 3) from the top down in the same hole as recorded in the removal procedure, and secure in place with a new 3/8-16 elastic locknut (4). Tighten the locknut securely.
Boom Note: ALWAYS use new o-rings when servicing the vehicle. 38. Install new o-rings into the fittings. Lubricate o-rings with clean hydraulic oil. 39. With optional auxiliary hydraulics: If the inner boom has been replaced with a new boom, the auxiliary hydraulic fittings need to be reassembled: a. Assemble the two bulkhead fittings (Fig. 3-91, 1) from the original boom to the bulkhead plate (2) inside the gooseneck (3).
Boom 49. Start the engine and operate all boom functions several times. Check the chain tension again and adjust as necessary. Check for leaks, and check the hydraulic fluid level in the tank; add fluid if required. 50. Apply grease to all lubrication points (grease fittings). (Refer to Model 6036 Legacy Owners/Operators Manual.) 51. Install the rear cover (Fig. 3-94, 1), by inserting the capscrew (2) at the top of the cover into the hole (3) in the top of the boom.
Boom 3.3.7 Boom Chains This vehicle uses double extend chains to extend the boom and a single retract chain to retract the boom. The extend and retract chains are constructed of 3/4" pitch links with 6 x 6 leaf lacing. Note: DO NOT attempt to service or repair a chain. Replace a stretched or damaged chain with a new one. Replacement chains are shipped pre-assembled with new clevis’. a.
Boom 2. Fully extend the boom until the extend chain is taut. Shut the engine OFF. The extend chains will be visible for inspection with the vehicle in this state. The retract chain can be visually inspected, at the rear of the boom, as the boom is slowly retracted. While doing the chain inspection, check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain. 3.
Boom Cracked Plates Other Modes of Failure 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. (Refer to Section 3.3.7, e. “Chain Replacement”.) It is important, however, to determine the cause of the crack before installing a new chain so the condition does not repeat itself. • Fatigue Cracking - Fatigue cracks (Fig.
Boom b. Chain Lubrication c. Boom Chain Tension Check After inspection and before being returned to service, chains must be lubricated with a quality chain lubricant (“LUBRIPLATE” Chain & Cable Fluid, “LPS3” or equivalent). 1. Start the engine. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to the NEUTRAL LOCK position and engage the parking brake switch. The lubricant must penetrate the chain joint to prevent wear.
Boom Note: Before making any adjustments to the extend chains, check the following measurement at the rear of the boom. 1 5. Start the engine, retract the boom completely and turn the engine OFF. 6. Remove the thumbscrew (Fig. 3-102, 1), one internal-tooth lockwasher (2) and one flat washer (3) holding the rear cover (4) to the rear of the outer boom. Lift the rear cover straight up until the capscrew in the top of the cover clears the hole in the top of the outer boom.
Boom 12. Recheck the measurement (Fig. 3-103, 1) from the top rear edge of the intermediate boom (2) to the top rear edge of the inner boom (3). Note: If, by adjusting the retract locknut (Fig. 3-104, 1), you still cannot get the the measurement range of 8.0" (203 mm) to 8.5" (216 mm), the boom may require extensive adjustment and/or repair. Contact the JLG Service Department or the nearest JLG Authorized Service Center (ASC). If the measurement is within the range of 8.0" (203 mm) to 8.
Boom 4. Equal chain tension can be checked by the position of the yoke (Fig. 3-108, 2) on the outer boom. The front of the yoke should be parallel with the front edge of the outer boom. 3 1 2 OA0491 1 Figure 3-109 Measure the Extend Chain-to-Top of Intermediate Boom Sag at the Closest Point OH0240 Figure 3-108 Boom Extend Chains and Yoke Plates 5. Start the vehicle, and cycle the boom in and out several times.
Boom e. Chain Replacement IMPORTANT: Chains and clevis’ are wear items and experience the same stress. DO NOT attempt to service or repair a chain or clevis. Replacement chains are shipped pre-assembled with new clevis’. Extend Chain Removal 6. At the front of the outer boom, remove the hex-socket head capscrew (Fig. 3-112, 1) and elastic locknut (2) holding the right side extend chain clevis (3) to the yoke plates (4). Discard the elastic locknut. 7. Inspect the hex-socket head capscrew (Fig.
Boom 10. Inspect wear and condition of the booms, chains, clevis’, chain sheaves, extend/retract cylinder, chain rods, clevis anchors and all mounting hardware. Replace any worn or damaged parts. DO NOT attempt to make any repairs to the chain. IMPORTANT: Chains and clevis’ are wear items and experience the same stress. DO NOT attempt to service or repair a chain or clevis. Replacement chains are shipped pre-assembled with new clevis’. 6. Place the 3/4" flat washer (Fig.
Boom 10. Repeat the entire “Extend Chain Removal and Installation” section. Starting with Step 4 of the “Extend Chain Removal” and continuing on to Step 9 of the “Extend Chain Installation,” to remove and replace the left side extend chain. 13. Install the rear cover (Fig. 3-118, 1), by inserting the capscrew (2) at the top of the cover into the hole (3) in the top of the boom. Secure the rear cover using one thumbscrew (4), one internal-tooth lockwasher (5) and one flat washer (6). 11.
Boom Retract Chain Removal 1. Park the vehicle on a hard, level surface. 2. Fully retract the boom and raise the boom to a horizontal position. Place the travel select lever in (N) NEUTRAL, move the neutral lock lever to NEUTRAL LOCK position, engage the parking brake switch and shut the vehicle OFF. 3 3. Remove the thumbscrew (Fig. 3-119, 1), lockwasher (2) and flat washer (3) holding the rear cover (4) to the rear of the outer boom.
Boom 8. Inspect wear and condition of the booms, chains, clevis’, chain sheaves, extend/retract cylinder, chain rods, clevis anchors and all mounting hardware. Replace any worn or damaged parts. DO NOT attempt to make any repairs to the chain. 2 1 Note: Chains and clevis’ are wear items and experience the same stress. DO NOT attempt to service or repair a chain or clevis. Always replace a stretched or damaged chain or clevis with a new part. Replacement chains are shipped pre-assembled with new clevis’.
Boom 8. Check and adjust the retract chain tension. (Refer to Section 3.3.7, c. “Boom Chain Tension Check.”) 9. Install the rear cover (Fig. 3-124, 1) by inserting the capscrew (2) at the top of the cover into the hole (3) in the top of the boom. Secure the rear cover using one thumbscrew (4), one internal-tooth lockwasher (5) and one flat washer (6). Wear Pad Gaps: FRONT, outer boom to intermediate boom, and intermediate boom to inner boom: TOP:............................. .07-.
Boom Use shims (Fig. 3-126, 1) under the upper rear wear pads as required to maintain a maximum gap of .06" (1,7 mm) (2) at the rear edge of the pads and maintain a total minimum gap of .07-.13" (1,8-3,3 mm) in the vertical direction. 1 Use shims as required to maintain a total minimum gap of .07-.13" (1,8-3,3 mm) between the side wear pads and boom surfaces.
Boom Use shims (Fig. 3-129, 1) under the upper rear wear pads as required, to maintain a maximum gap of .06" (1,7 mm) (2) at the rear edge of the pads and maintain a total minimum gap of .07-.13" (1,8-3,3 mm) in the vertical direction. 1 Use shims as required to maintain a total minimum gap of .07-.13" (1,8-3,3 mm) between the side wear pads and boom surfaces.
Boom 3.4 QUICK ATTACH ASSEMBLY This vehicle is equipped with a quick attach system for easy attachment changes. 7. Lower and then retract the boom until the attachment pivot pins have disconnected from the attachment. 3.4.2 3.4.1 Disconnecting from an Attachment 1. Park the vehicle on a hard, level surface. 2. 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. 3.
Boom 3.4.3 Quick Attach Removal 1. Remove the elastic locknut (Fig. 3-133, 1) and capscrew (2) holding the attachment tilt cylinder rod end pin (3) to the quick attach assembly (4). Save the capscrew and discard the elastic locknut. 2. Support the rod end (Fig. 3-133, 5) of the attachment tilt cylinder. Use a brass punch and rawhide hammer to remove the pin (3) from the quick attach assembly. 3. Inspect the pin (Fig. 3-133, 3) for nicks or surface corrosion.
Boom 3.5 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that occur during operation of the boom. Boom Troubleshooting 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 8.8, “Hydraulic Circuits and Troubleshooting.” 3.
Boom Boom Troubleshooting (Continued) Problem 4. Boom shifts to right or left when extending. 5. Excessive boom pivot pin noise and/or wear. 6. Excessive slave cylinder pivot pin noise and/or wear. 7. Excessive lift/lower cylinder pivot pin noise and/or wear. 8. Rapid boom pad wear. Cause Remedy 1. Boom pivot pin improperly shimmed. 1. Re-shim the boom to a maximum total gap of .10" (2.5 mm) with shims distributed evenly on both sides of the boom pivot pin. 2.
Boom Boom Troubleshooting (Continued) Problem 10. Excessive chain wear. Model 6036 Legacy Cause Remedy 1. Improper chain adjustment. 1. Adjust to correct tension. (Refer to Section 3.3.7, c. “Boom Chain Tension Check.”) Replace chain(s) as needed. (Refer to Section 3.3.7, e. “Chain Replacement.”) 2. Chain sheave(s) not properly lubricated. 2. Lubricate chain sheave. (Refer to Model 6036 Legacy Owners/ Operators Manual.) 3. Chain sheave(s) not rotating freely. 3. Lubricate chain sheave.
Boom This Page Intentionally Left Blank 3.
Section 4 Cab and Covers Contents PARAGRAPH 4.1 4.2 4.3 4.4 4.5 4.6 4.7 Model 6036 Legacy TITLE Operator’s Cab and Covers Component Terminology. . . . . . . . . . . . . . . . . . . . . Operator’s Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 Operator’s Cab Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab and Covers 4.1 OPERATOR’S 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 vehicle cab and covers. The following illustration identifies the components that are referred to throughout this section.
Cab and Covers WARNING: DO NOT service the vehicle without following all safety precautions as outlined in the “Safety Practices” section of this manual. Failure to follow the safety practices may result in death or serious injury. 4.2 4.2.1 OPERATOR’S CAB Operator’s Cab Description The welded metal cab features a modular design, allowing for a relatively quick, simple exchange of the entire cab and/or component parts. The cab is bolted directly to the frame.
Cab and Covers 4.3 4.3.1 OPEN CAB COMPONENTS 1 12 Seat/Seat Belt 2 3 9 4 5 13 15 a. Seat 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, engage the parking brake switch and shut the engine OFF. 14 4 3 6 16 2 15 1 2.
Cab and Covers 4.3.2 Steering Wheel, Column and Shifter b. Steering Wheel Installation The steering wheel and transmission travel and gear select lever are mounted on the steering column. 1. Install the steering wheel (Fig. 4-4, 4) onto the splined steering column shaft. a. Steering Wheel Removal 2. Secure the steering wheel with a M18-1,5 thin nut (Fig. 4-4, 3). Torque the nut to 50 lb/ft (68 Nm). 1. Park the vehicle on a firm, level surface.
Cab and Covers 6. Working through the right dash panel opening, disconnect the transmission travel and gear select lever wiring connector (Fig. 4-6, 1). 1 d. Transmission Travel and Gear Select Lever Installation 1. Position the transmission travel and gear select lever (Fig. 4-7, 2) onto the steering column, aligning the pin (4) with the hole (5) in the steering column. 2. Attach the transmission travel and gear select lever with the collar (Fig. 4-7, 3) and two hex socket-head screws (1).
Cab and Covers 3. Unlock and open the rear door. Allow the engine and hydraulic fluid to cool. 2 1 4. Disconnect the battery negative (-) ground cable at the battery negative (-) terminal. 5. Remove the four button-head screws securing the lower dash panel (Fig. 4-8, 3) to the cab. Remove the lower dash panel. 6. Remove the steering wheel. (Refer to Section 4.3.2, a. “Steering Wheel Removal.”) 7. Remove the transmission travel and gear selector lever. (Refer to Section 4.3.2, c.
Cab and Covers 9. Working through the left dash panel opening, label, disconnect and plug the load sense hose (Fig. 4-10, 1) at the top of the steering valve. Cap the fitting on the steering valve. 2 3 10. Disconnect the horn button wire (Fig. 4-10, 2) from the cab wiring harness. 1 5 4 1 MA8860 Figure 4-11 Remove the Steering Column and Valve 2 MA8680 Figure 4-10 Disconnect Load Sense Hose and Horn Button Wire 11. Support the bottom of the steering valve (Fig.
Cab and Covers Note: ALWAYS use new o-rings when servicing the vehicle. 5. Install new o-rings into the fittings. Lubricate the o-rings with clean hydraulic oil. 6. Working through the right dash panel opening, connect the four hoses (Fig. 4-12, 1-4) to the appropriate ports, as noted in Step 8 of the removal procedure. 2 10. Carefully examine all connections one last time before engine start-up. Rectify any faulty conditions.
Cab and Covers a. Brake Valve Removal 6. Remove the two hex-head capscrews (Fig. 4-15, 1), four flat washers (2), two pivots (3), and two hex nuts (4) securing the service brake pedal (5) to the cab. Refer to Section 8.12.4, a. “Service Brake Valve Removal” for removal information. 7. Remove the service brake pedal (Fig. 4-15, 5) from the cab. 4.3.4 Brake Pedal and Valve b. Brake Valve Installation Refer to Section 8.12.4, b. “Service Brake Valve Installation” for installation information. c.
Cab and Covers 4.3.5 b. Throttle Pedal Installation Throttle Pedal Replacement a. Throttle Pedal 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, engage the parking brake switch and shut the engine OFF. 2. Place an Accident Prevention Tag on both the ignition key switch and steering wheel, stating that the vehicle should not be operated.
Cab and Covers 4.3.6 6. Repeat Step 5 to remove the boom extend/retract control cable (Fig. 4-19, 5). Joystick Assembly Replacement Joystick Assembly Removal 1. Park the vehicle on a firm, level surface. Set the park brake, ground the carriage, place the travel select lever in the (N) NEUTRAL position, place the neutral lock lever in the (N) NEUTRAL LOCK position, engage the parking brake and turn the engine OFF. 3 4 2.
Cab and Covers 1 2 1 3 ~ 4 MA8630 Figure 4-22 Remove Joystick Panel Assembly Joystick Assembly Installation 2 1 5 Figure 4-20 Disconnect the Frame Sway and Attachment Tilt Control Cables 1. Route the control cables through the opening the console, and through the opening at the bottom of the cab. Secure the joystick panel assembly (Fig. 4-22, 2) with four button-head capscrews (1). 9. Remove four button-head screws (Fig. 4-21, 1) and remove the console panel (2). 2.
Cab and Covers 5. Connect the boom lift/lower control cable to the main control valve assembly: 9. Test the boom extend/retract and boom lift/lower joystick (Fig. 4-24, 1) function: a. Install the cable in the bracket, and slide the inner jam nut (Fig. 4-23, 1) over the end of the boom lift/lower control cable (2). DO NOT tighten the jam nuts at this time. a. Move the joystick handle rearward, activating the boom lift function. The boom should RISE. b.
Cab and Covers 12. Install the lower (Fig. 4-25, 1) and upper (2) transmission covers; secure using six hex-head capscrews, six lockwashers and six flat washers (3). 2 Note: Record the distance (Fig. 4-26, 1) from the outer jam nut to the end of the ferrule on cable, to ensure correct adjustment when reinstalling cable. 6. Disconnect the boom auxiliary hydraulics control cable: 3 a. Remove the spring pin and anchor pin (Fig. 426, 2). Save the spring pin and anchor pin for installation. ~ ~ 3 b.
Cab and Covers c. Adjust the jam nuts until the distance (Fig. 4-28, 4) from the outer jam nut to the end of the ferrule is the same as recorded during removal. Tighten the jam nuts. 8. Remove three hex-head capscrews (Fig. 4-27, 1) three lockwashers and three flat washers. 9. Remove the auxiliary hydraulics joystick assembly (Fig. 4-27, 2) from the vehicle. 2 3 1 1 MA8530 Figure 4-27 Remove the Auxiliary Hydraulics Joystick Assembly b. Auxiliary Hydraulics Joystick Installation 1.
Cab and Covers 5. Install the lower (Fig. 4-30, 1) and upper (2) transmission covers; secure using six hex-head capscrews, six lockwashers and six flat washers (3). 2 4.3.8 Electrical Components a. Fuse Panel/Cab Harness Refer to Section 9.1.1, “General Overview (Cab Harness).” 3 ~ ~ 3 1 MA8620 Figure 4-30 Install the Upper and Lower Transmission Covers Model 6036 Legacy 4.
Cab and Covers 4.3.9 Miscellaneous Cab Components 4 3 2 1 16 15 14 13 12 13 8 7 6 5 10 9 1 10 MA8810 1. Mirror Assembly 2. Lockwasher (2) 3. Hex-Head Capscrew (2) 4. Tilt Angle Gauge 5. 6. 7. 8. 9. Lock Nut (4) Lock Nut (3) Flat Washer (3) Document Holder Step 10. Flat Washer (4) 11. Hex-Head Capscrew (4) 12. Lock Nut (2) 13. Flat Washer (2) 14. Arm Rest 15. Self-Tapping Screw (6) 16. Brush Strip Assembly (2) Figure 4-31 Miscellaneous Cab Components 4.
Cab and Covers 4.4 4.4.1 ENCLOSED CAB (OPTIONAL) COMPONENTS Windshield Wiper Assembly 6. Place a funnel at the base of the radiator to channel the drained coolant into the container. Open the radiator drain plug (Fig. 4-32, 1) or petcock and allow the coolant to drain. Replace the drain plug, or close the petcock. Refer to Section 9.13.2, “Windshield Wiper Motor” for removal and installation information. 4.4.2 Roof Wiper Assembly Refer to Section 9.13.
Cab and Covers Note: The button-head screw (Fig. 4-34, 1) at the lower rear position on each side of the heater will be secured with an insert nut (2). 2 ~ 11. Remove eight button-head screws (Fig. 4-34, 3 and 1), six nuts (4) and six lockwashers (5). 12. Carefully pull the heater assembly (Fig. 4-34, 6) forward. Label and disconnect the wiring harness connections (7) at the blower. 13. Remove the heater assembly (Fig. 4-34, 6).
Cab and Covers 3. Pull the hoses (Fig. 4-36, 1 and 2) through the grommets, and connect to the heater. Secure with two hose clamps. 5. Fill the cooling system completely with a 50/50 mixture of ethylene glycol and water, allowing time for the coolant to fill the engine block. The cooling system capacity is listed in “Specifications,” Section 2. 4. Install the heater access panel (Fig. 4-36, 3) and secure with four button-head screws (4) and four acorn nuts (5). 6. Connect the battery negative (-) cable.
Cab and Covers c. Heater/Defroster System Components 7 6 1 5 2 3 4 8 12 9 11 10 11 13 19 27 14 28 2 2 15 21 20 2 22 23 2 22 23 2 26 2 2 24 18 17 9. 10. 11. 12. 13. 14. 15. 16. 17. 16 17 1 25 1. Heater Hose (return to engine) 2. Hose Clamp (10) 3. Reducer 4. Wiring Harness 5. Hose Clamp 6. Defroster Duct 7. Heater/Fan Control 8.
Cab and Covers 4.4.5 6. Remove the hex nut (Fig. 4-38, 9) and hex-head capscrew (6). Remove the lower door section (11). Door and Latches 1. Open and securely support the door assembly (Fig. 4-38, 1). 7. Remove two acorn nuts (Fig. 4-38, 12) two lockwashers (13), two screws (14) and the female door retainer (15). 2. Remove the strap (Fig. 4-38, 2), by slipping the looped ends of the strap through the openings in the “C” rings welded to the cab frame and door. 3. Remove the six caps (Fig.
Cab and Covers 4.4.6 Windows Note: The slider window assembly (Fig. 4-39, 1), skylight glass (2) and left side rear glass (12) are bonded to the cab with adhesive. 2 4 8 1 3 4 5 6 7 9 4 5 10 8 18 9 5 3 11 7 4 23 6 5 18 12 17 19 14 18 11 22 20 13 21 16 1. Slider Window Assembly 2. Skylight Glass 3. Rear Window Hinge Block (2) 4. Torx Screw (6) 5. Flat Washer (4) 6. 7. 8. 9. 10. 11.
Cab and Covers 4.5 CAB REMOVAL WARNING: Risk of death or serious personal injury. NEVER modify, weld or drill the cab. WARNING: The protection offered by this ROPS/FOPS will be impaired if subjected to any modification or structural damage, at which time replacement is necessary. ROPS/ FOPS must be properly installed using fasteners of correct size and grade, and torqued to their specified value. IMPORTANT: To help ensure safety and optimum performance, replace the cab if it is damaged.
Cab and Covers 7. Working under the cab, loosen the clamp screw (Fig. 4-41, 1) and disconnect the heater control cable (2) from the heater control valve (3). Note: Label all hoses to ensure correct installation. 8. Loosen the hose clamps (Fig. 4-41, 4 and 5), and disconnect the heater hoses (6 and 7). 10. Disconnect the two cab-to-wiring harness connectors (Fig. 4-43, 1 and 2). Push the harness connectors through the opening (3) at the bottom of the cab.
Cab and Covers 13. Working under the cab, label and disconnect the hydraulic hoses (Fig. 4-45, 1-8) at the cab fittings. Plug the hoses and cap the fittings. 1 3 2 1 4 5 2 3 8 4 7 6 MA8500 5 Figure 4-45 Disconnect Hydraulic Hoses 6 7 MA8520 14. Remove six hex-head capscrews, six lockwashers and six flat washers (Fig. 4-46, 1) securing the access panels to the frame. Remove the upper (2) and lower (3) transmissions covers. Figure 4-44 Disconnect Control Cables at Joysticks 2 12.
Cab and Covers 16. Remove one hex-lock elastic nut (Fig. 4-47, 1). Disconnect the throttle cable rod end (2) at the throttle lever extension bracket (3). 3 4 2 5 7 17. Remove two slotted pan-head screws (Fig. 4-47, 4) two lockwashers, two hex nuts and clamp (5) from the throttle cable bracket (6). 18. Cut the wire ties securing the throttle cable to the hydraulic hoses on the right side of the frame, and route the throttle cable (Fig.
Cab and Covers 4.6 CAB INSTALLATION WARNING: Wear protective footwear with reinforced toe caps and slip-resistant soles. Failure to comply can result in foot injury from falling objects or other bodily injury from slipping or falling. WARNING: NEVER lift a heavy object without the help of at least one assistant or a suitable sling or hoist. Failure to comply can result in death or serious personal injury. 1. Block all four wheels to help prevent the vehicle from moving.
Cab and Covers 13. Route the control cables through the opening at the bottom of the cab. 15. Route the wiring harness connectors through the opening (Fig. 4-51, 1) at the bottom of the cab. 14. Connect control cables at the joystick: 16. Connect the two cab-to-wiring harness connectors (Fig. 4-51, 2 and 3). a. Install the end of the boom extend/retract cable (Fig. 4-50, 1) into the slider head (4) as recorded during removal. Tighten the upper jam nut (2). 2 3 b. Loosely install the cable nut (Fig.
Cab and Covers 18. Install the lower (Fig. 4-53, 1) and upper (2) transmission covers; secure using six hex-head capscrews, six lockwashers and six flat washers (3). 2 21. Fill the cooling system completely with a 50/50 mixture of ethylene glycol and water, allowing time for the coolant to fill the engine block. The cooling system capacity is listed in “Specifications,” Section 2. 22. Connect the battery negative (-) cable. 3 23. Carefully examine all cab components, fasteners, etc.
Cab and Covers 4.7 ACCESS PANELS AND COVERS 4.7.1 Access Panel and Cover Replacement Note: Refer to Model 6036 Legacy Parts Manual for mounting hardware. The vehicle is equipped with various covers and guards. Removal and installation are easily accomplished by observing the mounting locations as shown in Fig. 4-55. 4 1 3 5 2 7 6 MA8920 1. Hydraulic Oil Reservoir/ Fuel Tank Cover 2. Transmission Cover, Lower 3. Transmission Cover, Upper 4. Right Engine Compartment Door 5. Rear Door Weldment 6.
Section 5 Axles, Drive Shafts, Wheels and Tires Contents PARAGRAPH 5.1 5.2 5.3 TITLE Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1 Axle Assembly Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axles, Drive Shafts, Wheels and Tires 5.1 AXLE, DRIVE SHAFT AND WHEEL 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 axles, drive shafts, wheel and tires. The following illustration identifies the components that are referred to throughout this section.
Axles, Drive Shafts, Wheels and Tires WARNING: DO NOT service the vehicle without following all safety precautions as outlined in the “Safety Practices” section of this manual. Failure to follow the safety practices may result in death or serious injury. 5.2 GENERAL INFORMATION IMPORTANT: To help ensure optimum performance, the drive shaft assemblies are specially balanced as a unit at the factory.
Axles, Drive Shafts, Wheels and Tires 5.3.3 Axle Serial Number Plate The front axle serial number plate (Fig. 5-1, 1) is located on a mounting pad on the inboard portion of the right beam trumpet. The rear axle serial number plate is located on a mounting pad on the inboard portion of the left beam trumpet. Information on the serial number plate is required in correspondence regarding the axle.
Axles, Drive Shafts, Wheels and Tires CLEANING: Clean parts with machined or ground surfaces (such as gears, bearings and shafts) with emulsion cleaners or petroleum-based cleaners. DO NOT steam clean internal components, and the interior of the planetary hub and axle housing. Water can cause corrosion of critical parts. Rust contamination in the lubricant can cause gear and bearing failure. Remove old gasket material from all surfaces. DRYING: Use clean, lintless towels to dry components after cleaning.
Axles, Drive Shafts, Wheels and Tires 5. If the axle will be disassembled after removal, place a suitable receptacle under the axle drain plug (Fig. 5-2, 1). Remove the drain plug and allow the axle oil to drain into the receptacle. Transfer the used axle oil into a suitable covered container, and label the container as “Used Oil.” Dispose of used oil at an approved recycling facility. 7.
Axles, Drive Shafts, Wheels and Tires 7 9 7 9 1 13 9 6 8 3 5 2 10 4 1 12 9 8 MA8890 Figure 5-4 Axle to Frame Mounting Configuration Model 6036 Legacy 5.
Axles, Drive Shafts, Wheels and Tires b. Axle Inspection, Internal Service and Repair Note: Detailed axle service instructions (covering axle, brakes and wheel-end safety, repair, disassembly, reassembly, adjustment and troubleshooting information) are provided in the ZF Axle Repair Manual, Model MS-T 3045, JLG P/N 8990419 (ZF P/N 5871 550 002).
Axles, Drive Shafts, Wheels and Tires 3 5 3 5 2 5 7 4 12 10 14 9 8 6 1 13 1 5 4 MA8890 Figure 5-6 Axle to Frame Mounting Configuration Model 6036 Legacy 5.
Axles, Drive Shafts, Wheels and Tires Note: ALWAYS use new o-rings when servicing the vehicle. 13. Install new o-rings into the fittings. Lubricate the o-rings with clean hydraulic oil. 17. Front Axle Only: Install the front access panel (Fig. 5-7, 1) and secure with four button-head screws (2) 14. Uncap and connect the steering and brake lines at their axle fittings. 15. Check wheel end and hydraulic reservoir oil levels.
Axles, Drive Shafts, Wheels and Tires 5.3.7 Axle Service and Troubleshooting This section provides an easy reference guide covering the most common problems that may occur during operation of the axles. Note: Contact the JLG Service Department at 1-877-554-5438 (Domestic) or 1-717-485-5161 (International), if internal axle repair is required during the warranty period. 5.3.
Axles, Drive Shafts, Wheels and Tires 5.3.8 Axle Assembly and Drive Shaft Troubleshooting (Continued) Problem 4. Oil leaking from axle (differential housing and/or axle housings). 5. Oil leaking from wheel end housing (planet carrier). 6. Oil leaking from steering cylinder. 5.12 Cause Remedy 1. Drain and/or inspection plugs loose and/or o-rings damaged or missing. 1. Replace o-rings as needed and tighten plugs to 96 lb/ft (130 Nm). 2. Hose fittings loose. 2. Tighten fittings. 3.
Axles, Drive Shafts, Wheels and Tires 5.3.8 Axle Assembly and Drive Shaft Troubleshooting (Continued) 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 vehicle or braking power reduced. Model 6036 Legacy Cause Remedy 1. Oil level too high. 1. Fill oil to correct level with Universal Tractor Fluid. (Refer to the appropriate Owners/ Operators Manual.) 2.
Axles, Drive Shafts, Wheels and Tires 5.3.9 Axle Internal Component Troubleshooting Note: The following conditions may be noticed when inspecting parts during axle repair. Perform all remedies that apply to the conditions noticed. Problem Cause Remedy (See Note) 1. Differential ring gear teeth broken on the heel of the tooth. 1. Incorrect alignment of ring and pinion gears (excessive play). 2. Differential ring gear teeth broken on the toe of the tooth. 1.
Axles, Drive Shafts, Wheels and Tires 5.4 5.4.1 DRIVE SHAFTS Drive Shaft Inspection and Service 4. Cross assemblies should flex and be free from excessive binding. A slight amount of drag or resistance is desirable on a new cross and bearing assembly. Excessive looseness causes unbalance. Whenever servicing the vehicle, conduct a visual inspection of the drive shafts, and cross and bearing assemblies (universal joints, or U-joints).
Axles, Drive Shafts, Wheels and Tires 5.4.2 Drive Shaft Maintenance Refer to the Model 6036 Legacy Owners/Operators Manual for information regarding the lubrication of the grease fittings on the drive shafts. 5.4.3 Drive Shaft Removal IMPORTANT: 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.
Axles, Drive Shafts, Wheels and Tires 4. Disconnect the battery negative (-) cable at the battery negative (-) terminal, to prevent the engine from starting accidentally. 5. The drive shaft assembly is a balanced assembly. Mark the yoke and axle, transmission, and the shaft and slip yoke so that these components can be returned to their original positions when reinstalled. Yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration. 6.
Axles, Drive Shafts, Wheels and Tires 4. Use a soft, round drive pin with a flat face approximately 1/32" (0,8 mm) smaller than the hole diameter in the yoke to drive on one end of the cross and bearing assembly until the opposite bearing assembly comes out of the yoke. 6 2 4 5. Turn the yoke over and tap on the exposed end of the cross until the opposite bearing assembly comes out of the yoke. 3 1 6. Remove the cross (Fig. 5-13, 2) from the yoke (4 or 5). 7.
Axles, Drive Shafts, Wheels and Tires 5.4.6 Drive Shaft Assembly 1. Install the dust cap (Fig. 5-13, 7), split retaining ring (8), and felt seal (9) onto the splines of the drive shaft tube assembly. IMPORTANT: Ensure that the reference marks made before removal on the drive shaft and slip yoke are aligned. The drive shaft and yokes must be in the same plane to help prevent excessive vibration. 2. Align the reference marks made before removal on the drive shaft and slip yoke. 3. Slide the slip yoke (Fig.
Axles, Drive Shafts, Wheels and Tires 5. The drive shaft assembly is a balanced assembly. Mark the yoke and axle, transmission, and the shaft and slip yoke so that these components can be returned to their original positions when reinstalled. Yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration. 6. Position the flange yoke (Fig. 5-15, 1) on the engine output flange. Secure the yoke with four hex-head capscrews (2), four lockwashers (3).
Axles, Drive Shafts, Wheels and Tires 5.5 WHEELS AND TIRES 1 WARNING: Risk of death or serious personal injury. Mismatched tire sizes, ply ratings or mixing of tire types (radial tires with bias-ply tire) may compromise vehicle stability and may cause vehicle to tip over. 2 Welded 13.00-24 steel wheels are used on the Model 6036 Legacy. The specified size and ply rating (star rating for radial tires) for this vehicle is 13.00-24, 12-ply.
Axles, Drive Shafts, Wheels and Tires 5.5.1 Removing Wheel and Tire Assembly from Vehicle WARNING: Risk of death or serious personal injury if proper safety procedures are not followed. When removing wheel and tire assembly from the vehicle, follow the instructions in the “Wheel Removal Instruction” box that follows: 4. Loosen but DO NOT remove the lug nuts on the wheel and tire assembly to be removed. 5. Place a suitable jack under the axle pad closest to the wheel being removed.
Axles, Drive Shafts, Wheels and Tires 5.5.2 Wheel Cleaning WARNING: Dirt and rust prevent the tire from seating properly on the wheel, which could result in an explosive separation. Such explosions could result in death or severe personal injury to the tire installer and to those in the area. 5.5.4 Installing Wheel and Tire Assembly Onto Vehicle IMPORTANT: The wheel and tire assemblies must be installed with the directional tread pattern “arrows” facing in the direction of forward travel (Fig. 5-18).
Axles, Drive Shafts, Wheels and Tires 1. Position wheel onto studs on wheel end of axle. Wheel Dismounting Instructions: 2. Install lug nuts and tighten in an alternating pattern (Fig. 5-19). Torque to 450 lb/ft (610 Nm). 1 • Deflate tire completely before servicing. NEVER attempt to unseat the beads of an inflated tire. 7 5 • Use safety chains, or place the wheel and tire assembly in a safety cage when deflating a tire or when inflating a newly mounted tire.
Axles, Drive Shafts, Wheels and Tires c. Tire and Wheel Lubrication WARNING: Risk of death or serious personal injury. Use an approved, tire-mounting lubricant only. NEVER use anti-freeze, silicones or petroleum-based lubricants. Prior to mounting the tire onto the rim, apply a suitable lubricant to the bead-seat area of the wheel rim and tire bead. Use a lubricant specified by the wheel and tire manufacturers. d. Mounting Tire Onto Wheel WARNING: Risk of death or serious personal injury.
Axles, Drive Shafts, Wheels and Tires e. Tire Speed and Road Surface Limitations The tires on this vehicle are designed for low-speed operations not to exceed 25 mph (40 km/hr). If the vehicle is towed at high speeds, high temperatures may develop under the tread bars, causing a shifting of the tread bars and a weakening of the tire material and cord fabric. There may be no visible evidence of this type of damage, but later, a failure can occur.
Section 6 Transmission: ZF 4 WG-98 TC Contents PARAGRAPH 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 Model 6036 Legacy TITLE Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . .
Transmission: ZF 4 WG-98 TC 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: ZF 4 WG-98 TC WARNING: DO NOT service the vehicle without following all safety precautions as outlined in the “Safety Practices” section of this manual. Failure to follow the safety practices may result in death or serious injury. 6.2 TRANSMISSION DESCRIPTION Instructions in this section pertain mainly to general specifications, towing, maintenance information, and transmission removal and installation procedures.
Transmission: ZF 4 WG-98 TC 6.5 6.5.1 TRANSMISSION SPECIFICATIONS Transmission General Specifications General transmission specifications are found in Section 2, “General Information and Specifications.” Transmission fluid information is found in Section 2.6.3, “Transmission.” 6.5.2 Transmission Performance Specifications Performance criteria is based on full throttle engine speed unless otherwise specified or not applicable. Travel Speed (standard tires, no load) First gear .........................
Transmission: ZF 4 WG-98 TC CAUTION: DO NOT exceed 165 psi (39.6 bar) when back flushing the oil cooler. Applying too much pressure may damage the oil cooler/radiator. 1 2 Disconnect and back flush the oil cooler portion of the radiator with oil and compressed air until all foreign material is removed. If necessary, remove the radiator from the vehicle and clean the oil cooler circuit using oil, compressed air and steam. ~ ~ OA1250 IMPORTANT: DO NOT use flushing compounds for cleaning purposes.
Transmission: ZF 4 WG-98 TC 6.7 TRANSMISSION REPLACEMENT Note: Contact the JLG Service Department at 1-877-554-5438 (Domestic) or 1-717-485-5161 (International), if internal transmission repair is required during the warranty period. 5. Drain the hydraulic oil reservoir. (Refer to the appropriate Owners/Operators Manual, “Hydraulic Oil and Filter Change.”) 6. Disconnect the battery negative (-) cable (Fig. 6-4, 1) at the battery negative (-) terminal, to prevent the engine from starting accidentally.
Transmission: ZF 4 WG-98 TC 9. Place a suitable receptacle under the transmission drain plug (Fig. 6-6, 1). Remove the transmission drain plug, and allow the transmission oil to drain into the receptacle. 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. 14. Label and disconnect the transmission temperature switch connector (Fig.
Transmission: ZF 4 WG-98 TC WARNING: Escaping hydraulic fluid under pressure can penetrate the skin, causing death or serious injury. Relieve hydraulic pressure before servicing any hydraulic component. 17. Label, disconnect and cap the transmission oil cooler inlet (Fig. 6-8, 1) and outlet (2) hoses at the transmission. The transmission oil cooler outlet hose, routed to the lower radiator fitting, is located on the top of the transmission.
Transmission: ZF 4 WG-98 TC 11 1 11 9 8 10 9 14 5 4 5 3 2 14 3 2 3 13 12 7 6 MA8980 Figure 6-9 Remove Transmission from Frame Model 6036 Legacy 6.
Transmission: ZF 4 WG-98 TC 28. Remove any external transmission components as required, including the transmission temperature switch (Fig. 6-10, 1), and inlet (2) and outlet (3) cooler hose fittings. Cover all transmission openings. 29. Remove the transmission oil filter (Fig. 6-10, 4) and dispose of it properly. Clean the filter mounting surface. Cover or cap the oil filter mount. 6.7.3 Transmission Installation WARNING: Risk of severe personal injury.
Transmission: ZF 4 WG-98 TC 3 6 3 8 7 2 8 1 13 10 13 12 11 9 12 1 12 4 5 15 14 MA8980 Figure 6-11 Transmission Installation Model 6036 Legacy 6.
Transmission: ZF 4 WG-98 TC 7. Connect the transmission temperature switch connector (Fig. 6-12, 1) and shift solenoid wiring harness connectors (2 and 3). 11. Install the hydraulic pump. (Refer to Section 8.11.2, h. “Pump Installation.”) 8. Attach the black wire (Fig. 6-12, 4) to the transmission housing with a capscrew (5). 12. Install the engine-to-transmission drive shaft. (Refer to Section 5.4.7, b. “Engine-to-Transmission Drive Shaft.”) 9.
Transmission: ZF 4 WG-98 TC 6.7.4 After Transmission Service or Replacement 1 Refer to the ZF 4 WG-98 TC Transmission Repair Manual (ZF part number 5871 135 002) for information on servicing the transmission after overhaul or repair. In general: 1. Check the transmission oil level and add oil as required. 2. Install a new transmission filter. 3. Check the torque on the drive shaft yoke capscrews. 4. Wear suitable eye protection.
Transmission: ZF 4 WG-98 TC 6.9 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 1-877-554-5438 (Domestic) or 1-717-485-5161 (International) if internal transmission repair is required during the warranty period. 6.9.
Transmission: ZF 4 WG-98 TC 6.9.1 Transmission Troubleshooting (Continued) Problem 3. Low clutch pressure. 4. Lack of power. 5. Transmission overheating (oil above 248° F [120° C]). Cause Remedy 1. Incorrect oil level. 1. Fill transmission to correct level with Universal Tractor Fluid. (Refer to the appropriate Owners/Operators Manual.) 2. Main pressure valve stuck open. 2. Clean the valve spool and housing. 3. Broken or worn coupling shaft or piston o-rings. 3. Replace coupling and/or o-rings.
Transmission: ZF 4 WG-98 TC 6.9.1 Transmission Troubleshooting (Continued) Problem 6. Grinding or “clunking” noise from transmission. 7. Oil leaking from transmission. 6.16 Cause Remedy 1. Oil level too low. 1. Fill oil to correct level. (Refer to the appropriate Owners/ Operators Manual.) 2. Transmission filled with incorrect oil. 2. Drain transmission and fill to correct level with Universal Tractor Fluid. (Refer to the appropriate Owners/Operators Manual.) 3. Incorrect clutch engagement. 3.
Section 7 Engine: Cummins 4BT3.9 Contents PARAGRAPH 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 7.13 Model 6036 Legacy TITLE Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.2 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . .
Engine: Cummins 4BT3.9 7.1 7.1.1 INTRODUCTION Disclaimer and Scope These instructions are written for worldwide use. In territories where legal requirements govern engine smoke emission, noise, safety factors, etc., apply all instructions, data and dimensions provided herein in such a way that after maintenance, service and repair of the engine, engine operation does not violate local regulations.
Engine: Cummins 4BT3.
Engine: Cummins 4BT3.9 7.2 SAFETY INFORMATION WARNING: General Vehicle Operation WARNING: Before attempting to start the engine and/or operate the vehicle, read the owners/operators manual. • Before operating the engine and/or the vehicle, install any engine guards that were removed and clear all personnel from the immediate area. • Check that the brakes are fully functional. • DO NOT exceed the stability limits of the vehicle. • Allow only ONE person to have control of the engine and the vehicle.
Engine: Cummins 4BT3.9 Rotating Parts and Fan Blades Engine Repair WARNING: WARNING: Keep away from parts which rotate; the fan blades can appear invisible when the fan is rotating. Before beginning any adjustments or repairs, place accident prevention tags in the operator’s compartment and on the controls, and disconnect the battery negative cable. DO NOT pull or pry on the fan blades. This practice will cause fan failure. Use only approved methods and tools for manually rotating the engine.
Engine: Cummins 4BT3.9 7.3 ENGINE SERIAL NUMBER 7.5.2 The Cummins 4BT3.9 serial number (Fig. 7-1, 1) is stamped on the front of the engine block, near the fan pulley. Information contained in the serial number is required in correspondence with the engine manufacturer. Front of vehicle Cleanliness Cleanliness is very important during engine repair. Contamination of the engine during repair will reduce the life of an engine.
Engine: Cummins 4BT3.9 7.6 ENGINE COOLING SYSTEM The engine cooling system is a closed, pressurized system that consists of coolant passages in the engine, plus the oil cooler, thermostat, water pump, coolant heater, hoses, radiator and radiator overflow bottle. The engine is cooled by the circulation of coolant through passages in the cylinder block, engine head and radiator. Circulation is by thermo-siphon action, assisted by an impeller-type water pump, driven by a fan belt from the crankshaft pulley.
Engine: Cummins 4BT3.9 WARNING: Hot coolant can cause severe burns or eye injury. NEVER remove the radiator cap while the engine is hot. The cooling system is under pressure. Wear protective clothing and safety glasses. 1 2 Note: Drain approximately two quarts (2 liters) of coolant. 4. Slowly turn the radiator cap (not shown) to the first stop and allow any pressure to escape. Remove the radiator cap. Place a funnel at the base of the radiator to channel the drained coolant into a container.
Engine: Cummins 4BT3.9 8. Remove the three capscrews (Fig. 7-6, 1) securing the thermostat housing (2) to the engine. 2 5 3 6 b. Thermostat Installation Note: Ensure that notched edge (arrow) of thermostat seal (Fig. 7-6, 5) is facing the thermostat. 1. Install the engine lift bracket (Fig. 7-6, 6), thermostat seal (5), thermostat (4) gasket (3) and thermostat housing (2). Secure with the three capscrews (1) removed earlier. Torque to 18 lb/ft (24 Nm). 4 1 2. Raise the alternator (Fig.
Engine: Cummins 4BT3.9 7.6.3 Radiator/Oil Cooler and Coolant Heater Replacement Before considering radiator or oil cooler replacement for other than obvious damage, conduct a cooling system pressure test, check the coolant specific gravity, coolant level, fan belt tension and instrument cluster temperature indicator. 5 • If the engine runs hot, check the temperature of the upper radiator hose. • If the hose is not hot, the thermostat may be stuck in the closed position.
Engine: Cummins 4BT3.9 9. Loosen clamps (Fig. 7-9, 1 and 2) on the radiator return (lower) hose (3). Work the hose off the radiator. Inspect the hose, and replace if necessary. 10. Loosen both clamps (Fig. 7-9, 4) on the radiator input (upper) hose (5). Work the hose off the radiator. Inspect the hose, and replace if necessary. 11. Remove oil cooler input (Fig. 7-9, 6) and output (7) fittings from oil cooler (8) and cap the lines. 5 12. Remove the six oil cooler capscrews (Fig.
Engine: Cummins 4BT3.9 b. Radiator and Oil Cooler Installation 3. Install the shroud (Fig. 7-11, 20) on the radiator (19). 1. If replacing the radiator, install the right (Fig. 7-11, 22) and left (21) side support brackets by installing the plain washer (27), hex-head capscrew (26), radiator isolator mount (25), lockwasher (23) and hex nut (24) to the new radiator. 2. Install radiator (Fig. 7-11, 19). 5 4. Install the radiator (Fig.
Engine: Cummins 4BT3.9 14. Install the battery (Fig. 7-13, 2) and battery hold-down (5). 18. Check hydraulic oil level at hydraulic tank. Hydraulic oil level should be to the middle of the sight gauge. Check oil cooler and transmission hose connections for leaks. c. Coolant Heater Removal 1. Level the vehicle, ground the attachment, place the travel select lever in NEUTRAL (N), and engage the parking brake switch and shut off the engine. 4 _ Remove the ignition key.
Engine: Cummins 4BT3.9 4. Place a suitable container beneath the radiator petcock (Fig. 7-15, 1). Slowly turn the radiator cap (not shown) to the first stop and allow any pressure to escape. Remove the radiator cap. 3 1 2 2 1 OA1310 Figure 7-15 Fill the Radiator and Overflow Tank 5. Open the radiator petcock (Fig. 7-15, 1) and allow the coolant to drain into a suitable container. Transfer the coolant into a properly labeled container. Dispose of properly if coolant needs to be replaced.
Engine: Cummins 4BT3.9 7.8 FUEL SYSTEM The fuel system includes a fuel tank (Fig. 7-17, 1), fuel level sender with gasket (2), instrument cluster gauge (not shown), fuel strainer (3), fuel lift pump (4), fuel filter (5), fuel supply hose (6) and fuel return line (7). The threaded fuel filler (Fig. 7-17, 8) has a keyed fuel cap (9) and permits entry of diesel fuel into the tank. The fuel level sender (Fig. 7-17, 2) and instrument cluster gauge are described in Section 9.15.
Engine: Cummins 4BT3.9 7.8.1 Diesel Fuel Fuel represents a major portion of vehicle operating costs and therefore must be used efficiently. ALWAYS use a premium brand of high-quality, clean diesel fuel. Low cost, inferior fuel can lead to poor performance and expensive engine repair. Note: Use only diesel fuel designed for diesel engines. Some heating fuels contain harmful chemicals that can seriously affect engine efficiency and performance.
Engine: Cummins 4BT3.9 8 5 1 6 9 10 7 17 13 14 18 4 19 16 20 2 11 3 15 12 MA9110 Figure 7-18 Fuel/Hydraulic Oil Tank Components Model 6036 Legacy 7.
Engine: Cummins 4BT3.9 13. Disconnect the lower hydraulic oil strainer hose from the strainer connection (Fig. 7-19, 15) and cap hose. 14. Disconnect the return hose from the lower fitting (Fig. 7-19, 16). 15. Position and connect a suitable chain support to the tank lifting point (Fig. 7-19, 17), and take up slack in chain. 16. While supporting the tank, remove the four 5/8-11 hex nuts (Fig. 7-19, 18) and lockwashers (19) securing the tank to the vehicle frame.
Engine: Cummins 4BT3.9 6. Install the inlet (Fig. 7-19, 12) and outlet (11) hoses to the fuel tank. Secure with clamps (21). 10. Connect the hydraulic oil temperature sensor (Fig. 7-19, 2). 7. Connect the upper hydraulic hoses (Fig. 7-19, 13 and 14) to the hydraulic oil tank. 11. Fill fuel tank with No. 2 D fuel. 8. Connect the return hose (Fig. 7-19, 16) to the hydraulic oil tank. 13. Check fuel and hydraulic oil tanks for leaks. 12. Fill the hydraulic tank with ISO-46 hydraulic oil. 14.
Engine: Cummins 4BT3.9 7.8.3 b. Cleaning and Drying Fuel Level Sender and Gauge The fuel level sender and gauge assembly is described in Section 9.15.14, “Fuel Level Indicator and Fuel Level Sender.” 7.8.4 Fuel Lift Pump Inspection and Testing 1. Inspect the camshaft lever and return spring for excessive wear. Clean the exterior of the pump with mineral spirits, and blow dry with compressed air. Note: Parts replacement is not practical. The fuel lift pump is serviced as an entire assembly. c.
Engine: Cummins 4BT3.9 IMPORTANT: DO NOT attempt to adjust injection pressure without a testing pump and pressure gauge. It is not possible to accurately adjust the setting of fuel injectors without the proper equipment. a.
Engine: Cummins 4BT3.9 1. Use a 16-mm wrench to prevent the injector body (Fig. 7-23, 1) from turning. Loosen the hold-down nut (2) with a 24 mm box wrench. 1 2 2 1 4 5 3 MA1960 MT3160 Figure 7-23 Fuel Injector 2. Clean the injector nozzle bore. Figure 7-24 Fuel Injector Fuel Line and Drain Manifold 3. Remove the injector hold-down nut from the injector body. 12. Install the high-pressure fuel lines (Fig. 7-24, 1), and torque to 18 lb/ft (24 Nm). 4.
Engine: Cummins 4BT3.9 7.9 ENGINE EXHAUST SYSTEM WARNING: Exhaust fumes contain carbon monoxide, a colorless, odorless gas which is fatal when inhaled in a confined area. Avoid breathing exhaust fumes, and prevent engine operation from becoming a cause of toxic emissions. Exhaust system components reach high temperatures and can cause severe burns. DO NOT come into contact with hot exhaust system components.
Engine: Cummins 4BT3.9 7.9.2 Exhaust System Installation CAUTION: NEVER run the engine with only the inner safety element installed. 1. Install the muffler bracket (Fig. 7-26, 11) to the engine, along with the battery cable clamp (not shown). IMPORTANT: Before transferring the air cleaner assembly to the new engine, completely clean the interior and exterior of the air cleaner assembly, and replace the outer primary and inner safety elements.
Engine: Cummins 4BT3.9 7.10.2 Air Cleaner Assembly Installation Note: Apply Loctite® 242 threadlock to the hex-head capscrew threads before installation. 1. Install the air cleaner mounting bracket (Fig. 7-27, 7) and air cleaner assembly (4) using two hex-head capscrews (5) and lockwashers (6). 5 2. Place the loosened T-bolt clamps (Fig. 7-27, 1 and 2) over the air intake hose (3), and install hose on the air cleaner assembly (4) and engine intake. Tighten T-bolt clamps. 7.
Engine: Cummins 4BT3.9 8. Disconnect the back-up alarm harness connector (Fig. 7-30, 4) from alarm (5). Disconnect and remove the back-up alarm. 11. Label and disconnect the alternator ground wire (Fig. 7-32, 1), D+ (2) and B+ (3) harness wire leads. 1 4 2 5 2 3 MA7970 Figure 7-30 Battery Hold-down and Back-up Alarm Location 9. Position a suitable container beneath the radiator (Fig. 7-31, 1). Remove the radiator cap (not shown) and open the radiator drain petcock (2).
Engine: Cummins 4BT3.9 RE Note: The engine harness is routed and attached to the engine at various places using hold-down clamps and plastic wire ties. Before removing engine, ensure that the harness has been completely separated (disconnected) from the engine. Move the harness clear of the engine and with the help of an observer, ensure that the engine clears the harness during removal. D 2W 3 BL K 1 38 G ORG D+ 6 B+ YEL 2 D- MA8400 16.
Engine: Cummins 4BT3.9 18. Remove the four hex-head capscrews (Fig. 7-35, 2) and lockwashers (3) securing the flange yoke to the engine. 19. Remove the drive shaft assembly (Fig. 7-35, 1) from engine. Engine 3 24. Remove the right side exhaust pipe mount bracket (Fig. 7-37, 1) and hex-head capscrews (23) and lockwashers (24) from the rear engine mount bracket (2). Note: Always discard used elastic locknuts and install new elastic locknuts. 25. Remove the elastic locknut (Fig.
Engine: Cummins 4BT3.9 8 13 14 7 6 5 4 15 3 1 2 24 23 16 12 22 19 18 9 10 21 20 11 29. Place engine on a flat, level surface. 30. If replacing the engine, attach a lifting chain to the front (Fig. 7-37, 13) and rear (14) engine lift bracket and lift engine clear of the ground. 31. Remove the front right (Fig. 7-37, 7), and left (8) engine mounting brackets and muffler bracket (15). 17 MA9100 32. Remove the upper rear (Fig. 7-37, 2) and lower rear (12) engine mount brackets from the engine.
Engine: Cummins 4BT3.9 7.11.2 Engine Disassembly, Inspection and Service Engine disassembly, internal inspection, service, repair and assembly procedures are covered in the Cummins 4BT3.9 service manual. Several special engine service tools are required to properly service the Cummins engine. Contact a local Cummins parts distributor for further information. 3. Install the muffler bracket (Fig. 7-38, 15), front right (7) and left (8) engine mounting brackets to the engine. 4.
Engine: Cummins 4BT3.9 8 13 14 7 6 24 5 4 15 3 1 23 2 16 12 22 20 21 11 9 10 19 18 17 MA9100 Figure 7-38 Engine Component Location Model 6036 Legacy 7.
Engine: Cummins 4BT3.9 13. Uncap the lines and install the transmission oil input (Fig. 7-39, 1) and output (2) hoses to the radiator fittings (3 and 4). 16. Connect the fuel inlet line (Fig. 7-40, 3) to the fuel lift pump (4). 17. Connect the fuel return line (Fig. 7-40, 5) to the fuel injector pump (6). 18. Raise the drive shaft assembly (Fig. 7-41, 1) into position. The slip-yoke end of the drive shaft mounts toward the engine.
Engine: Cummins 4BT3.9 5 1 6 7 13 14 16 11 15 12 MA9110 Figure 7-42 Fuel/Hydraulic Oil Tank Components 22. Install the inlet (Fig. 7-42, 12) and outlet (11) hoses to the fuel tank. Secure with clamps. 24. Connect the return hose (Fig. 7-42, 16) to the hydraulic oil tank. IMPORTANT: Remove the hydraulic pump hose and prime the hydraulic pump by filling the pump inlet opening with fresh, filtered hydraulic oil from a clean container. Install pump hose. Refer to Section 8.11.2, “Pump Replacement.
Engine: Cummins 4BT3.9 5 29. Connect the engine coolant temperature switch lead (Fig. 7-43, 1) and oil pressure switch lead (2). (Refer to Section 9.15.11, “Engine Coolant High Temperature Sender,” and Section 9.15.10, “Engine Low Oil Pressure Sender.”) 3 RE 1 D 2W BL K G 30. Connect the fuel shut-off solenoid harness connector (Fig. 7-43, 3) to the fuel shut-off solenoid. 38 ORG D+ 6 B+ YEL 2 3 D- MA8400 2 Figure 7-44 Connect the Tagged Alternator Wires 1 32.
Engine: Cummins 4BT3.9 35. Install the front (Fig. 7-46, 9) and rear (10) band clamps around the muffler (4), and install muffler. Install the battery cable clamp (not shown) when installing the muffler bracket (11) to the engine. 1 10 Rear of Vehicle 11 2 1 OA1310 8 7 2 3 9 4 5 6 PH28302 Figure 7-47 Radiator Installation Procedure 42. Install the back-up alarm (Fig. 7-48, 1) to the frame, and connect engine harness connector (2) to back-up alarm. 43. Install the battery (Fig.
Engine: Cummins 4BT3.9 45. Connect the negative (-) grounding cable (Fig. 7-49, 1) to the vehicle frame. Note: Have an assistant stand by with a Class B fire extinguisher. Start and idle the engine. 49. Fill the overflow tank (Fig. 7-51, 1), 1/4 to 1/2 full with a 50/50 mixture of ethylene glycol and water. Replace and tighten overflow tank cap (2). 50. Run engine to normal operating temperature, then shut off the engine. While the engine is cooling, check for leaks. 1 51. Allow the engine to cool.
Engine: Cummins 4BT3.9 7.12 ENGINE STORAGE If the engine is properly protected and stored according to the following recommendations, no corrosion damage will normally occur. Cummins Engine Company, Inc. and JLG Industries Inc. are not responsible for any damage that occurs in relation to a service storage period. Use the following procedures immediately upon removing engine from service if being stored for an extended period of time. 1. Clean the outside of the engine. 2.
Engine: Cummins 4BT3.9 7.
Section 8 Hydraulic System Contents PARAGRAPH 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 Model 6036 Legacy TITLE Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Fluid . . . . . . . . . . . . . . . . . . . .
Hydraulic System 8.9 8.10 8.11 8.12 8.13 8.2 Four-Wheel Steer Indexing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10.1 Hydraulic Reservoir Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11.
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 vehicle. The following illustration identifies the components that are referred to throughout this section.
Hydraulic System 8.2 SAFETY INFORMATION WARNING: DO NOT service the vehicle without following all safety precautions as outlined in the “Safety Practices” section of this manual. Failure to follow the safety practices may result in death or serious injury. WARNING: Wait for hydraulic fluid to cool before servicing any hydraulic component. Hot hydraulic fluid can cause severe burns. Petroleum-based hydraulic fluids are used in this vehicle.
Hydraulic System 8.3 SPECIFICATIONS Refer to Section 2.5, Specifications for hydraulic system specifications. 8.4 HYDRAULIC FLUID General information and specifications pertaining to hydraulic fluid are found in Section 2.5.9, Hydraulic System. Use only clean, filtered fluid in the hydraulic system. After servicing or replacing a hydraulic system component, cycle all vehicle functions several times to remove (purge or “bleed”) air from the hydraulic system.
Hydraulic System 8.5 HOSES, TUBE LINES, FITTINGS, ETC. There are numerous hydraulic hoses, tubes, fittings, etc. used on this vehicle. Periodically inspect all of these and carefully examine any signs of wear, abrasion and/or deterioration. Determine whether any further use of the component would constitute a hazard. If in doubt, replace the component. 8.5.1 Replacement Considerations Conditions including, but not limited to, the following are sufficient for considering component replacement: 1.
Hydraulic System 8.6 HYDRAULIC PRESSURE DIAGNOSIS JLG has two kits available to use for hydraulic system maintenance and troubleshooting: the Sky Trak Pressure Test Kit and the Sky Trak Flowmeter Kit. The kits are contained in a durable polyethylene carrying case for demanding field service conditions. Pressure Test Kit The hydraulic pressure test kit (Fig. 8-1) is used to pressure test the various hydraulic components in the hydraulic system.
Hydraulic System 8.6.1 Pressure Checks and Adjustments When diagnosing trouble in the hydraulic system, use the hydraulic testing information in Section 8.7, “Hydraulic System Testing.” In general, follow the steps below whenever conducting pressure checks and performing adjustments: 1. Park the vehicle on a firm, level surface. Engage the park brake, place the travel select lever in (N) NEUTRAL, place the neutral lock lever in the (N) NEUTRAL LOCK position, level the boom and turn the engine OFF. 2.
Hydraulic System This Page Intentionally Left Blank Model 6036 Legacy 8.
Hydraulic System 8.7 8.7.
Hydraulic System Equipment Needed to Perform Tests from Hydraulic Diagnostic Test Kit Engine Information Idle . . . . . . . . . . . . . . . . . . . . . . . .1,050 ±50 rpm Full Speed . . . . . . . . . . . . . . . . .2,750 ±100 rpm Circuit 2 3 4 Gauge 4,000 psi gauge (276 bar) 5 6 7 1,000 psi gauge (69 bar) Unit equipped with fittings from factory. 4,000 psi gauge (276 bar) Requires a male or female quick-disconnect coupler.
Hydraulic System This Page Intentionally Left Blank 8.
Hydraulic System 8.8 HYDRAULIC CIRCUITS AND TROUBLESHOOTING This section covers the hydraulic circuits and includes a circuit drawing, troubleshooting chart and description of the circuit for each function. Typically, the circuit drawings illustrate the flow of oil for the hydraulic function being shown. The troubleshooting charts cover some common problems that can occur during the operation of the hydraulic system. Electrical and hydraulic functions are often related.
Hydraulic System 8.8.1 Brake Circuit and Troubleshooting (Refer to Section 8.8.19, “Brake Circuit Description” for a more detailed explanation of this circuit.
Hydraulic System Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the following: 1. Hydraulic oil level in the reservoir 2. All hoses, tubes, fittings for leaks, kinks, interference, etc. 3. Air in the lines If service brakes are not holding, check the pressure at the brake valve. Not OK Replace brake valve. Not OK Replace brake valve. Not OK Refer to Model 6036 Legacy Owners/Operators Manual. Check the brakes for mechanical failure.
Hydraulic System 8.8.2 Boom Extend Circuit and Troubleshooting LS ATTACH TILT AUX FRAME IN T LFT/LW T EXT/RET (Refer to Section 8.8.20, “Boom Extend/Retract Circuit Description” for a more detailed explanation of this circuit.
Hydraulic System Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the following: If the extend/retract cylinder does not extend, check cable connections at main control valve. 1. Hydraulic oil level in the reservoir 2. All hoses, tubes, fittings for leaks, kinks, interference, etc. 3. Air in the lines If OK NOTE: When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing” for correct pressure readings. NOTE: Refer to Section 2.5.
Hydraulic System 8.8.3 Boom Retract Circuit and Troubleshooting LS ATTACH TILT AUX FRAME IN T LFT/LW T EXT/RET (Refer to Section 8.8.20, “Boom Extend/Retract Circuit Description” for a more detailed explanation of this circuit.
Hydraulic System Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the following: 1. Hydraulic oil level in the reservoir 2. All hoses, tubes, fittings for leaks, kinks, interference, etc. 3. Air in the lines NOTE: When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing” for correct pressure readings. NOTE: Refer to Section 2.5.4, “Performance Specifications” for approximate cylinder cycle times.
Hydraulic System 8.8.4 Boom Lift Circuit and Troubleshooting LS ATTACH TILT AUX FRAME IN T LFT/LW T EXT/RET (Refer to Section 8.8.21, “Boom Lift/Lower Circuit Description” for a more detailed explanation of this circuit.
Hydraulic System Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the following: 1. Hydraulic oil level in the reservoir 2. All hoses, tubes, fittings for leaks, kinks, interference, etc. 3. Air in the lines If the lift/lower cylinders do not raise, check the cable connections at the main control valve. Not OK Repair/replace cable connections. Ensure lift/lower section of main control valve is functioning. Not OK Adjust/repair/replace relief valve on unloader valve.
Hydraulic System 8.8.5 Boom Lower Circuit and Troubleshooting LS ATTACH TILT AUX FRAME IN T LFT/LW T EXT/RET (Refer to Section 8.8.21, “Boom Lift/Lower Circuit Description” for a more detailed explanation of this circuit.
Hydraulic System Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the following: If the lift/lower cylinders do not lower, check the cable connections at the main control valve. 1. Hydraulic oil level in the reservoir 2. All hoses, tubes, fittings for leaks, kinks, interference, etc. 3. Air in the lines If OK NOTE: When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing” for correct pressure readings. NOTE: Refer to Section 2.5.
Hydraulic System 8.8.6 Frame Sway (Left) Circuit and Troubleshooting (Refer to Section 8.8.22, “Frame Sway Circuit Description” for a more detailed explanation of this circuit.
Hydraulic System Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the following: 1. Hydraulic oil level in the reservoir 2. All hoses, tubes, fittings for leaks, kinks, interference, etc. 3. Air in the lines NOTE: When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing” for correct pressure readings. If the frame sway cylinder will not sway left, drifts or reacts slowly, check cable connections at the main control valve. NOTE: Refer to Section 2.5.
Hydraulic System 8.8.7 Frame Sway (Right) Circuit and Troubleshooting (Refer to Section 8.8.22, “Frame Sway Circuit Description” for a more detailed explanation of this circuit.
Hydraulic System Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the following: 1. Hydraulic oil level in the reservoir 2. All hoses, tubes, fittings for leaks, kinks, interference, etc. 3. Air in the lines NOTE: When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing” for correct pressure readings. If the frame sway cylinder will not sway right, drifts or reacts slowly, check cable connections at the main control valve. NOTE: Refer to Section 2.5.
Hydraulic System 8.8.8 Attachment Tilt (Down) and Slave Cylinder Circuit and Troubleshooting (Refer to Section 8.8.23, “Attachment Tilt and Slave Circuit Description” for a more detailed explanation of this circuit.
Hydraulic System Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the following: 1. Hydraulic oil level in the reservoir 2. All hoses, tubes, fittings for leaks, kinks, interference, etc. 3. Air in the lines If the attachment tilt cylinder retracts slowly, check cable connections at main control Not OK Repair/replace cable connections. Ensure attachment tilt section of main control valve is functioning. Not OK Adjust/repair/replace relief valve on unloader valve.
Hydraulic System 8.8.9 Attachment Tilt (Up) and Slave Cylinder Circuit and Troubleshooting (Refer to Section 8.8.23, “Attachment Tilt and Slave Circuit Description” for a more detailed explanation of this circuit.
Hydraulic System Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the following: 1. Hydraulic oil level in the reservoir 2. All hoses, tubes, fittings for leaks, kinks, interference, etc. 3. Air in the lines If the attachment tilt cylinder extends slowly, check cable connections at main control Not OK Repair/replace cable connections. Ensure attachment tilt section of main control valve is functioning. Not OK Adjust/repair/replace relief valve on unloader valve.
Hydraulic System 8.8.10 Pump, Unloader Valve and Cooling Circuit and Troubleshooting LS ATTACH TILT AUX FRAME IN T LFT/LW T EXT/RET (Refer to Section 8.8.24, “Pump, Unloader Valve and Cooling Circuit Description” for a more detailed explanation of this circuit.
Hydraulic System Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the following: 1. Hydraulic oil level in the reservoir 2. All hoses, tubes, fittings for leaks, kinks, interference, etc. 3. Air in the lines NOTE: When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing” for correct pressure readings. If the pump is not functioning properly, check the suction line from the reservoir. Not OK Repair/replace suction line. Check the oil flow to the pump.
Hydraulic System 8.8.11 Auxiliary Hydraulics Circuit and Troubleshooting (Male Coupler Pressurized) (Refer to Section 8.8.25, “Auxiliary Hydraulics Circuit Description” for a more detailed explanation of this circuit.
Hydraulic System Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the following: 1. Hydraulic oil level in the reservoir 2. All hoses, tubes, fittings for leaks, kinks, interference, etc. 3. Air in the lines NOTE: When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing” for correct pressure readings. If there are no auxiliary hydraulic functions, check cable connections at main control valve. Not OK Repair/replace cable connections.
Hydraulic System 8.8.12 Auxiliary Hydraulics Circuit and Troubleshooting (Female Coupler Pressurized) (Refer to Section 8.8.25, “Auxiliary Hydraulics Circuit Description” for a more detailed explanation of this circuit.
Hydraulic System Before troubleshooting any hydraulic circuit, ALWAYS begin by checking the following: 1. Hydraulic oil level in the reservoir 2. All hoses, tubes, fittings for leaks, kinks, interference, etc. 3. Air in the lines NOTE: When checking pressures in circuits, refer to Section 8.7, “Hydraulic System Testing” for correct pressure readings. If there are no auxiliary hydraulic functions, check cable connections at main control valve. Not OK Repair/replace cable connections.
Hydraulic System 8.8.13 Front-Wheel Steering Circuit (Left Turn) and Troubleshooting (Refer to Section 8.8.26, “Steering Circuit Descriptions” for a more detailed explanation of this circuit.
Hydraulic System If there is no front-wheel steering, check the pressure at the “PSG” port of the secondary function manifold. Not OK Adjust/repair/replace the pressurereducing valve on secondary function manifold. Not OK Adjust/replace the differential pressure sense valve. Not OK Replace check valve fitting. Not OK Replace shuttle valve. Not OK Replace power steering unit. Not OK Repair/replace steering cylinder(s). Check pump flow. Not OK Repair/replace pump.
Hydraulic System 8.8.14 Front-Wheel Steering Circuit (Right Turn) and Troubleshooting (Refer to Section 8.8.26, “Steering Circuit Descriptions” for a more detailed explanation of this circuit.
Hydraulic System If there is no front-wheel steering, check the pressure at the “PSG” port of the secondary function manifold. Not OK Adjust/repair/replace the pressurereducing valve on secondary function manifold. Not OK Adjust/replace the differential pressure sense valve. Not OK Replace check valve fitting. Not OK Replace shuttle valve. Not OK Replace power steering unit. Not OK Repair/replace steering cylinder(s). Check pump flow. Not OK Repair/replace pump.
Hydraulic System 8.8.15 Four-Wheel Steering Circuit (Left Turn) and Troubleshooting (Refer to Section 8.8.26, “Steering Circuit Descriptions” for a more detailed explanation of this circuit.
Hydraulic System Not OK Refer to the steering circuits and components in Section 9.7, “Electrical System Troubleshooting” and Section 9.15, “Switches and Solenoids.” Not OK Adjust/repair/replace the pressurereducing valve. Not OK Adjust/repair/replace the differential pressure sense valve. Not OK Replace check valve fitting. Not OK Replace shuttle valve. Not OK Replace power steering unit. Not OK Repair/replace steering cylinder(s). Check pump flow. Not OK Repair/replace pump.
Hydraulic System 8.8.16 Four-Wheel Steering Circuit (Right Turn) and Troubleshooting (Refer to Section 8.8.26, “Steering Circuit Descriptions” for a more detailed explanation of this circuit.
Hydraulic System Not OK Refer to the steering circuits and components in Section 9.7, “Electrical System Troubleshooting” and Section 9.15, “Switches and Solenoids.” Not OK Adjust/repair/replace the pressurereducing valve. Not OK Adjust/repair/replace the differential pressure sense valve. Not OK Replace check valve fitting. Not OK Replace shuttle valve. Not OK Replace power steering unit. Not OK Repair/replace steering cylinder(s). Check pump flow. Not OK Repair/replace pump.
Hydraulic System 8.8.17 Crab Steering Circuit (Left) and Troubleshooting (Refer to Section 8.8.26, “Steering Circuit Descriptions” for a more detailed explanation of this circuit.
Hydraulic System Not OK Refer to the steering circuits and components in Section 9.7, “Electrical System Troubleshooting” and Section 9.15, “Switches and Solenoids.” Not OK Adjust/repair/replace the pressurereducing valve. Not OK Adjust/repair/replace the differential pressure sense valve. Not OK Replace check valve fitting. Not OK Replace shuttle valve. Not OK Replace power steering unit. Not OK Repair/replace steering cylinder(s). Check pump flow. Not OK Repair/replace pump.
Hydraulic System 8.8.18 Crab Steering Circuit (Right) and Troubleshooting (Refer to Section 8.8.26, “Steering Circuit Descriptions” for a more detailed explanation of this circuit.
Hydraulic System Not OK Refer to the steering circuits and components in Section 9.7, “Electrical System Troubleshooting” and Section 9.15, “Switches and Solenoids.” Not OK Adjust/repair/replace the pressurereducing valve. Not OK Adjust/repair/replace the differential pressure sense valve. Not OK Replace check valve fitting. Not OK Replace shuttle valve. Not OK Replace power steering unit. Not OK Repair/replace steering cylinder(s). Check pump flow. Not OK Repair/replace pump.
Hydraulic System 8.8.19 Brake Circuit Description The brake system circuit (Fig. 8-4) includes the park brake and the service brake, along with the secondary function manifold, main control valve and various hoses, fittings and other components. When the engine is OFF and the ignition key switch is in the OFF position, the park brake is ON. The park brake is part of the front axle ONLY. The vehicle is designed so that the service brake can be used to stop the vehicle with the engine OFF.
Hydraulic System 1 4 2 3 10 5 7 6 9 8 MS1880 Figure 8-22 Cross-Section of Service Brake Valve 4. Pressure in both the front and rear axle brake lines is equal. A groove in each of the two spools opens to a cross-hole between the two spool bores, preventing uneven brake pressure. This feature is called the “equalizer” function. 5. Power-mode braking begins when the metering notches (Fig. 8-22, 6) in the spool (7) meter oil from the inlet port to the spool chamber.
Hydraulic System 8. Controlling the force applied to the service brake pedal determines the amount of braking power. 9. If the first application of force applied to the service brake pedal was not enough to deliver the braking required, the one-way orifices at the work ports help give the brake valve “pump up” ability. The one-way orifices allow unrestricted flow to the brake lines but also restrict the rate of decompression. 8.8.
Hydraulic System a. Boom Lift Circuit (Fig. 8-7) With the joystick in the boom lift position, pressure shifts the lift/lower spool valve in the main control valve to direct system pressure MA7200 through the counterbalance valve to the base end of both the left and right lift/lower cylinders. Return oil from the rod end of the cylinder flows through the pilot-operated check valve to the spool valve, to the unloader valve, to the oil cooler, to the return filter and then to the reservoir.
Hydraulic System 8.8.23 Attachment Tilt and Slave Circuit Description System pressure is applied in the attachment tilt and slave cylinder circuit (Fig. 8-11 and Fig. 8-12) from the attachment tilt section of the main control valve. Fluid flow is directed to either side of the attachment tilt and slave cylinder pistons by shifting of the spool valve in the attachment tilt section of the main control valve assembly. The spool valve is shifted by the operator joystick and its associated control cable.
Hydraulic System 1 3 1 2 4 MA7010 Figure 8-23 Front-Wheel Steering Mode 8.8.26 Steering Circuit Descriptions Vehicle steering includes front-wheel steering (Fig. 8-16 and Fig. 8-17), four-wheel steering (Fig. 8-18 and Fig. 8-19) and crab steering (Fig. 8-20 and Fig. 8-21). a. Front-Wheel Steering When the steer select switch (Fig.
Hydraulic System 1 3 1 2 4 MA7020 Figure 8-24 Four-Wheel Steering Mode b. Four-Wheel Steering When the steer select switch (Fig. 8-24, 1) is in the four-wheel steer (rear) position (2), the front wheels (3) will steer in the direction the steering MT3880 wheel is turned and the rear wheels (4) will steer in the opposite direction. 1. Four-Wheel Steering Left Turn (Fig. 8-18) With the steer select switch (Fig.
Hydraulic System 1 3 1 2 4 MA7030 Figure 8-25 Crab Steering Mode c. Crab Steering When the steer select switch (Fig. 8-25, 1) is in the crab steer (FORWARD) position (2), the front wheels (3) will steer in the direction the steering MT3890 wheel is turned and the rear wheels (4) will steer in the same direction. 1. Crab Steering Left Turn (Fig. 8-20) With the steer select switch (Fig. 8-25, 1) in the crab steer (FORWARD) position (2), one of the steer select valve solenoids is energized.
Hydraulic System 8.9 FOUR-WHEEL STEER INDEXING PROCEDURE If the vehicle does not drive “straight,” the steering could be out-of-phase. Perform the following indexing procedures to synchronize the front and rear steering. 1. With the steer select switch in the four-wheel steer position, turn the steering wheel full left. 2. While holding the steering wheel full left, toggle the steer select switch to the front-wheel steer position and steer the front wheels back to center. 4.
Hydraulic System This Page Intentionally Left Blank Model 6036 Legacy 8.
Hydraulic System 8.10 HYDRAULIC RESERVOIR The hydraulic reservoir (Fig. 8-26, 1) and the fuel tank (2) are one unit. They are located on the right side of the vehicle under a cover (3). To remove the fuel tank/ hydraulic reservoir cover, remove the hex-head capscrews (4), lockwashers (5) and flat washers (6) from the clips (7) on the cover. The fuel tank/hydraulic reservoir is secured to the right side of the vehicle frame with four carriage bolts (8), lockwashers (9) and hex nuts (10).
Hydraulic System Occasionally, fluid may seep, leak or be more forcefully expelled from the filter head (Fig. 8-26, 11) when system pressure exceeds the rating of the filter head or breather. If the return filter becomes plugged, return hydraulic oil will bypass the filter when pressure reaches 25 psi (1,7 bar) and return to the reservoir unfiltered. 8.11 HYDRAULIC SYSTEM PUMP The gear pump (Fig.
Hydraulic System 8.11.2 Pump Replacement a. Pump Removal 1. Park the vehicle on a firm, level surface, fully retract the boom, raise the boom, place the travel select lever in (N) NEUTRAL position, place the neutral lock lever in the (N) NEUTRAL LOCK position, engage the park brake switch and shut the engine OFF. 2. Place an Accident Prevention Tag on both the ignition key switch and the steering wheel, stating that the vehicle should not be operated. Refer to Section 1.5, “Accident Prevention Tag Usage.
Hydraulic System 2. A special steel sleeve made from 1-1/2" (38,1 mm) diameter round steel bar stock, 4-5/8" (117,5 mm) in length as shown in Fig. 8-30. This sleeve is used to insert the drive shaft through the lip seal without causing damage. 1/4" DIAMETER DRILL THROUGH HOLE C RADIUS • • • • Medium-Grit Carborundum Stone Oil and Grease Snap-Ring Pliers Scale, 1/32" (0,79 mm) or 1/64" (0,40 mm) Graduations • Small Screwdriver • Torque Wrench • Vise with 8" Minimum Open Spread c.
Hydraulic System 5 6 1 10 9 11 8 7 7 8 9 11 3 4 7 10 14 12 13 2 MT1410 Figure 8-31 Hydraulic System Pump d. Pump Disassembly 1. Secure the pump (Fig. 8-31, 1) with the pump drive shaft pointing down in a suitable holding device or bench vise if possible. Scribe or otherwise make a mark across the two pump housings (2 and 3) and the gear housing (4), perpendicular to the parting lines for easy identification and proper alignment during assembly later. 2. Remove the four capscrews (Fig.
Hydraulic System f. Pump Inspection 1. Inspect internal pump components for wear, damage, etc. If inner surfaces of the pump DO NOT display an ultra-smooth, polished finish, or are damaged in any way, replace the damaged part. Often, dirty hydraulic fluid causes failure of internal pump seals and damage to the polished surfaces within the pump and other hydraulic system components. 2. If a dowel (Fig. 8-31, 7) or dowel-mounting hole is damaged, replace the dowel or housing as required. 3.
Hydraulic System 5 6 1 10 9 11 8 7 7 8 9 11 3 4 7 10 14 12 13 2 MT1410 Figure 8-32 Hydraulic System Pump 11. Install the remaining thrust plate (Fig. 8-32, 11) with channel (9) and back-up (10) seals over the gears so that the groove in the thrust plate will face away from the gear housing (4). The flat side of the seal should face up with the relief groove facing the outlet side of the housing. 12. Place the gear housing (Fig. 8-32, 4) over the gear set.
Hydraulic System h. Pump Installation 1. Place the pump (Fig. 8-33, 1) and a new oiled o-ring (2) into position on the transmission. Align the pump gear shaft with the internal transmission gear so that the machined teeth mesh together. 2. Align the bolt holes with the pump mount holes. Secure the pump to the transmission with four plain washers (Fig. 8-33, 4), four lockwashers (3) and four hex-head capscrews (5). Torque the capscrews to 75 lb/ft (102 Nm). 3. If necessary, slide the T-bolt band clamp (Fig.
Hydraulic System 8.12 VALVES AND MANIFOLDS WARNING: Valves are devices that open or close passageways. Manifolds contain circuit passageways involved in the distribution of hydraulic fluid flowing under pressure. There are various valves and manifolds in use on this vehicle. As valves open and close, hydraulic fluid is directed to flow through various passageways to the prescribed circuit, causing vehicle functions to occur. 8.12.1 Unloader Valve The unloader valve (Fig.
Hydraulic System b. Unloader Valve Disassembly, Inspection and Assembly 2 2 1. Safely secure the unloader valve (Fig. 8-36, 1) in a bench vise or by other suitable means. 2 WARNING: 11 Significant pressure may be trapped inside the valve. Exercise caution when removing a valve. Escaping hydraulic fluid under pressure can penetrate the skin, causing death or serious injury. 10 2. Slowly remove the check valve (Fig. 8-36, 2). G V LSG 5 9 7 3. Remove the relief valve (Fig.
Hydraulic System c. Unloader Valve Installation 1. Secure the unloader valve (Fig. 8-35, 1) to the vehicle frame with the three hex-head capscrews (7), the three lockwashers (8) and the three washers (9). Torque the capscrews to 31 lb/ft (42 Nm). Secure the check valve manifold (10) to the unloader valve with the flange connection. 8.12.2 Main Control Valve The main control valve (Fig. 8-37, 1) is mounted on the frame under the lower transmission cover.
Hydraulic System The main control valve assembly (Fig. 8-38, 1) consists of various working sections with their own valve assemblies, each providing a specific hydraulic function. The section assemblies are the outlet (2), lift/lower (3), extend/retract (4), mid-inlet/outlet (5), auxiliary hydraulics (6), frame sway (7), attachment tilt (8) and load sense outlet (9) sections. Note: If the vehicle has auxiliary hydraulics installed, the auxiliary hydraulics section will have relief valves (Fig. 8-38, 10).
Hydraulic System 9. Wipe up any hydraulic fluid spillage in, on, near and around the vehicle and the work area. 10. Remove the three hex flange nuts (Fig. 8-39, 1) and carriage bolts (2 and 3) securing the main control valve (4) to the frame (5). 11. Remove the main control valve (Fig. 8-39, 4) from the frame. 1 4 2 3 5 1 Front MA7280 Figure 8-39 Main Control Valve Removal 8.
Hydraulic System This page intentionally left blank. Model 6036 Legacy 8.
Hydraulic System 1 9 10 67 66 43 4 2 8 24 25 44 6 7 27 26 3 22 13 14 28 43 44 32 31 30 33 32 35 34 5 18 40 41 15 19 16 12 36 44 22 42 25 11 29 39 44 23 23 16 38 63 45 56 52 58 62 60 44 54 61 16 43 59 57 48 51 55 53 46 49 47 50 MA7340 Figure 8-40 Main Control Valve - Auxiliary/Frame Sway/Attachment Tilt/Load Sense Outlet Sections 8.
Hydraulic System Disassemble the Attachment Tilt Section b. Main Control Valve Disassembly This section covers disassembly of one half (Fig. 8-41, 1) of the main control valve, including the auxiliary hydraulics (2), frame sway (3), attachment tilt (4) and load sense outlet (5) sections of the main control valve. 1. Carefully separate the attachment tilt section (Fig. 8-40, 5) from the frame sway section (11).
Hydraulic System 1 9 10 67 66 43 4 2 8 24 25 44 6 7 27 26 3 22 13 14 28 43 44 32 31 30 33 32 35 34 5 18 40 41 15 19 16 12 36 44 22 42 25 11 29 39 44 23 23 16 38 63 45 56 52 58 62 60 44 54 61 16 43 59 57 48 51 55 53 46 49 47 50 MA7340 Figure 8-42 Main Control Valve - Auxiliary Hydraulics/Frame Sway/Attachment Tilt/Load Sense Sections 8.
Hydraulic System Disassemble the Frame Sway Section 1. Carefully separate the frame sway section (Fig. 8-42, 11) from the auxiliary hydraulics section (38). Avoid dislodging or losing the shuttle (39), spring (40) and poppet (41) in the auxiliary hydraulics section. 2. Remove the o-ring (Fig. 8-42, 42) from between the two sections. 3. Remove the shuttle (Fig. 8-42, 12), spring (13) and poppet (14) from the frame sway section (11). 4. Remove both socket head capscrews (Fig.
Hydraulic System 80 81 78 73 79 75 1 72 35 38 34 54 77 40 31 74 54 39 30 54 36 76 42 41 38 44 33 32 43 9 37 11 7 46 48 47 49 50 52 51 53 29 5 12 16 3 28 14 13 41 45 6 15 59 57 4 61 38 67 65 58 19 21 60 69 23 62 71 64 54 66 68 70 2 15 56 63 55 8 10 25 18 17 20 27 22 24 26 16 MA7350 Figure 8-44 Main Control Valve - Mid-Inlet/Outlet, Extend/Retract, Lift/Lower and Outlet Sections 8.
Hydraulic System 1. To disassemble the outlet, lift/lower, extend/retract and mid-inlet/outlet sections of the main control valve (Fig. 8-44, 1), remove the three nuts (2 and 3) from the end of the three tie rods (4 and 5). Pull the tie rods out through the section assemblies. 2. Remove the o-ring (Fig. 8-44, 36) from between the two sections. Remove the shuttle (29), spring (30) and poppet (31) from the lift/lower section (28). 2. Disassemble each section as required. 4. Remove the relief valve (Fig.
Hydraulic System 80 81 78 73 79 75 1 72 35 38 34 40 54 77 31 74 54 39 30 54 36 76 42 41 32 38 44 33 43 9 37 11 7 46 48 47 49 50 52 51 53 29 5 12 16 3 28 14 13 41 45 6 15 59 57 4 61 38 67 65 58 19 21 60 69 23 62 71 64 54 66 68 70 2 15 56 63 55 8 10 25 18 17 20 27 22 24 26 16 MA7350 Figure 8-45 Main Control Valve - Mid-Inlet/Outlet, Extend/Retract, Lift/Lower and Outlet Sections 8.
Hydraulic System Disassemble the Relief Valve (Lift/Lower and Extend/Retract Sections) On the lift/lower section (Fig. 8-45, 28) and the extend/ retract section (32) the relief valves (38) are preset at 3250 ±50 psi (224 ±3,5 bar). 1. Remove the relief valve (Fig. 8-45, 38) from the appropriate section. 2. Remove the o-ring (Fig. 8-45, 54) from the relief valve. 3. Grip the relief valve body (Fig.
Hydraulic System 1 9 10 67 66 43 4 2 8 24 25 44 6 7 27 26 3 22 13 14 28 43 44 32 31 30 33 32 35 34 5 18 40 41 15 19 16 12 36 44 22 42 25 11 29 39 44 23 23 16 38 63 45 56 52 58 62 60 44 54 61 16 43 59 57 48 51 55 53 46 49 47 50 MA7340 Figure 8-46 Main Control Valve - Auxiliary Hydraulics/Frame Sway/Attachment Tilt/Load Sense Sections 8.
Hydraulic System f. Main Control Valve Assembly This section covers the assembly of the load sense outlet, attachment tilt, frame sway and auxiliary hydraulics sections of the main control valve (Fig. 8-46, 1). Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. Assemble the Load Sense Outlet Section 1. Install a new oiled o-ring (Fig.
Hydraulic System 80 81 78 73 79 75 1 72 35 38 34 40 54 77 76 31 74 54 39 30 54 36 42 41 38 44 33 32 43 9 37 11 7 46 48 47 49 50 51 52 53 29 5 12 16 28 13 41 6 15 59 57 4 61 38 65 58 19 21 60 69 23 62 71 64 54 66 68 70 2 15 56 63 67 3 14 45 55 8 10 25 18 17 20 27 22 24 26 16 MA7350 Figure 8-47 Main Control Valve - Mid-Inlet/Outlet, Extend/Retract, Lift/Lower and Outlet Sections 8.
Hydraulic System g. Main Control Valve Assembly This section covers assembly of the outlet, lift/lower, extend/retract and mid-inlet/outlet sections of the main control valve (Fig. 8-47, 1). Note: ALWAYS replace o-rings with new o-rings lubricated with clean hydraulic oil to help ensure a leakproof seal and proper vehicle performance. Assemble the Outlet Section 1. Assemble the outlet section (Fig. 8-47, 6) in the reverse order from the disassembling procedure.
Hydraulic System h. Main Control Valve Installation 1. Insert the carriage bolts (Fig. 8-48, 2 and 3) from the bottom into the main valve (4). 5. Use new oiled o-rings as required. Reattach and secure all hoses, clamps, etc. to the main control valve. 1 6. Check the routing of all hoses, wiring and tubing for sharp bends or interference with any rotating members, and install tie wraps and/or protective conduit as required. Tighten all tube and hose clamps. 4 2 4.
Hydraulic System 8.12.3 a. Secondary Function Manifold Replacement Secondary Function Manifold The secondary function manifold (Fig. 8-49, 1) is a directional control valve. Hydraulic oil from the unloader valve flows into the secondary function manifold where the pressure is reduced before the oil is directed to the power steering unit or the park brake. 1.
Hydraulic System b. Secondary Function Manifold Disassembly, Cleaning, Inspection and Assembly 5. Remove the solenoid nuts (Fig. 8-50, 5), coils (6) and cartridges (7). 1. Secure the secondary function manifold (Fig. 8-50, 1) in a suitable bench vise if possible.
Hydraulic System c. Secondary Function Manifold Installation 1. Align the secondary function manifold with its mount holes on the frame. 2. Align gaskets, bolt holes, etc., with component mount holes. Secure the secondary function manifold with the necessary fasteners. Torque fasteners to specification. Refer to the fastener torque chart in Section 2.3, “Torques.” 3.
Hydraulic System WARNING: Hot hydraulic fluid can cause severe burns. Wait for hydraulic fluid to cool before servicing any hydraulic component. 3. Unlock and open the rear door. Allow the hydraulic fluid to cool. 6. Remove the four hex-head capscrews (Fig. 8-53, 1) and four lockwashers (2) mounting the service brake valve to the steering column support. DO NOT disassemble the service brake valve. The service brake valve is not serviceable and must be replaced in its entirety if defective.
Hydraulic System b. Service Brake Valve Installation 1. Install the service brake valve (Fig. 8-53, 3) with the four lockwashers (2) and four capscrews (1) to mount the brake valve to the steering column support. Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. 2. Use new oiled o-rings as required. Reattach and secure all valves, hoses, clamps, wiring, etc. (Fig. 8-52). 3.
Hydraulic System 1 ``` ` ` MA8070 Figure 8-54 Brake Bleeder Locations c. Brake Test Carefully bleed the brake lines as soon as the brake valve is installed in the vehicle. Air in the system will not allow the brakes to apply properly. There are four brake bleeder locations (Fig. 8-54) on the axles. Work with an assistant to perform this procedure. WARNING: Avoid prolonged engine operation in closed areas with inadequate ventilation.
Hydraulic System 8.12.5 Shuttle Valve The shuttle valve (Fig. 8-55, 1) is attached to the brake valve (2) with a tee fitting (3). The shuttle valve joins the the brake valve load-sense line (4), the shuttle-in line from the main control valve (5) and the steering valve shuttle-in line (6). The shuttle valve contains a pressuredependent two-way check and is a non-serviceable item. It must be replaced in its entirety if defective. 3 4 WARNING: Hot hydraulic fluid can cause severe burns.
Hydraulic System c. Shuttle Valve Installation Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. 1. Reattach and secure hoses, fittings, etc. Attach the shuttle-in steering valve line at port P1 (Fig. 8-56, 2) and the shuttle-in main control valve line at port P2 (3), and the load-sense brake valve line at port P3 (4) of the shuttle valve (1).
Hydraulic System a. Power Steering Valve Removal 1. Park the vehicle on a firm, level surface, fully retract all hydraulic cylinders, ground the attachment (if any), place the travel select lever in (N) NEUTRAL, place the neutral lock lever in the (N) NEUTRAL LOCK position, engage the park brake switch and shut the engine OFF. 1 2. Place an Accident Prevention Tag on both the ignition key switch and the steering wheel, stating that the vehicle should not be operated. Refer to Section 1.
Hydraulic System 8.12.7 Steer Select Valve 1 The vehicle can be used in the front-wheel, four-wheel or crab steering mode. The steer select valve (Fig. 8-59, 1) controls the direction of hydraulic fluid flow to the steering cylinders mounted on each axle. The steer select valve (1) is attached to a manifold (2) mounted on a mounting plate inside the frame near the fuel tank (3).
Hydraulic System WARNING: Hot hydraulic fluid can cause severe burns. Wait for hydraulic fluid to cool before servicing any hydraulic component. 5 2 4 1 4. Unlock and open the rear door. Allow the hydraulic fluid to cool. 3 WARNING: Escaping hydraulic fluid under pressure can penetrate the skin, causing death or serious injury. Relieve hydraulic pressure before servicing any hydraulic component. 5. Label or otherwise mark the hydraulic hoses (Fig.
Hydraulic System c. Steer Select Manifold and Valve Installation 1. Attach the steer select manifold (Fig. 8-63, 2) and valve (5) to the mounting plate on the frame (4) using the two socket head capscrews (3). 1 2 5 3. Check the routing of all hoses, wiring and tubing for sharp bends or interference with any rotating members, and install tie wraps and/or protective conduit as required. Tighten all tube and hose clamps.
Hydraulic System This Page Intentionally Left Blank Model 6036 Legacy 8.
Hydraulic System 8.13 HYDRAULIC CYLINDERS 8.13.1 This section covers servicing the attachment tilt (Fig. 8-64, 1), slave (2), extend/retract (3), lift/lower (4), frame sway (5), steering (front axle shown) (6) and optional (swing carriage and side tilt) hydraulic cylinders on the vehicle. 2 WARNING: To help prevent severe burns, proceed with caution when applying heat to parts. IMPORTANT: Avoid the use of excessive heat, which will damage parts and make them unusable.
Hydraulic System 4. ALWAYS use new oiled o-rings, seals, gaskets, etc. DO NOT over-stretch seals, wipers and o-rings. After installing such parts, verify that they are not twisted in their grooves. 5. To aid in installation, lubricate piston seals and the seal installation path with clean, filtered hydraulic oil. 6. Lubricate the outer surfaces of the seals and o-rings and the inside of the tube, piston and head gland with clean, filtered hydraulic oil.
Hydraulic System Apply Loctite #243 to threads and torque to 200-300 lb/ft (271-407 Nm) 19 Torque to 20 30-35 lb/ft (41-47 Nm) 1 8 21 4 5 10 9 3 22 7 6 11 12 2 23 14 13 24 15 Torque to 300-400 lb/ft (407-542 Nm) Apply Loctite #243 to threads and torque to 155-175 lb/in (18-20 Nm) 18 17 16 26 25 MA7100 Figure 8-66 Attachment Tilt Cylinder Components b. Attachment Tilt Cylinder Disassembly Note: An additional o-ring may be included at the base of the cylinder rod.
Hydraulic System 9. Remove the two setscrews (Fig. 8-66, 9) from the piston (8). Pry or drill out the setscrews as required. DO NOT damage the piston threads. New setscrews will be required for reassembly. 10. Remove the piston (Fig. 8-66, 8) from the rod (4). The piston was installed with Loctite #243 and torqued to 200-300 lb/ft (271-407 Nm). Note: It may be necessary to apply heat to break the bond of the sealant between the piston (Fig. 8-66, 8) and the rod (4) before the piston can be removed.
Hydraulic System Apply Loctite #243 to threads and torque to 200-300 lb/ft (271-407 Nm) 19 Torque to 20 30-35 lb/ft (41-47 Nm) 1 8 21 4 5 10 9 3 22 7 6 11 23 12 2 14 13 24 15 Torque to 300-400 lb/ft 26 (407-542 Nm) Apply Loctite #243 to threads and torque to 155-175 lb/in (18-20 Nm) 18 17 16 25 MA7100 Figure 8-67 Attachment Tilt Cylinder Components 4. Install both precision wearbands (Fig. 8-67, 19) and the capped T-seal (20) onto the piston (8).
Hydraulic System f. Attachment Tilt Cylinder Installation 1. Attach a suitable sling to an overhead crane or other suitable device and to the attachment tilt cylinder. Make sure the device used can actually support the cylinder. Place the attachment tilt cylinder in position within the gooseneck. Refer to Section 3.3, “Boom Assembly Maintenance.” 2. Install the lower attachment tilt cylinder pin by tapping it through the bottom of the Quick Attach (if installed). Install the retaining bolt. 3.
Hydraulic System Apply Loctite #271 to threads and torque to 675-750 lb/ft (915-1017 Nm) 12 1 17 10 11 3 5 13 18 7 4 8 16 15 19 9 14 6 21 2 Torque to 250-300 lb/ft (339-407 Nm) 20 MA7080 Figure 8-69 Slave Cylinder Components WARNING: Escaping hydraulic fluid under pressure can penetrate the skin, causing death or serious injury. Relieve hydraulic pressure before servicing any hydraulic component. 4. Label or otherwise mark the hydraulic hoses in relation to the slave cylinder being removed.
Hydraulic System 6. Fasten the rod end in a soft-jawed vise and put a padded support below and near the threaded end of the rod to help prevent damage to the rod. 2. Discard all seals, back-up rings and o-rings. Replace with new items from a complete seal kit (Fig. 8-69, 19) to help ensure proper cylinder function. 7. Remove the locking insert (Fig. 8-69, 6) from its hole in the head gland threads. Pry or drill out the insert as required. DO NOT damage the head gland threads.
Hydraulic System Apply Loctite #271 to threads and torque to 675-750 lb/ft (915-1017 Nm) 12 1 17 10 11 3 5 13 18 7 4 8 16 19 15 9 14 6 21 2 Torque to 250-300 lb/ft (339-407 Nm) 20 MA7080 Figure 8-70 Slave Cylinder Components 5. Carefully install the head gland (Fig. 8-70, 4) onto the rod (3). 6. Carefully install the piston (Fig. 8-70, 5) onto the rod (3).
Hydraulic System 3. Use new oiled o-rings and reattach and secure the hydraulic hoses to the slave cylinder fittings. WARNING: Avoid prolonged engine operation in closed areas with inadequate ventilation. Failure to properly ventilate exhaust fumes can result in death or serious injury. 8.13.6 Extend/Retract Cylinder The extend/retract cylinder (Fig. 8-71, 1) is located under the boom attached to the bottom of the outer boom and the intermediate boom. 4.
Hydraulic System Apply Loctite #241 to threads and torque to 155-165 lb/in (18-19 Nm) Torque to 45-50 lb/ft (61-68 Nm) 25 26 1 10 11 4 6 18 13 14 15 3 17 12 13 22 8 5 16 19 20 29 21 7 30 Apply Loctite #241 to threads and torque to 300-400 lb/ft (407-542 Nm) 25 9 24 23 27 2 Torque to 300-400 lb/ft (407-542 Nm) 28 MA7090 Figure 8-72 Extend/Retract Cylinder Components 6. Attach a suitable sling to an overhead crane or other suitable device and to the extend/retract cylinder.
Hydraulic System 5. Using a pin spanner wrench, unscrew the head gland (Fig. 8-72, 7) from the tube (2). The head gland was originally torqued to 300-400 lb/ft (407-542 Nm), so a considerable amount of force is required. Carefully slide the head gland down along the rod toward the eyelet end, away from the cylinder tube (2). IMPORTANT: When sliding the rod and piston assembly into the tube, prevent the threaded end of the tube from damaging the piston (Fig. 8-72, 8).
Hydraulic System Apply Loctite #241 to threads and torque to 155-165 lb/in (18-19 Nm) Torque to 45-50 lb/ft (61-68 Nm) 25 26 1 10 11 4 6 18 13 14 15 3 17 12 13 22 8 5 19 16 20 29 21 7 30 Apply Loctite #241 to threads and torque to 300-400 lb/ft (407-542 Nm) 25 9 24 23 27 2 Torque to 300-400 lb/ft (407-542 Nm) 28 MA7090 Figure 8-73 Extend/Retract Cylinder Components e. Extend/Retract Cylinder Assembly Note: Follow Section 8.13.3, “General Cylinder Assembly Instructions.” 1.
Hydraulic System 11. Lubricate the inside of the tube (Fig. 8-73, 2) and outside of the piston (8) and head gland (7) with clean, filtered hydraulic oil. 12. Apply a compression sleeve or other suitable tool to the head gland (Fig. 8-73, 7) and piston (8) in order to compress the o-rings, back-up rings and seals, while inserting the assembled piston, rod and head gland into the tube (2). IMPORTANT: When sliding the rod (Fig.
Hydraulic System 8.13.7 Lift/Lower Cylinder The lift/lower cylinders (Fig. 8-74, 1) are anchored to the underside of the outer boom and to the vehicle frame. WARNING: Escaping hydraulic fluid under pressure can penetrate the skin, causing death or serious injury. Relieve hydraulic pressure before servicing any hydraulic component. 4. Label or otherwise mark the lift/lower cylinder hydraulic hoses. Disconnect and cap all hoses and fittings. 5.
Hydraulic System Apply Loctite #271 to Threads and Torque to 1750-2000 lb/ft (2373-2712 Nm) 1 10 Torque to 30-35 lb/ft (41-47 Nm) 5 9 15 3 11 8 12 7 16 18 13 4 6 14 19 17 20 21 2 Torque to 300-400 lb/ft (407-542 Nm) MA7070 Figure 8-75 Lift/Lower Cylinder Components IMPORTANT: When sliding the rod and piston assembly into the tube, prevent the threaded end of the tube from damaging the piston (Fig. 8-75, 8). Keep the rod centered within the tube to help prevent binding. 6.
Hydraulic System Apply Loctite #271 to Threads and Torque to 1750-2000 lb/ft (2373-2712 Nm) 1 10 Torque to 30-35 lb/ft (41-47 Nm) 5 9 15 3 11 8 12 7 16 18 13 4 6 14 19 17 20 21 2 Torque to 300-400 lb/ft (407-542 Nm) MA7070 Figure 8-76 Lift/Lower Cylinder Components 11. Remove the small o-ring (Fig. 8-76, 12) from within the piston (8). 12. Remove the o-ring (Fig. 8-76, 13) and back-up ring (14) from the head gland (7). Slide the rings off the rod (5) to remove them from the rod. 13.
Hydraulic System 1. Install a new small oiled o-ring (Fig. 8-76, 12) into the piston (8). IMPORTANT: When sliding the rod (Fig. 8-76, 5) and piston assembly into the tube, prevent the threaded end of the tube from damaging the piston (8). Keep the rod centered within the tube to help prevent binding. Protect the finish on the rod at all times. Damage to the surface of the rod can cause seal failure. 2. Install the capped T-seal (Fig. 8-76, 11) and both precision wearbands (10) onto the piston (8). 12.
Hydraulic System 4. Connect all hoses according to the labels or other marks used to identify their locations during removal. WARNING: Escaping hydraulic fluid under pressure can penetrate the skin, causing death or serious injury. 8.13.8 Frame Sway Cylinder The frame sway cylinder (Fig. 8-77, 1) is attached to the right side of the frame at the front axle and to the cast loop on the axle. 5. Operate the vehicle in order to check all boom functions and check for hydraulic system leaks. 6.
Hydraulic System 1 17 9 Torque to 300-400 lb/ft (407-542 Nm) 4 14 13 12 6 15 19 16 11 3 8 Torque to 35-40 lb/ft (47-54 Nm) 2 5 7 20 10 18 Apply Loctite #271 to threads and torque to 1100-1250 lb/ft (1492-1695 Nm) 2 MT1900 Figure 8-78 Frame Sway Cylinder Components 5. Disconnect and cap all hoses and fittings, etc. 6. Use a sling and hoist or other suitable lifting device to support the cylinder.
Hydraulic System 1 17 9 Torque to 300-400 lb/ft (407-542 Nm) 4 14 13 12 6 15 19 16 11 3 8 Torque to 35-40 lb/ft (47-54 Nm) 2 5 7 20 10 Apply Loctite #271 to threads and torque to 1100-1250 lb/ft (1492-1695 Nm) 18 2 MT1900 Figure 8-79 Frame Sway Cylinder Components IMPORTANT: When sliding the rod and piston assembly into the tube, DO NOT damage the piston by scraping it against the threads in the tube. Keep the rod in line with the tube to prevent binding. 6. Carefully withdraw the rod (Fig.
Hydraulic System d. Frame Sway Cylinder Inspection and Repair 1. Inspect all parts for wear, damage, etc. If inner surfaces of the cylinder (Fig. 8-79, 1) do not display an ultra-smooth, polished finish, or are damaged in any way, replace the damaged part. Often, dirty hydraulic fluid causes failure of internal seals and damage to the polished surfaces within the component. 2. Inspect the inside of the tube (Fig. 8-79, 5) for scoring and other damage. If the tube is damaged, replace it with a new tube. 3.
Hydraulic System f. Frame Sway Cylinder Installation 1. Lubricate the cylinder pins with multi-purpose, lithium-based grease. 2. Use a sling and hoist or other suitable lifting device to help install the cylinder. Orient the cylinder with the cylinder eyelet on top and the rod eyelet on the bottom. 3. Install the upper cylinder pin. Drive the lubricated cylinder pin through the cylinder eyelet, frame mount and self-aligning bearing. Secure the pin with a capscrew and hex-locknut.
Hydraulic System 5. Place an Accident Prevention Tag on both the ignition key switch and the steering wheel, stating that the vehicle should not be operated. Refer to Section 1.5, “Accident Prevention Tag Usage.” WARNING: Hot hydraulic fluid can cause severe burns. Wait for hydraulic fluid to cool before servicing any hydraulic component. 6. Unlock and open the rear door. Allow the hydraulic fluid to cool.
Hydraulic System Torque to 250-300 lb/ft (339-407 Nm) 1 4 14 17 15 8 12 Torque to 35-40 lb/ft (47-54 Nm) 3 9 18 19 5 23 20 16 10 11 13 21 14 24 2 25 22 7 9 8 6 Apply Loctite #242 to threads and torque to 85-95 lb/ft (115-124 Nm) Apply Loctite #271 to threads and torque to 440-500 lb/ft (597-678 Nm) MT1910 Figure 8-83 Swing Carriage Cylinder Components (Optional) b. Swing Carriage Cylinder Disassembly Note: An additional o-ring may be included at the base of the cylinder rod.
Hydraulic System 9. Remove the two setscrews (Fig. 8-83, 8), with locking inserts (9), from the piston (7). Pry or drill out the setscrews as required. DO NOT damage the piston threads. New setscrews with locking inserts will be required for reassembly. 10. Remove the piston (Fig. 8-83, 7) from the rod (4). Note: Loctite Threadlocker #271 (red) and 440-500 lb/ft (597-678 Nm) were applied to the piston (Fig. 8-83, 7) when it was installed.
Hydraulic System Torque to 250-300 lb/ft (339-407 Nm) 1 4 14 17 15 8 12 Torque to 35-40 lb/ft (47-54 Nm) 3 9 18 19 5 23 20 16 10 11 13 21 14 24 2 25 22 7 9 8 6 Apply Loctite #242 to threads and torque to 85-95 lb/ft (115-124 Nm) Apply Loctite #271 to threads and torque to 440-500 lb/ft (597-678 Nm) MT1910 Figure 8-84 Swing Carriage Cylinder Components (Optional) 5. Install two new locking inserts (Fig. 8-84, 14) into their holes in the head gland threads. 6.
Hydraulic System 18. If the bearing (Fig. 8-84, 23) requires replacement, support the rod (4) in a soft-jawed vise or other suitable holding device. Carefully press a new bearing into the rod eyelet. f. WARNING: Avoid prolonged engine operation in closed areas with inadequate ventilation. Failure to properly ventilate exhaust fumes can result in death or serious injury. Swing Carriage Cylinder Installation 1. Install the swing carriage cylinder(s) (Fig. 8-85, 1) on the pivot mount (5).
Hydraulic System 3 1 4 6 2 4 4 5 7 MT1950 Figure 8-87 Side Tilt Carriage (Optional) 8.
Hydraulic System a. Side Tilt Carriage (Optional) Removal 1. Level the boom (place the boom in a horizontal position). 2. Tilt the carriage (Fig. 8-87, 1) to fully retract the side tilt carriage cylinder (2). 3. Use suitable blocks to support the side tilt carriage (Fig. 8-87, 1) in this position. 4. Engage the park brake switch, place the travel select lever in (N) NEUTRAL, place the neutral lock lever in the (N) NEUTRAL LOCK position and shut the engine OFF. 5.
Hydraulic System 2 6 1 7 9 20 19 21 12 22 11 10 14 13 5 8 18 17 9 23 16 15 4 2 Torque to 300-400 lb/ft (407-542 Nm) 3 Torque to 30-35 lb/ft (41-47 Nm) 5 Apply Loctite #271 to threads and torque to 550-650 lb/ft (746-881 Nm) MT1920 Figure 8-88 Side Tilt Carriage Cylinder Components b. Side Tilt Carriage Cylinder Disassembly Note: An additional o-ring may be included at the base of the cylinder rod.
Hydraulic System 11. Remove the locking inserts (Fig. 8-88, 9) from their holes in the head gland threads. Pry or drill out the insert as required. DO NOT damage the head gland threads. New locking inserts will be required for reassembly. 12. Remove the o-ring (Fig. 8-88, 10), back-up ring (11) and o-ring (12) from the head gland (7). 13. Remove the precision wearband (Fig. 8-88, 13) and capped T-seal (14) from the piston (8).
Hydraulic System 2 6 1 7 9 20 19 21 12 22 11 10 14 13 5 18 17 8 9 16 15 4 Torque to 300-400 lb/ft (407-542 Nm) 2 3 Torque to 30-35 lb/ft (41-47 Nm) 23 5 Apply Loctite #271 to threads and torque to 550-650 lb/ft (746-881 Nm) MT1920 Figure 8-89 Side Tilt Carriage Cylinder Components e. Side Tilt Carriage Cylinder Assembly Note: Follow the general assembly instructions in Section 8.13.3, “General Cylinder Assembly Instructions.” 1. If necessary, press the self-aligning bearings (Fig.
Hydraulic System IMPORTANT: When sliding the rod and piston assembly in the tube, prevent the threaded end of the tube from damaging the piston seal (Fig. 8-89, 14). Keep the rod centered within the tube to help prevent binding. 13. Carefully insert the rod (Fig. 8-89, 6) with all attachments straight into the tube (4). Use a pin spanner wrench begin to thread the head gland into the tube. Install new locking inserts (9) into the head gland.
Hydraulic System 3 1 6 4 2 4 4 5 7 MT1950 Figure 8-90 Side Tilt Carriage (Optional) f. Side Tilt Carriage Cylinder Installation 1. Install the side tilt carriage cylinder (Fig. 8-90, 2) onto the side tilt carriage (1). Secure the rod end to the side tilt carriage with the cylinder rod pin (6) and snap rings (4). Secure the tube end to the pivot base (7) with the cylinder base pin (5) and snap rings (4). 2. Lubricate the pivot pins (5 and 6) with multi-purpose grease.
Hydraulic System g. Side Tilt Carriage Cylinder Pressure Checking and Circuit Bleeding 1. Attach a 4000 psi (276 bar) gauge to the test fitting on the “VG” port of the unloader valve to test the system pressure. Pressure readings should be 3000 ±100 psi (207 ±7 bar). Refer to Section 8.7, “Hydraulic System Testing.” To check the cylinder pressure, consult the factory. 8.13.11 Steering Cylinders The steering cylinders (Fig. 8-91, 1 and 2) are secured to the axle assemblies.
Hydraulic System This Page Intentionally Left Blank 8.
Section 9 Electrical System Contents PARAGRAPH 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 Model 6036 Legacy TITLE Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1.1 General Overview (Cab Harness) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1.2 General Overview (Engine Harness) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System 9.9 9.10 9.11 9.12 9.13 9.14 9.15 9.2 9.8.4 Transmission, Forward Fourth Gear Circuit. . . . . . . . . . . . . . . . . . . . . . . . 9.8.5 Transmission, Reverse First Gear Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 9.8.6 Transmission, Reverse Second Gear Circuit. . . . . . . . . . . . . . . . . . . . . . . 9.8.7 Transmission, Reverse Third Gear Circuit. . . . . . . . . . . . . . . . . . . . . . . . . Dash Panel Warning Indicator Troubleshooting. . . . . . . . . . . .
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 names and locations of the electrical components of the vehicle. The following illustration identifies the components that are referred to throughout this section. 9.1.
Electrical System 9.1.2 General Overview (Engine Harness) Tie Strap Engine Block Heater Boom Switch Connector (Not Used) Back-Up Alarm Fuel Shut-off Solenoid Connector Water Temperature Sensor Connector Hyd. Oil Tank Fuel Tank Oil Pressure Switch Connector Upper Trans. Connector Fuel Sender Conn. Hyd. Temp. Starter Engine Block Heater Trans. Temp. Conn. Steer Mode Conn. Alternator Connectors Lower Trans. Connector Diodes Boom Extend Conn.
Electrical System 9.2 9.2.1 SERVICE WARNINGS CAUTION: DO NOT disconnect the battery while the engine is running. This will cause a voltage surge in the alternator charging system that will immediately ruin internal components. General CAUTION: DO NOT disconnect any wiring without first stopping the engine, turning all electrical switches to the OFF position and disconnecting the battery negative (-) cable from the battery.
Electrical System 9.4 EFFECTIVE GROUND CONNECTIONS 1. Effective ground connections are essential to the efficient operation of electrical components. If an inadequate ground is suspected or determined, establishing another ground may be desired. Also, in the event a factory-authorized accessory is being installed, it is necessary to follow the proper sequence for providing an electrical ground. The sequence for installing or attaching a component to an electrical ground to a stud, bolt or capscrew (Fig.
Electrical System 9.5.3 Cleaning and Drying Clean a wire harness with a natural bristle brush and the same detergent used to clean the vehicle. Allow the harness to air dry. DO NOT allow surface temperatures to exceed 300° F (149° C). 9.5.4 Inspection and Repair Replace a harness only if it is damaged or unusable. If a splice or repair must be made to a wire, always use rosin core solder to bond wires together. Use heat-shrink tubing or insulating electrical tape to cover all splices or bare wires. 9.
Electrical System 9.6 FUSES AND RELAYS Fuses and relays help to protect the electrical system. In general, a blown fuse is a symptom of another electrical problem. Address the true problem, not just the symptom. Simply replacing the fuse often will not solve the problem. Blown fuses are usually due to simple causes, including loose or corroded connections, or a defective relay.
Electrical System Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open (Fig. 9-6, 2), remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of an equal current rating. 9.6.
Electrical System 9.7 9.7.1 ELECTRICAL SYSTEM TROUBLESHOOTING Introduction The electrical system produces, stores and distributes electricity in the operation of the vehicle. An engine-driven, 12-volt, 65-amp alternator, equipped with an internal, solid-state voltage regulator, produces electricity. Current from the alternator charges the battery and powers electrical system components.
Electrical System 9.7.3 Probing Electrical Connectors a. Front Probe Measuring Voltage Drop The following test (Fig. 9-8) determines the difference in voltage potential between two points. Disconnect the connector and probe the terminals from the mating side (front) of the connector. Note: DO NOT insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals.
Electrical System Testing for Continuity With a Test Lamp The following procedures verify good continuity in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. With a DMM 2. Disconnect the load. 1. Set the rotary dial of the DMM to the Ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested.
Electrical System 2. The neutral start relay (Fig. 9-10, 1) is located at the fuse block and is mounted behind the right side console access panel (Fig. 9-9, 1). To gain access, remove the screws (2) that secure the right side panel in place. 4. Apply 12 volts to terminal 86 (Fig. 9-11, 1 and (Fig. 9-12) and attach the ground (-) probe to terminal 85 (2) ground. An audible click should be heard indicating that the relay is functioning properly.
Electrical System 9.7.4 Electrical Symbols Directory The following directory (Fig. 9-13) shows the most common electrical symbols used in the electrical schematics and circuit diagrams in this section.
Electrical System 9.7.5 Electrical Schematic Legend (6036) Wire No.
Electrical System Wire No.
Electrical System Wire No.
Electrical System Wire No.
Electrical System Wire No. Gauge Color 2 14 BLU Front Wiper Switch to Front Wiper Motor (HIGH) Conn. From Function To 3 14 WHT Front Wiper Switch to Front Wiper Motor (LOW) Conn. 4A 14 GRN Front Wiper Motor (PARK) to Front Wiper Switch 5 14 YEL Roof Wiper Switch to Roof Wiper Motor Conn. 6 14 RED/WHT Cab Harness Conn. 6F to Front Wiper Switch 6A 14 RED/WHT Front Wiper Switch (POWER) to Front Wiper Switch Jumper Pin Conn. 6B 14 RED/WHT Cab Harness Conn.
Electrical System J10 J3 FUEL GAUGE J2 WATER TEMP. J7 ENGINE OIL J15 ALTERNAT0R INSTRUMENT PANEL J14 TRANS. TEMP. J5 ALTERNAT0R J1 HYD. OIL TEMP. GROUND Main Electrical Schematic POWER 9.7.6 28 J12 J11 J8 J9 J6 J4 40 40B 6 16 15 152A-2 47 17 38 151 17 40 40B 18 2GG 22 18 152A-1 11B IGNITION KEY SWITCH 15 3C 3 7.5 26 NOT USED 51 10.0 35 27 20 2KK NOT USED 27 11A 1 34 LIGHT SWITCH RELAY 40A STEER SELECT SW.
Electrical System 47 47 47B 2K 28 28 28B 2P 40 17 + 2M 28A 47A BATTERY BATTERY GROUND STABIL-TRAK CYL. NOT USED NOT USED 18 106 B00M SENSOR 151 2L STARTER 35 28A 2N 10 152 27 2T 27 35 5 10 34 FUEL SHUTOFF SOL. 34 38 6 G B+ (-) D+ 6 8 H P 5 38 2W ALTERNATOR 9 STEER SEL.
Electrical System 9.7.7 Engine Start Circuit and Troubleshooting 7.5 AMP TRANS.
Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: Engine will not crank or starter solenoid does not engage. 1. All connections relating to circuit are clean and tight. Check that transmission gear select lever is in (N) NEUTRAL. If OK Check that park brake switch is engaged. If OK Check 40-amp main fuse. If OK Check battery for proper charge and that connections are clean and tight.
Electrical System 9.7.8 Charging Circuit and Troubleshooting 40 AMP MAIN FUSE (+) TO INSTRUMENT CLUSTER BATTERY INDICATOR (+) BATTERY + - BATTERY GROUND TO INSTRUMENT CLUSTER HOURMETER 27 106 (- STARTER 152 6 38 34 152 FUEL SHUTOFF SOLENOID H P G 5 2S 38 B+ 6 GRD. D+ ALTERNATOR TO IGNITION SWITCH 2W (-) (-) MA8800 Figure 9-15 Charging Circuit 9.
Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. Fuses. 2. All connections relating to circuit are clean and tight. 3. Check that bulb is OK. Model 6036 Legacy Dash panel charge indicator ON continuously. Check alternator at terminal “B+” for voltage output of 13.8-14.2 volts. If OK Replace instrument cluster. Not OK On alternator, check wire 2W (BLK) to ground. If OK Replace alternator. 9.
Electrical System 9.7.9 Front Steer Circuit and Troubleshooting (+) ACC. POWER (+) 10 AMP STEER SELECT FUSE 11A 11B 11A 9 STEER SELECT SWITCH 8 9 8 DE DE STEER SELECT VALVE SOLENOID COIL STATE DE DE-ENERGIZED 4-WHEEL CRAB E ENERGIZED 2C 2B (-) GROUND (-) MA8580 Figure 9-16 Front Steer Circuit 9.
Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: With front-wheel steer mode selected, all four wheels steer. 1. Fuses. 2. All connections relating to circuit are clean and tight. Model 6036 Legacy Check circuit 9 (GRY/BLK) for battery voltage at steer select solenoid. Should read “0” volts. Not OK Replace steer select switch. 9.
Electrical System 9.7.10 Four-Wheel Steer Circuit and Troubleshooting (+) ACC. POWER (+) 10 AMP STEER SELECT FUSE 11A 11B 11A 9 STEER SELECT SWITCH 8 9 8 DE E STEER SELECT VALVE SOLENOID COIL STATE DE DE-ENERGIZED 4-WHEEL CRAB E ENERGIZED 2C 2B (-) GROUND (-) MA8600 Figure 9-17 Four-Wheel Steer Circuit 9.
Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. All connections relating to circuit are clean and tight. With steer select switch in 4-wheel steer mode, only 2-wheel steering is active. Check 10-amp steer select fuse. If OK Check for battery voltage at circuit 9 (GRY/BLK) at steer select manifold valve solenoid. Check 2C (BLK) ground connections. If OK Check steer select manifold valve solenoid resistance. Should have 5 to 7 ohms resistance.
Electrical System 9.7.11 Crab Steer Circuit and Troubleshooting (+) ACC. POWER (+) 10 AMP STEER SELECT FUSE 11A 11B 11A 9 STEER SELECT SWITCH 8 9 8 DE E STEER SELECT VALVE SOLENOID COIL STATE DE DE-ENERGIZED 4-WHEEL CRAB E ENERGIZED 2C 2B (-) GROUND (-) MA8590 Figure 9-18 Crab Steer Circuit 9.
Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. All connections relating to circuit are clean and tight. With steer select switch in crab steer mode, only 2-wheel steering is active. Check 10-amp steer select mode fuse. If OK Check for battery voltage at circuit 8 (LT GRN/WHT) at steer select valve. Check 2C (BLK) ground connection. Not OK Check circuit 8 (LT GRN/ WHT) from steer select solenoid to steer select switch.
Electrical System 9.7.12 Front Windshield Wiper Circuit and Troubleshooting (Option) 10 AMP FUSE (+) (+) GRY/WHT 32 WIPER SWITCH GRN 4A RED/WHT 6 RED/WHT 6A 3 4A 7 4A 7 2 1 2 3 1A 7 6A PUR BLK 1 BLK GRN WHT 3 BLU 4A 2 LOW PARK HIGH WIPER MOTOR M 1 BLK 1 (-) (-) MA8820 Figure 9-19 Front Windshield Wiper Circuit 9.
Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. All connections relating to circuit are clean and tight. With front wiper switch in LOW or HIGH position, the wiper does not operate. Check 10-amp wiper fuse. Not OK Replace fuse. Not OK Repair or replace wiper harness. Not OK Replace wiper switch. Not OK Repair or replace wiper harness. Not OK Repair or replace wiper harness.
Electrical System 9.7.13 Roof Windshield Wiper Circuit and Troubleshooting (Option) 10 AMP FUSE (+) (+) GRY/WHT 32 WIPER SWITCH GRN RED/WHT 6B RED/WHT 9 8 5 8 9 8 2 1 5 6C 8 6C PUR 1B BLK GRN 9 YEL 9 5 ON PARK WIPER MOTOR M BLK 1E 1E (-) (-) MA8830 Figure 9-20 Roof Windshield Wiper Circuit 9.
Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. All connections relating to circuit are clean and tight. Roof windshield wiper does not work with switch in ON position. Check 10-amp wiper fuse. If OK Check for battery voltage at circuit 32 (GRY/WHT) and 6B (RED/WHT) at cab/wiper harness connection. Check 1B (BLK) ground connection. Not OK Repair or replace cab/wiper harness. Not OK Replace switch. Not OK Repair or replace wiper harness.
Electrical System 9.7.14 Windshield Washer Circuit and Troubleshooting (Option) 10 AMP FUSE (+) (+) GRY/WHT 32 WASHER SWITCH 6D 10 10 RED/WHT 2 RED/WHT 1 1C 6E BLK 6E GRN 10 WASHER MOTOR 1F M BLK 1F (-) (-) MA8840 Figure 9-21 Windshield Washer Circuit 9.
Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. All connections relating to circuit are clean and tight. Washer does not spray water on front and top of windshield. Check reservoir for washer fluid. Check hose connections. Check 10-amp washer fuse. If OK Check for battery voltage at circuit 32 (GRY/WHT), 6D (RED/WHT) and 6E (RED/ WHT) at cab/washer harness connections. Check 1C (BLK) ground connection.
Electrical System 9.7.15 Heater Circuit and Troubleshooting (Option) 10 AMP FUSE (+) (+) ORG 52 RED/WHT HEATER SWITCH 1 4 2 3 RED/WHT ORG 2 5 RED YEL BLK 1 4 3 HEATER MOTOR M BLK 5 5 (-) (-) MA8850 Figure 9-22 Heater Circuit 9.
Electrical System Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: 1. All connections relating to circuit are clean and tight. Heater fan does not operate. Check 10-amp heater fuse. If OK Check for battery voltage at circuit 52 (ORG) at heater switch. Check circuit 2 (RED/WHT) ground connection. Not OK Repair or replace heater harness.
Electrical System 9.8 TRANSMISSION GEAR SELECTION TROUBLESHOOTING The following seven electrical circuit schematics address each transmission position. For additional troubleshooting information, refer to Section 9.15.5, “Transmission Shift Control Switch.” 9.
Electrical System 9.8.1 Transmission, Forward First Gear Circuit (+) (+) 107 7.5 AMP TRANS.
Electrical System 9.8.2 Transmission, Forward Second Gear Circuit (+) (+) 107 7.5 AMP TRANS.
Electrical System 9.8.3 Transmission, Forward Third Gear Circuit (+) (+) 107 7.5 AMP TRANS.
Electrical System 9.8.4 Transmission, Forward Fourth Gear Circuit (+) (+) 107 7.5 AMP TRANS.
Electrical System 9.8.5 Transmission, Reverse First Gear Circuit (+) (+) 107 7.5 AMP TRANS.
Electrical System 9.8.6 Transmission, Reverse Second Gear Circuit (+) (+) 107 7.5 AMP TRANS.
Electrical System 9.8.7 Transmission, Reverse Third Gear Circuit (+) (+) 107 7.5 AMP TRANS.
Electrical System 9.9 DASH PANEL WARNING INDICATOR TROUBLESHOOTING The following troubleshooting flow charts discuss each instrument cluster panel indicator separately. Additional information for each indicator can be found by referring to Section 9.7.6, “Main Electrical Schematic.” Note: The Instrument cluster light bulbs can be replaced. Bulb function should be checked before proceeding to each troubleshooting chart. Refer to Section 9.12.3, “Instrument Cluster.” 9.
Electrical System 9.9.1 Engine Alternator Charging Warning Indicator Troubleshooting Engine Alternator Charging Warning Indicator P Optional 0000 00 Not Used MA7560 Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: Engine alternator charging warning indicator stays ON while operating. 1. Fuses. 2. Battery for proper charge. 3. All connections relating to circuit are clean and tight. 4. Check instrument cluster bulb for proper function.
Electrical System 9.9.2 Engine Coolant Temperature Warning Indicator Troubleshooting P Engine Coolant Temperature Warning Indicator Optional 0000 00 Not Used MA7570 Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: Engine coolant temperature warning indicator stays ON while operating. 1. Fuses. 2. Battery for proper charge. 3. All connections relating to circuit are clean and tight. 4. Check instrument cluster bulbs for proper function.
Electrical System 9.9.3 Transmission Temperature Warning Indicator Troubleshooting P Transmission Temperature Warning Indicator Optional Not Used 0000 00 MA7580 Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: Transmission temperature warning indicator stays ON while operating and alarm sounds. 1. Fuses. 2. Battery for proper charge. 3. All connections relating to circuit are clean and tight. 4. Check instrument cluster bulbs for proper function.
Electrical System 9.9.4 Hydraulic Oil Temperature Warning Indicator Troubleshooting P Hydraulic Oil Temperature Warning Indicator Optional Not Used 0000 00 MA7590 Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: Hydraulic oil temperature warning indicator stays ON while operating. 1. Fuses. 2. Battery for proper charge. 3. All connections relating to circuit are clean and tight. 4. Check instrument cluster bulbs for proper function.
Electrical System 9.9.5 Park Brake Warning Indicator Troubleshooting P Park Brake Warning Indicator Optional Not Used 0000 00 MA7600 Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: Park brake warning indicator stays ON with park brake disengaged. 1. Fuses. 2. Battery for proper charge. 3. All connections relating to circuit are clean and tight. 4. Check instrument cluster bulbs for proper function.
Electrical System 9.9.6 Engine Oil Pressure Warning Indicator Troubleshooting Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: P Engine Oil Pressure Warning Indicator 1. Fuses. 2. Battery for proper charge. Optional 3. All connections relating to circuit are clean and tight. 0000 00 4. Check instrument cluster bulbs for proper function. MA7610 Not Used Engine oil pressure warning indicator stays ON while operating. Check engine for oil pressure.
Electrical System 9.9.7 Fuel Level Indicator Troubleshooting Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: P 1. Fuses. 2. Battery for proper charge. Optional 3. All connections relating to circuit are clean and tight. Fuel Level Indicator 4. Check instrument cluster bulbs for proper function. 0000 00 MA7620 Not Used Fuel level indicator reads EMPTY while operating. Verify fuel quantity level in tank. Not OK Fill fuel tank.
Electrical System 9.9.8 Hourmeter Indicator Troubleshooting Before troubleshooting any electrical circuit, ALWAYS begin by checking the following: P 1. Fuses. 2. Battery for proper charge. Optional 3. All connections relating to circuit are clean and tight. 0000 00 4. Check instrument cluster bulbs for proper function. Not Used MA7640 Hourmeter Indicator Hourmeter indicator does not register operating hours. Check circuit 38 (ORG) for battery voltage to instrument cluster connector.
Electrical System 9.10 ENGINE START CIRCUIT The purpose of the engine start circuit is to energize the starter solenoid and engage the starter motor to start the engine. To start the engine, the ignition key switch must be in the START position, the park brake switch must be in the ON position and the transmission shift control switch (travel select lever) must be in the NEUTRAL (center) position. When the ignition key switch (Fig.
Electrical System 9.10.2 b. Starter Circuit Checks Starter The starter (Fig. 9-31, 1) is located on the left side of the engine (the left side of the vehicle). 6 1. Check wires and connections for looseness, corrosion, damage, etc. 2. If a “whirring” noise is heard but the engine does not turn over, the starter is spinning but not engaging the flywheel. The starter drive or solenoid that pushes the drive forward to engage the flywheel may be defective.
Electrical System d. Starter Cleaning and Drying 1. While the starter is being removed, wipe away any grease or dirt that has accumulated around the starter mounting opening. 2. If reinstalling the starter, clean the exterior of the starter with an approved solvent. DO NOT submerse the starter or allow the solvent to contact the starter bushings. 3. Dry the starter with a clean, lint-free cloth. e.
Electrical System The alternator charging warning indicator (Fig. 9-32, 1), a battery-shaped icon on the instrument cluster panel, illuminates for three seconds when the engine is started and will remain illuminated if the engine is not running. The alternator charging warning indicator illuminates when the battery is at a low state of charge, and when the alternator is no longer able to charge the battery.
Electrical System 9.11.1 4. Remove the lower mounting capscrew (Fig. 9-35, 1) securing the alternator to the lower mounting hole (2) on the engine. Alternator a. Alternator Removal 1. Disconnect the negative (-) battery cable at the negative (-) battery terminal. 2. Install a 1/2" square drive ratchet into the square hole (Fig. 9-33, 1) in the tensioner bracket (2). Turn the ratchet to remove belt tension, and remove the engine fan belt (3). 4 3 2 1 1 3 2 MA61902 Figure 9-35 Alternator Mounting 5.
Electrical System 9.11.2 Battery WARNING: All lead-acid batteries generate hydrogen gas, which is highly flammable. If ignited by a spark or flame, the gas may explode violently, causing spraying of acid, fragmentation of the battery and cause possible severe personal injuries. Wear safety glasses when working near batteries. In case of contact with acid, flush area immediately with water.
Electrical System Note: The accuracy of this test procedure depends on closely following the load, time and temperature specifications. Relation of Battery Temperature to Minimum Voltage Temperature Minimum Voltage 70° F (21° C) and above 9.6 50° F (10° C) 9.4 30° F (-1° C) 9.1 15° F (-10° C) 8.8 0° F (-18° C) 8.5 • State of Charge: A completely discharged battery requires more than twice as much charge as a half-charged battery.
Electrical System f. Jump-Starting with an Auxiliary (“Booster”) Battery Note: Use this information in addition to that found in the Model 6036 Legacy Owners/Operators Manual. Both the auxiliary or “booster” battery and the discharged battery should be treated carefully when using jumper cables. Follow the following procedure exactly, and DO NOT cause sparks to occur: 2. Prepare a mixture of baking soda and water, and obtain a non-metallic scrub brush.
Electrical System 9.12 ELECTRICAL SYSTEM COMPONENTS Electrical components include warning devices such as the indicators in the operator’s instrument cluster, horn, back-up alarm, and other components such as the various solenoids and all accessories. Examine the appropriate wiring diagrams and schematics earlier in this section, to help understand the wiring circuits involved. 9.12.1 If the problem is still not located, unplug the horn connector (Fig.
Electrical System d. Transmission Temperature Warning Indicator g. Engine Oil Pressure Warning Indicator This indicator (Fig. 9-39) illuminates when the transmission fluid temperature exceeds 250° F (121° C). An audible alarm will sound, and the OH25302 vehicle should be stopped and the engine allowed to run at high idle for five minutes. This indicator (Fig. 9-39) illuminates and an audible alarm sounds after 15 seconds if the engine is not started; this is normal.
Electrical System The back-up alarm is energized via current from the transmission shift control switch, part of the travel select lever, mounted within the steering column. See the appropriate wiring schematic and diagram in this section to help understand the back-up alarm circuit. Refer to Section 4.3.2, c. “Transmission Travel and Gear Select Lever Removal” for information on removing and replacing the transmission shift control switch.
Electrical System Directional Light Indicator (Optional) b. Normal Operating Lights After the engine starts, the operator’s instrument cluster (Fig. 9-42, 6) provides information via the following indicators: MA8270 The directional light (turn signal) indicator (Fig. 9-42, 5) illuminates when the optional directional light lever is moved either to the LEFT or RIGHT turn position. Fuel Level Indicator The fuel level indicator (Fig. 9-42, 1) represents The quantity of fuel remaining in the fuel tank.
Electrical System e. Operator’s Instrument Cluster Bulb Removal f. Operator’s Instrument Cluster Installation 1. Disconnect the negative (-) battery cable at its battery terminal. 1. Install the instrument cluster rear access plate (Fig. 9-44, 2) using three screws (1). 2. Unscrew the plastic ring retainer from the back of the instrument cluster. Disconnect the harness plug connector from the back of the instrument cluster (Fig. 9-44, 3).
Electrical System 9.13 WINDOW WIPER/WASHER (OPTION) 9.13.1 e. Installation and Testing 1. Connect the windshield wiper switch to the cab harness connector. Windshield Wiper Switch 2. Position the switch over the rectangular switch bezel, and snap into position. 3. Connect negative (-) battery cable at the negative battery terminal. 4. Turn the ignition key switch to the RUN position and test the windshield wiper LOW speed and HIGH speed functions. 1 OH18502 9.13.
Electrical System 6. From the outside and front of the cab, remove the windshield wiper blade arm nuts (Fig. 9-48, 2 and 3) and washer (4) from the motor shaft (5). 7. Disconnect the washer hose (Fig. 9-50, 2) from hose connector (3). 8. Remove the wiper arms (Fig. 9-48, 6), knurled driver (7) and rubber cap (8) from the motor shaft (5). 9. Remove the metal hex jam nut (Fig. 9-48, 9) and metal washer (10) from motor shaft. 10. Remove the motor mounting bolts (Fig.
Electrical System 10. Install right side defroster hose to the dash panel hose connector. d. Inspection and Replacement 11. If previously removed, install hydraulic hoses under the dash. (Refer to Section 4.3.3, “Steering Column/ Valve Replacement.”) 1. Inspect the switch terminals for continuity with the switch in the OFF and ON positions. (Refer to Section 9.7.13, “Roof Windshield Wiper Circuit and Troubleshooting (Option).”) 12. Install the top right dash panel and lower dash panel. 2.
Electrical System 4. From inside the cab, remove screws (Fig. 9-52, 4) from top locknut plate (7). 9.13.5 Windshield/Roof Washer Switch 5. Unclip the plastic motor cover (Fig. 9-52, 5) and remove. 6. From the top of the cab, remove the hex nut (Fig. 9-52, 6) from the wiper motor shaft (2). 7. From inside the cab, pull the wiper motor down and away from the roof. 8. Label and disconnect the cab harness connectors from the wiper motor. b. Disassembly DO NOT disassemble the motor.
Electrical System a. Removal d. Inspection and Replacement 1. Inspect the switch terminals for continuity with the switch in the OFF and ON positions. For additional information, refer to Section 9.7.14, “Windshield Washer Circuit and Troubleshooting (Option).” 1. Disconnect the negative (-) battery cable at the negative (-) battery terminal. 2. Replace the switch if it fails any of the tests in Step 1. 3. Pull the washer reservoir (Fig. 9-54, 4) out and away from the mounting studs. e.
Electrical System 9.14 9.14.1 CAB HEATER AND FAN (OPTION) Cab Heater Controls Note: If the suspect component is found to be within the heater box, the heater box must be removed as a complete unit and replaced. For additional information on the removal and installation of the heater box, refer to Section 4.4.4, a. “Heater Assembly Removal.” 9 6 3 1 2 6. If removing the temperature control knob, disconnect the cable connector and remove control knob. 7.
Electrical System 9.15 SWITCHES AND SOLENOIDS Note: For information on the front windshield wiper, roof wiper and windshield washer systems, refer to Section 9.13, “Window Wiper/Washer (Option).” During freezing temperatures, if the ignition key switch fails to turn, or does not allow the key to be inserted, warm the switch with a heat gun (blow-dryer), or use liquid lock deicer to help evaporate frozen moisture from within the switch. 9.15.
Electrical System c. Inspection and Replacement To determine the proper operation of the ignition key switch, and using the following charts, test the wires on the back of the switch for continuity with an ohmmeter. Test the ignition key switch for continuity, by checking from the ignition (BLUE) wire to each of the following wires in each switch position.
Electrical System e. Transmission Neutral Start Feature The transmission neutral start feature is a safety feature designed to prevent the engine from starting with the transmission in (F) FORWARD or (R) REVERSE. 1 Shifting into (N) NEUTRAL (Fig. 9-60, 1) activates the neutral start relay (Fig. 9-59, 1) located in the fuse and relay panel (2). When the travel select lever is in (N) NEUTRAL, electrical power flows to the starter relay, allowing the starter to engage and start the engine.
Electrical System b. Fuel Shut-off Solenoid Disassembly DO NOT disassemble a fuel shut-off solenoid. Replace a defective fuel shut-off solenoid with a new one. c. Fuel Shut-off Solenoid Inspection and Replacement Use a 12-volt DC source and ground to test the solenoid. Energize the solenoid, and watch for the plunger to retract. If the plunger does not retract, replace the fuel shut-off solenoid with a new one. d. Fuel Shut-off Solenoid Installation 1. Clean the exterior of the fuel injector pump. 2.
Electrical System Examine the fluid in the hydraulic oil sight glass (Fig. 9-63, 1) to check whether there is a sufficient amount of fluid in the system (the oil level should be at the bottom of the sight glass with all hydraulic cylinders retracted) and whether the fluid is contaminated. Replace the hydraulic oil filter as required. Explore other causes for excessive temperature, such as high air temperature, plugged oil cooler or lines, loose fan belt, plugged radiator, etc. (Refer to Section 9.9.
Electrical System 6. Start the engine, check for hydraulic fluid leaking at the hydraulic oil temperature switch and allow the hydraulic fluid to reach operating temperature. Cycle the boom several times and check whether the hydraulic oil temperature warning indicator illuminates on the operator’s display panel. 9.15.4 1 Park Brake Switch The park brake switch (Fig. 9-65, 1) is located on the dash to the left of the steering column and is pressed or “snapped” into a rectangular switch bezel.
Electrical System d. Park Brake Switch Installation and Testing a. Park Brake Switch Removal 1. Disconnect the negative (-) battery cable at the negative battery terminal. 2. Carefully pry the park brake switch (Fig. 9-68, 1) and wiring out of the mounting hole. 3. Label and disconnect the wiring from the park brake switch. Remove the switch from the vehicle. 1. Route the wiring from the dash through the bezel, then connect the wiring to the park brake switch (Fig.
Electrical System 9.15.5 Transmission Shift Control Switch a. Travel Select Lever The transmission shift control switch (travel select lever) is located on the left side of the steering column. The switch has three positions (Fig. 9-69, 1): (F) FORWARD (all the way up), (N) NEUTRAL (center), and (R) REVERSE (all the way down). The switch or lever must be in the (N) NEUTRAL position to permit engine starting. b. Gear Select Lever The gear select lever (Fig.
Electrical System 9.15.6 Transmission Solenoid Valves The transmission is shifted via six solenoids. Three solenoids valves (Y1, Y2 and Y3) are contained in an UPPER spool-type solenoid cartridge assembly (valve body) (Fig. 9-71, 1). 1 The remaining three solenoid valves (Y4, Y5 and Y6) are contained in the LOWER spool-type solenoid cartridge assembly (valve body) (Fig. 9-71, 2).
Electrical System c. Travel Select Lever and Wiring Harness Testing Note: An assistant will be required to operate the travel select lever in order to perform the following test. 1. Remove the plug from the UPPER (Fig. 9-72, 1 and Fig. 9-72, 1) and LOWER (Fig. 9-72, 2 and Fig. 9-73, 1) transmission solenoid valve bodies. Turn the ignition key switch to the RUN position. Y1 3.
Electrical System Note: The following chart shows which solenoids are active with any given selection of the transmission shift control switch (travel select lever) and gear select position.
Electrical System e. Transmission Upper Valve Body Solenoid Removal f. Note: Before removing the valve body protective cover, clean the area around the housing to prevent contamination. Note: When installing the solenoid valve into the valve body, position the solenoid valve wires so that they do not interfere with the protective cover plate. 1. Disconnect the negative (-) battery cable at the negative battery terminal. 2. Remove the six capscrews (Fig.
Electrical System 4. Remove upper valve body housing from transmission and set aside in a clean area, free of dirt, grease and oil. For further information, refer to the Transmission Service Manual, Model ZF 4 WG-98 TC, JLG P/N 8990455 (ZF P/ N 5871 135 002). 5. Remove the upper valve housing flat gasket. 6. Remove the nine lower valve body protective cover screws (Fig. 9-77, 1), washers (2) protective cover (3) and gasket (4). 1 2 3 7. Disconnect the internal wire connector (Fig.
Electrical System 9.15.7 b. Steer Modes and Conditions Steering Certain steering functions are dependent upon electrical operations, described below. Consult the Owners/ Operators Manual for further information related to steering. a. Steer Select Switches Four-Wheel Steer Mode With the steer select switch (Fig. 9-78, 1) in the lower position (Fig. 9-78, 2), the following conditions must be met: OH2611 The steer select switch (Fig. 9-78, 1) is located on the right side of the operator’s control panel.
Electrical System Crab-Steer Mode With the steer select switch in the uppermost position (Fig. 9-82, 4), the following conditions must be met: 1 OH2591 1. Front wheels (Fig. 9-81, 1) must steer in the direction that the steering wheel is turned. 1 2 4 3 2 OH1680 Figure 9-81 Crab Steer OH19412 2. Rear wheels (Fig. 9-81, 2) must steer in the direction that the steering wheel is turned. (Refer to Section 9.7.11, “Crab Steer Circuit and Troubleshooting.”) c.
Electrical System 9.15.8 Steer Select Switches Top of Switch For additional information, refer to Section 9.7.9, “Front Steer Circuit and Troubleshooting.” 9 8 1. Disconnect the negative (-) battery cable at the negative battery terminal. 3. Label and disconnect the wiring from the switch. Note and mark the “front” or top of the switch in relation to the switch wiring terminals, and remove the switch from the vehicle. b. Steer Select Switch Disassembly, Inspection and Replacement 1 11A GRN a.
Electrical System 9.15.9 Steer Select Valve The steer select valve (Fig. 9-84, 1), is secured to the steer select manifold and frame with four capscrews and o-rings (Fig. 9-85, 1) on the inside wall of the vehicle frame. When the solenoid is de-energized, the control spool (Fig. 9-85, 4) is returned to its normal (centered) condition by the centering springs (5).
Electrical System 9.15.10 a. Engine Oil Pressure Sender Removal Engine Low Oil Pressure Sender The engine low oil pressure sender (Fig. 9-87, 1) is located on the engine, and is connected to the operator’s instrument cluster via the engine wiring harness, bulkhead connector and cab wiring harness. 1. Disconnect the negative (-) battery cable at the negative battery terminal. 2. Unplug the engine low oil pressure sender connector (Fig. 9-87, 1) from the wiring harness connector. 3. The sender (Fig.
Electrical System 9.15.11 Engine Coolant High Temperature Sender 1 The engine coolant high temperature sender (Fig. 9-89, 1) is threaded into the engine block (2) and is connected to the operator’s instrument cluster via the engine wiring harness, bulkhead connector and cab wiring harness. P 3 1 2 0000 00 MA7570 Figure 9-90 Engine High Coolant Temperature Indicator a. Engine Coolant High Temperature Sender Removal 1. Disconnect the negative (-) battery cable at the negative battery terminal. 2.
Electrical System 5. Start the engine, allow it to reach operating temperature and observe the operator’s instrument cluster for warning indication. If the sender is not defective, the problem could be elsewhere; possibly in a shorted wire, improper-running engine, improper or low coolant, obstructed or faulty radiator, coolant pump, loose fan belt, defective instrument cluster, etc. 9.15.12 Transmission Temperature Sender P 1 0000 00 The transmission temperature sender (Fig.
Electrical System 9.15.13 Engine Block Heater The engine is equipped with an engine block heater (Fig. 9-93, 1) that can be plugged into a standard 110/120V A.C. grounded outlet to heat the engine coolant. When temperatures are below 10° F (-12° C), the block heater should be used to aid in starting. WARNING: DO NOT attempt this procedure when the engine is hot. Wait for the engine, muffler and tailpipes to cool down before proceeding. Failure to do so could result in severe burns. 3.
Electrical System b. Engine Block Heater Disassembly e. Engine Block Heater Installation DO NOT disassemble the heater element. Replace a defective or faulty heater with a new part. 1. Apply Teflon tape to coolant heater element threads (Fig. 9-93, 4) and install element. DO NOT overtighten. c. Engine Block Heater Inspection and Replacement 2. Plug-in 110-volt cord (2) into heater element and install plastic retainer (5) around coolant heater element and 110-volt cord.
Electrical System 9.15.14 Fuel Level Indicator and Fuel Level Sender The fuel level indicator (Fig. 9-95, 1) can be found on the operator’s instrument cluster. The operator’s instrument cluster fuel level indicator (Fig. 9-95, 1) shows the level of fuel remaining in the fuel tank. The fuel level sender wiring harness connector can be accessed from the top of the fuel tank. The fuel level sender (Fig.
Electrical System b. Fuel Level Circuit Tests For additional information refer to Section 9.9.7, “Fuel Level Indicator Troubleshooting.” If the fuel level indicator is suspected of giving a false reading, perform the following checks: 1. Check for loose or defective wiring, faulty ground connections, and corrosion on the fuel tank sender and wiring lead. 2. If the fuel level indicator needle does not move after the ignition key switch is turned to the RUN (Fig.
Electrical System This Page Intentionally Left Blank 9.
Section 10 Index A Access Panels and Covers Access Panel and Cover Replacement ..........................4.32 Accident Prevention Tags ...............1.4 After Service Startup and Checks Axle Service ..............................2.24 Boom Service............................2.24 Brake System Service...............2.23 Electrical/Electronic Component Service ...............2.22 Engine Service..........................2.24 Fuel System Service .................2.23 Hydraulic Component Service .................
Index Electrical Schematic Legend ...................................9.15 Electrical Symbols Directory ................................9.14 Engine Start Circuit...................9.22 Four Wheel Steer Circuit ..........9.28 Front Steer Circuit.....................9.26 Front Windshield Wiper Circuit.....................................9.32 Heater Circuit............................9.38 Introduction ...............................9.10 Main Electrical Schematic .................... 9.20–9.
Index Extend/Retract Cylinder ......... 8.109 Frame Sway Cylinder ............. 8.118 General Cylinder Assembly Instructions .......................... 8.100 General Cylinder Cleaning Instructions .......................... 8.100 General Cylinder Disassembly Instructions..... 8.100 Lift/Lower Cylinders................ 8.114 Side Tilt Carriage Cylinder (Optional)............................. 8.127 Slave Cylinders ...................... 8.105 Steering Cylinders .................. 8.
Index Straight Thread O-ring Fitting (Non-Adjustable) ...................... 2.5 Training Mechanics as Operators ... 1.3 Transmission After Service or Replacement...6.13 General Specifications................ 6.4 Inspection and Internal Repair ....................................6.10 Installation.................................6.10 Lubrication .................................. 6.4 Performance Specifications ........ 6.4 Related Fuse Ratings, Amps ...... 6.4 Removal......................................
Accident Prevention Tags Accident Prevention Tags 8990403 Origin 5/00 OS2180
Accident Prevention Tags 8990403 Origin 5/00 OS2180
Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: (717) 485-5161 Customer Support Toll Free: (877) 554-5438 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W.
