Skytrak 6036 Service Manual
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Skytrak 6036 Service Manual

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Table Of Contents
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Table of Contents

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Service Manual
Models
6036, 6042, 8042,
10042 & 10054
SN 0160069719 to Present
including 0160065791, 0160065792, 0160065796,
0160065798, 0160065824, 0160065825,
0160065826, 0160069336, 0160069359,
0160069383, 0160069411, 0160069441,
0160069566, 0160069567 & 0160069568
31211015
Revised
July 31, 2017
An Oshkosh Corporation Company

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Summary of Contents for Skytrak 6036

  • Page 1 Service Manual Models 6036, 6042, 8042, 10042 & 10054 SN 0160069719 to Present including 0160065791, 0160065792, 0160065796, 0160065798, 0160065824, 0160065825, 0160065826, 0160069336, 0160069359, 0160069383, 0160069411, 0160069441, 0160069566, 0160069567 & 0160069568 31211015 Revised July 31, 2017 An Oshkosh Corporation Company...
  • Page 3 Revised pages 2-4 thru 2-78, 4-5, 4-8 thru 4-12, 7-8 thru 7-11, 8-6 thru 8-37, 8-43, 8-44, 9-4 thru 9-18, 9-20, 9-35 thru 9-94, 10-7 July 31, 2017 Revised page 2-12, pages 7-9 thru 7-16, 9-43 thru 9-45 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 4 Maximum engine power can be found on the decals (2) located on the inside of the side engine compartment doors. (8042, 10042, 10054) ULTRA LOW SULFUR DIESEL XXXhp (XXkW) @ XXXX RPM FUEL ONLY S < 15 mg/kg 1001125387 A XXXXXXXXXX_A O 5603 XXXhp (XXkW) @ XXXX RPM XXXXXXXXXX_A (6036, 6042) 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 5: Table Of Contents

    Boom System - Three Section (6036, 6042, 8042 & 10042) .......

  • Page 6: Table Of Contents

    Hydraulic Cylinders ..............8-51 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 7: Table Of Contents

    Stabil-TRAK™ Hydraulic Circuit Operation and Troubleshooting ......10-26 10.12 Boom Extend System Hydraulic Circuit Operation and Troubleshooting ....10-42 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 8 Section Subject Page 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 9: Safety Practices

    Safety Decals ..............6036, 6042, 8042, 10042, 10054...

  • Page 10: Introduction

    An Operation & Safety Manual is supplied with each machine and must be kept in the manual holder located in the cab. In the event that the Operation & Safety Manual is missing, consult your local authorized service distributor before proceeding. 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 11: Safety Instructions

    HAND TOOLS: Always use the proper tool for the job; keep tools clean and in good working order, and use special service tools only as recommended. 6036, 6042, 8042, 10042, 10054 31211015...

  • Page 12: Safety Decals

    Turn the radiator cap to the first stop and allow pressure to escape before removing the cap completely. Failure to follow the safety practices could result in death or serious injury. Properly disconnect battery(s) prior to service the fuel or hydraulic systems. 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 13: General Information And Specifications

    Metric Fastener Torque Chart ..........2-27 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 14 O-ring Installation (Replacement) ......... . . 2-78 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 15: Replacement Parts And Warranty Information

    Registration activates the warranty period and helps to assure that warranty claims are promptly processed. To guarantee full warranty service, verify that the distributor has returned the business reply card of the warranty registration form to JLG. 6036, 6042, 8042, 10042, 10054 31211015...

  • Page 16: Specifications

    Outrigger - Left or Right, — — — 4.0 - 9.0 4.0 - 9.0 UP or DOWN Outrigger - Left and Right, — — — 4.0 - 10.0 4.0 - 10.0 UP or DOWN 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 17 Dry Type, Replaceable Primary and Safety Elements Note: No adjustment of the throttle is required. The engine Low Idle and High Idle are controlled by the engine ECM and cannot be adjusted without Cummins programing tools. 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 18 70 psi (4,8 bar) 17.50 x 25 G-2/L-2 Bias Ply Traction 12 Ply Foam - Approx 785 lb (356 kg) Pneumatic 76 psi (5,2 bar) 400/75x28 DuraForce 14 Ply Foam - Approx 570 lb (259 kg) 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 19: Fluid Specifications

    Mobil ATF-D/M (SN 0160074878 to Present) Air Conditioning Refrigerant R-134A Tetrafluoroethane Note: *Friction Modifier may be added to axle differentials, see Section 2.4, “Fluid and Lubricant Capacities”. **See Note on page 2-12 for details. 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 20 (S < 500 mg/kg) (Maximum B5 Biodiesel) Brake Fluid Mobil ATF-D/M (SN 0160074878 to Present) Air Conditioning Refrigerant R-134A Tetrafluoroethane Note: *Friction Modifier may be added to axle differentials, see Section 2.4, “Fluid and Lubricant Capacities”. 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 21: Fluid And Lubricant Capacities

    10042 &10054 Front Axle 2.1 quart (2 liter) Rear Axle 2.2 quart (2,1 liter) Window Washer Bottle (if equipped) Capacity 2.2 quart (2,1 liter) Air Conditioning System (if equipped) Capacity 1.9 lbs (0,86 kg) 6036, 6042, 8042, 10042, 10054 31211015...

  • Page 22: Service And Maintenance Schedules

    Every 50 Hours O 1010 O 1020 Check Washer Lubrication Fluid Schedule 2.5.4 First 250 Hours O 1040 O 1050 O 1070 Change Axle Oil Change Wheel End Change Transmission Fluid and Filter 2-10 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 23 O 1160 O 0990 O 1150 Check Fan Belt Change Engine Oil Check Battery Check Wheel Lug and Filter (if Not Torque equipped for LS) 2.5.8 Every 750 Hours OCXXX6 Change Hydraulic Fluid 6036, 6042, 8042, 10042, 10054 31211015 2-11...
  • Page 24 O 1240 O 1250 OC1310 Change Engine Change Change Engine Coolant DEF Tank Filter Coolant and Clean (if equipped for DEF Engine ULS/85 or 110 HP) Coolant Strainer (if equipped for ULS/85 or 110HP) 2-12 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 25 General Information and Specifications 2.5.12 Every 4000 Hours or 3 Years O 1260 Change DEF Pump Filter (if equipped for ULS/85 or 110HP) 2.5.13 Every 5000 Hours or 4 Years O 1270 Engine Valve Lash Adjustment 6036, 6042, 8042, 10042, 10054 31211015 2-13...

  • Page 26: Lubrication Schedules

    General Information and Specifications LUBRICATION SCHEDULES 2.6.1 50 Hour a. 6036 & 6042 EVERY O 5721 2-14 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 27 General Information and Specifications b. 8042 & 10042 EVERY O 5731 6036, 6042, 8042, 10042, 10054 31211015 2-15...
  • Page 28 General Information and Specifications c. 10054 EVERY O 5711 2-16 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 29 General Information and Specifications 2.6.2 250 Hour a. 6036 & 6042 EVERY 6042 ONLY OA1820 6036, 6042, 8042, 10042, 10054 31211015 2-17...
  • Page 30 General Information and Specifications b. 8042, 10042 & 10054 EVERY OH4172 2-18 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 31 General Information and Specifications 2.6.3 1000 Hour EVERY 1000 OH4181 6036, 6042, 8042, 10042, 10054 31211015 2-19...

  • Page 32: Thread Locking Compound

    0100071 Medium - High Strength (Red) Vibra-TITE ® ® Note: Loctite ™ can be substituted in place of Loctite ™ . Vibra-TITE ™ 122 can be substituted in place of Vibra-TITE ™ 121. 2-20 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 33: Torque Charts

    NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER 6036, 6042, 8042, 10042, 10054 31211015 2-21...
  • Page 34 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER 2-22 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 35 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER 6036, 6042, 8042, 10042, 10054 31211015 2-23...
  • Page 36 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER 2-24 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 37 3. * ASSEMBLY USES HARDENED WASHER 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. 6036, 6042, 8042, 10042, 10054 31211015 2-25...
  • Page 38 3. * ASSEMBLY USES HARDENED WASHER 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. 2-26 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 39 3. * ASSEMBLY USES HARDENED WASHER 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. 6036, 6042, 8042, 10042, 10054 31211015 2-27...
  • Page 40 3. * ASSEMBLY USES HARDENED WASHER 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. 2-28 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 41 3. * ASSEMBLY USES HARDENED WASHER 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. 6036, 6042, 8042, 10042, 10054 31211015 2-29...
  • Page 42 3. * ASSEMBLY USES HARDENED WASHER 4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. 2-30 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 43: Hydraulic Connection Assembly And Torque Specification

    ISO 8434, DIN 2353 MAE9050 MAE9010 BH - Bulkhead connection – JIC, ORFS, MBTL, or MBTS types b. Straight Thread Types, Tube and Hose Connections JIC - 37° flare per SAE J514 MAE9060 MAE9020 6036, 6042, 8042, 10042, 10054 31211015 2-31...
  • Page 44 2. When making a connection to tubing, compression or flare, inspect the tube in the area of the fitting attachment to ensure that the tube has not been damaged. 2-32 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 45 Steel fittings with steel mating components b. Steel fittings with aluminum or brass mating components c. Aluminum or brass fittings with steel mating components d. Aluminum or brass fittings with aluminum or brass mating components. MAE9100 6036, 6042, 8042, 10042, 10054 31211015 2-33...
  • Page 46 1.5 to 2.5 2 - 11 1/2 2.37 60.09 1.5 to 2.5 * ØA thread dimension for reference only. NOTE: ** Refer to Section 2.9.15, “FFWR and TFFT Methods, ” for TFFT procedure requirements. 2-34 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 47 1.5 to 2.5 2 - 11 2.35 59.61 1.5 to 2.5 * ØA thread dimension for reference only. NOTE: ** Refer to Section 2.9.15, “FFWR and TFFT Methods, ” for TFFT procedure requirements. 6036, 6042, 8042, 10042, 10054 31211015 2-35...
  • Page 48 2 1/2-12 2.42 61.50 2.50 63.50 3/4 to 1 * ØA and ØB thread dimensions for reference only. NOTE: ** Refer to Section 2.9.15, “FFWR and TFFT Methods, ” for FFWR procedure requirements. 2-36 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 49 2 1/2-12 2.42 61.50 2.50 63.50 3/4 to 1 * ØA and ØB thread dimensions for reference only. NOTE: ** Refer to ,Section 2.9.15, “FFWR and TFFT Methods, ” for FFWR procedure requirements. 6036, 6042, 8042, 10042, 10054 31211015 2-37...
  • Page 50 Steel fittings with aluminum or brass mating components b. Aluminum or brass fittings with steel mating components c. Aluminum or brass fittings with aluminum or brass mating components. 2-38 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 51 0.63 15.90 ALUMINUM/BRASS MATING 3/4-16 0.69 17.50 0.75 19.10 COMPONENTS; 7/8-14 0.81 20.60 0.87 22.20 UN-LUBRICATED THREADS 1 1/16-14 0.98 25.00 1.06 27.00 * ØA and ØB thread dimensions for reference only. NOTE: 6036, 6042, 8042, 10042, 10054 31211015 2-39...
  • Page 52 Steel fittings with aluminum or brass mating components b. Aluminum or brass fittings with steel mating components c. Aluminum or brass fittings with aluminum or brass mating components. 2-40 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 53 61.67 2.50 63.50 1/4 to 1/2 1/2 to 3/4 * ØA and ØB thread dimensions for reference only. NOTE: ** Refer to Section 2.9.15, “FFWR and TFFT Methods, ” for FFWR procedure requirements. 6036, 6042, 8042, 10042, 10054 31211015 2-41...
  • Page 54 10. Slide collet into position and tighten until finger tight. Mark nut and tube in the finger-tight position. Tighten nut to the number of flats listed while using the Double Wrench Method. The tube must not turn with the nut. 2-42 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 55 M52 x 2 49.90 52.00 16.00 38.30 1.5 to 1.75 NOTE: * ØA, ØB,C, & ØD thread dimensions for reference only. ** Refer to Section 2.9.15, “FFWR and TFFT Methods, ” for FFWR procedure requirements. 6036, 6042, 8042, 10042, 10054 31211015 2-43...
  • Page 56 3. Insert the bulkhead side of the fitting into the panel or bulkhead bracket opening. 4. Hand thread the locknut onto the bulkhead end of the fitting body. 5. Torque nut onto fitting while using the Double Wrench Method. 2-44 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 57 Thread Dash Size Type [Ft-Lb] [Nm] Size (UNF) STEEL FITTINGS 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 ° FLARE (JLIC) 7/8-14 BULKHEAD 1 1/16-12 FITTING 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12 6036, 6042, 8042, 10042, 10054 31211015 2-45...
  • Page 58 M16 x 1.5 M18 x 1.5 M20 x 1.5 DIN 24° CONE M22 x 1.5 FLARELESS BITE (MBTS) BULKHEAD M24 x 1.5 FITTING M30 x 2 M36 x 2 M42 x 2 M52 x 2 2-46 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 59 General Information and Specifications This Page Intentionally Left Blank 6036, 6042, 8042, 10042, 10054 31211015 2-47...
  • Page 60 • Aluminum or brass fittings with aluminum or brass mating components. 7. Inspect to ensure the o-ring is not pinched and the washer is seated flat on the counter bore of the port. 2-48 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 61 2 1/2-12 2.50 63.50 NOTE: 1. * ØA thread OD dimension for reference only. 2. Removal torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque. 6036, 6042, 8042, 10042, 10054 31211015 2-49...
  • Page 62 2 1/2-12 2.50 63.50 NOTE: 1. * ØA thread OD dimension for reference only. 2. Removal torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque. 2-50 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 63 2 1/2-12 2.50 63.50 NOTE: 1. * ØA thread OD dimension for reference only. 2. Removal torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque. 6036, 6042, 8042, 10042, 10054 31211015 2-51...
  • Page 64 2 1/2-12 2.50 63.50 NOTE: 1. * ØA thread OD dimension for reference only. 2. Removal torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque. 2-52 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 65 2 1/2-12 2.50 63.50 NOTE: 1. * ØA thread OD dimension for reference only. 2. Removal torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque. 6036, 6042, 8042, 10042, 10054 31211015 2-53...
  • Page 66 2 1/2-12 2.50 63.50 NOTE: 1. * ØA thread OD dimension for reference only. 2. Removal torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque. 2-54 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 67 General Information and Specifications This Page Intentionally Left Blank 6036, 6042, 8042, 10042, 10054 31211015 2-55...
  • Page 68 • Aluminum or brass fittings with aluminum or brass mating components. 7. Inspect to ensure the o-ring is not pinched and the washer is seated flat on the counter bore of the port. 2-56 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 69 Torque Torque Thread Connecting M Size Tube O.D Material [Ft-Lb] [Nm] [Ft-Lb] [Nm] (mm) (metric) M10x1 M12x1.5 M14x1.5 ALUMINUM/BRASS M16x1.5 FITTINGS OR ALUMINUM/BRASS M18x1.5 MATING M22x1.5 COMPONENTS; UN-LUBRICATED M27x2 THREADS M33x2 M42x2 M48x2 6036, 6042, 8042, 10042, 10054 31211015 2-57...
  • Page 70 Thread Connecting M Size Tube O.D Material [Ft-Lb] [Nm] [Ft-Lb] [Nm] (mm) (UNF) M10x1 M12x1.5 ALUMINUM/ M14x1.5 BRASS FITTINGS M16x1.5 OR ALUMINUM/ M18x1.5 BRASS MATING M22x1.5 COMPONENTS; M27x2 UN-LUBRICATED M33x2 THREADS M42x2 M48x2 2-58 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 71 173 182 190 235 247 258 108 114 119 146 155 161 THREADS M42x2 259 272 285 351 369 386 173 182 190 235 247 258 M48x2 335 352 369 454 477 500 173 182 190 235 247 258 6036, 6042, 8042, 10042, 10054 31211015 2-59...
  • Page 72 M Size Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] Material (metric) (mm) Nom Max M12x1.5 M14x1.5 ALUMINUM/ M16x1.5 BRASS FITTINGS M18x1.5 OR ALUMINUM/ M20x1.5 BRASS MATING M22x1.5 COMPONENTS; M27x2 UN-LUBRICATED M33x2 THREADS M42x2 M48x2 2-60 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 73 M Size Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] Material (metric) (mm) Nom Max M10x1 M12x1.5 ALUMINUM/ M14x1.5 BRASS FITTINGS M16x1.5 OR ALUMINUM/ M18x1.5 BRASS MATING M22x1.5 COMPONENTS; M27x2 UN-LUBRICATED M33x2 THREADS M42x2 M48x2 6036, 6042, 8042, 10042, 10054 31211015 2-61...
  • Page 74 MATING COMPONENTS; M27x2 98 153 161 169 207 218 229 UN-LUBRICATED M33x2 173 182 190 235 247 258 THREADS M42x2 259 272 285 351 369 386 M48x2 335 352 369 454 477 500 2-62 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 75 General Information and Specifications This Page Intentionally Left Blank 6036, 6042, 8042, 10042, 10054 31211015 2-63...
  • Page 76 • Aluminum or brass fittings with aluminum or brass mating components. 7. Inspect to ensure the o-ring is not pinched and the washer is seated flat on the counter bore of the port. 2-64 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 77 OR ALUMINUM/ M20 x 1.5 BRASS M22 x 1.5 MATING M27 x 2 COMPONENTS; UN-LUBRICATED M30 x 2 THREADS M33 x 2 M38 x 2 M42 x 2 M48 x 2 M60 x 2 6036, 6042, 8042, 10042, 10054 31211015 2-65...
  • Page 78 • Aluminum or brass fittings with aluminum or brass mating components. 7. Inspect to ensure the o-ring is not pinched and the washer is seated flat on the counter bore of the port. 2-66 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 79 BRASS FITTINGS G 1/4A OR ALUMINUM/ G 3/8A BRASS G 1/2A MATING G 1/2A COMPONENTS; G 3/4A UN-LUBRICATED THREADS G 1A G 1-1/4A NOTE: ** Non typical for Straight Male Stud Fittings, reference only. 6036, 6042, 8042, 10042, 10054 31211015 2-67...
  • Page 80 BRASS FITTINGS G 1/4A OR ALUMINUM/ G 3/8A BRASS G 1/2A MATING G 1/2A COMPONENTS; UN-LUBRICATED G 3/4A THREADS G 1A G 1-1/4A NOTE: ** Non typical for Straight Male Stud Fittings, reference only. 2-68 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 81 153 161 169 207 218 229 96 101 106 130 137 144 THREADS G 1-1/4A 259 272 285 351 369 386 216 227 237 293 308 321 G 1-1/2A 335 352 369 454 477 500 216 227 237 293 308 321 6036, 6042, 8042, 10042, 10054 31211015 2-69...
  • Page 82 BRASS FITTINGS G 3/8A OR ALUMINUM/ G 1/2A BRASS MATING G 1/2A COMPONENTS; G 3/4A UN-LUBRICATED G 1A THREADS G 1-1/4A G 1-1/2A NOTE: ** Non typical for Straight Male Stud Fittings, reference only. 2-70 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 83 G 3/8A OR ALUMINUM/ G 1/2A BRASS MATING G 1/2A COMPONENTS; G 3/4A UN-LUBRICATED G 1A THREADS G 1-1/4A G 1-1/2A NOTE: * Typical for Straight Male Stud Fittings ***Typical for Adjustable Fittings. 6036, 6042, 8042, 10042, 10054 31211015 2-71...
  • Page 84 89 111 117 122 150 159 165 specific procedure in UN-LUBRICATED this Service Manual. G 1A 153 161 169 207 218 229 THREADS G 1-1/4A 259 272 285 351 369 386 G 1-1/2A 335 352 368 454 477 499 2-72 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 85 General Information and Specifications This Page Intentionally Left Blank 6036, 6042, 8042, 10042, 10054 31211015 2-73...
  • Page 86 3. Position flange and clamp halves. 4. Place lock washers on bolt and bolt through clamp halves. 5. Tighten all bolts by hand. 6. Torque bolts in diagonal sequence in two or more increments to the torque listed. 2-74 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 87 2.00 50.80 3/8-16 CODE 62 1.00 2.25 57.15 7/16-14 SPLIT 1.25 2.62 66.55 1/2-13 FLANGE 1.25 2.62 66.55 (FL62) 1.50 3.12 79.25 5/8-11 2.00 3.81 96.77 3/4-10 NOTE: * A dimension for reference only. 6036, 6042, 8042, 10042, 10054 31211015 2-75...
  • Page 88 1.25 2.62 66.55 M12 x 1.75 FLANGE 1.25 2.62 66.55 M14 x 2 (FL62) 1.50 3.12 79.25 M16 x 2 2.00 3.81 96.77 M20 x 2.5 NOTE: * A dimension for reference only. 2-76 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 89 For hose connections, the ‘layline’ printed on the hose is a good indicator of proper hose installation. A twisted lay-line usually indicates the hose is twisted. Double Wrench Method to Prevent Hose Twist MAE9490 6036, 6042, 8042, 10042, 10054 31211015 2-77...
  • Page 90 After the connection has been properly tightened, mark a straight line across the connecting parts, not covering the dots, to indicate the connection has been properly tightened. 2-78 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 91: Boom

    Safety Information ............Boom System - Three Section (6036, 6042, 8042 & 10042) ......
  • Page 92 Troubleshooting ............. . 3-50 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 93: Boom System Component Terminology

    Boom BOOM SYSTEM COMPONENT TERMINOLOGY The following illustrations identify the components that are referred to throughout this section. THREE SECTION BOOM (6036, 6042, 8042 & 10042) FIRST BOOM BOOM EXTEND SECOND BOOM SECTION BOOM RETRACT CHAINS SECTION THIRD BOOM CHAIN...

  • Page 94: Safety Information

    Section 1, “Safety Practices”, of will be impaired if subjected to any repair involving this manual. welding or drilling. BOOM SYSTEM - THREE SECTION (6036, 3.4.1 Boom Removal 6042, 8042 & 10042) 1. Remove any attachment from quick coupler assembly.
  • Page 95 Allow the hoses to hang from the rear of the boom. 13. Remove the top and side wear pads and spacers to the inside of the second boom section. Label and tag each set of wear pads being removed. 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 96 Label and tag each set of wear pads being removed. 19. Inspect all wear pads for wear. Refer to Section 3.8, “Boom Wear Pads”. 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 97 Reassemble the capscrews, lockwashers and flat section. Set the second boom section down on blocks washers to hold the lower wear pad in place for second on a hard, level surface. boom section removal. 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 98 Remove the locknut and flat washer. 3. Remove the retract chain by pulling it out through the rear of the boom. Place the retract chain on a clean surface. MH1201 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 99 Lower the rod end of the Extend/Retract cylinder. At the base end of the cylinder, remove a cylinder, and allow it to rest on the rubber bumper. retaining ring from one side of the cylinder base end pin. 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 100 14. Install the Extend and Retract tubes (16) to the inside bulkhead fitting and the Extend/Retract cylinder. 15. Install the Extend and Retract tube clamp halves (15). 16. Uncap and connect the hydraulic hoses and attach to their appropriate cylinder locations. 3-10 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 101 Pull the other end out the opening on the left side of the boom where the hoses will exit the boom. Position the strings all the way to the left side of the first boom section. 6036, 6042, 8042, 10042, 10054 31211015 3-11...
  • Page 102 4. Position the attachment tilt and auxiliary hydraulic hoses with the edge of the tape at the hose clamps (1). Hold the hoses in this position, and tighten the hose clamps. 3-12 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 103 Stretch the chain forward and place the clevis between the two anchor plates. Align the hole in the clevis with the second hole from the rear of the anchor plates. 6036, 6042, 8042, 10042, 10054 31211015 3-13...
  • Page 104 24. Properly connect the battery. Refer Section 9.8, Refer to Section 3.7.6, “Boom Chain Tension Adjustment “Battery”, for procedure. (6036, 6042, 8042 & 10042)”. 25. Remove the Do Not Operate Tags from both the ignition 11. Properly connect the battery. Refer Section 9.8, key switch and the steering wheel.

  • Page 105: Boom System - Four Section (10054)

    The structural integrity of the boom the mounting plate (1). Cap the hose ends. will be impaired if subjected to any repair involving welding or drilling. 6036, 6042, 8042, 10042, 10054 31211015 3-15...
  • Page 106 15. Return to the cab, start the engine and extend the boom approximately 2 in (51 mm). Retract the boom slightly until there is slack in the fourth boom section extend chain. Shut the engine OFF. 3-16 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 107 28. At the rear of the fourth boom section, remove the remaining wear pads, shims and hardware. Label and tag each set of wear pads being removed. 29. Inspect all wear pads for wear. Refer to Section 3.8, “Boom Wear Pads”. 6036, 6042, 8042, 10042, 10054 31211015 3-17...
  • Page 108 2. Remove the shoulder bolt (15) holding the yoke plates to the mount at the front of the first boom section. 3. Remove the extend chain sheave pin and sheave on the third boom section. 3-18 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 109 Set the boom section down on a hard, level surface. Support the boom as needed to prevent it from tipping over. 6036, 6042, 8042, 10042, 10054 31211015 3-19...
  • Page 110 (20). Measure the amount of threads protruding MH1201 beyond the locknut and record the measurement for 10. Label, disconnect and cap the hydraulic hoses attached reassembly of the chain. to the compensation cylinders (24). 3-20 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 111 16. Inspect all wear pads for wear. Refer to Section 3.8, “Boom Wear Pads”. 17. Use a hoist and slings to support the Extend/Retract cylinder. 18. Remove the retaining rings from the ends of the Extend/Retract cylinder. 6036, 6042, 8042, 10042, 10054 31211015 3-21...
  • Page 112 (if equipped) tube assemblies to their appropriate bulkhead fittings. secure with tube clamps. 16. Uncap and connect the previously labeled attachment tilt and auxiliary (if equipped) hydraulic hoses to their appropriate bulkhead fittings. 3-22 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 113 8. Install the center wear pad mount (29) and wear pad to in the left ear. Secure the pin. the bottom front of the first boom section. 6036, 6042, 8042, 10042, 10054 31211015 3-23...
  • Page 114 Tighten the locknut enough so the threads are even with the top of the locknut. 6. Grease the sections of the boom in areas where the wear pads will slide. 3-24 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 115 Tighten the locknut enough so the threads are even with the top of the locknut. Note: The hose carrier only folds one way; DO NOT force it. DO NOT twist the hose carrier while folding. 6036, 6042, 8042, 10042, 10054 31211015 3-25...
  • Page 116 14. Using a suitable sling, lift the fourth boom section. While guiding the hoses into the third boom section, carefully slide the fourth boom section into the front of the third boom section. 3-26 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 117 21. Place the fourth boom section extend chain up and around the sheave at the front of the third boom section. MH1691 25. Assemble the hoses to the hose reel (2) at the rear of the boom. 6036, 6042, 8042, 10042, 10054 31211015 3-27...

  • Page 118: Boom Extend And Retract Chains

    35. Clean up all debris, hydraulic fluid, etc., in, on, near and and scoring are not readily noticeable to the naked around the machine. eye. 36. Install the rear cover to the boom. 37. Close and secure the engine rear and side engine doors. 3-28 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 119 5. Inspect the retract chains every 1000 hours of operation. 6. Inspect the chains for the following conditions: MY1360 If the distance measured (3) is 3% greater than the normal length (4), discard and replace the chain. 6036, 6042, 8042, 10042, 10054 31211015 3-29...
  • Page 120 If the problem is caused by dirt or foreign substance packed in the joints, clean and lubricate thoroughly before re-installing the chain. If the problem is caused by corrosion and rust or bent pins, replace the chain. 3-30 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 121 Always replace both the chain and the clevis. It is recommended that when any chain is replaced, that all chains and clevis’ be replaced at the same time. 6036, 6042, 8042, 10042, 10054 31211015 3-31...
  • Page 122 Acceptable boom chain sag is between MH1752 1.5 in (38 mm) and 2.5 in (64 mm) on the 6036, 6042, If the chain sag measurement (1) is less than 8942, 10042 & 10054. For the 10054, also measure the 1.5 in (38 mm), tighten the two extend chain...
  • Page 123 6. Recheck chain tension. Refer to Section 3.7.5, “Boom 5. Install the rear boom cover. Chain Tension Check”. 6. If the third to second boom separation distance cannot be achieved, contact your local JLG service distributor. 6036, 6042, 8042, 10042, 10054 31211015 3-33...
  • Page 124 2.5 in (63,5 mm), loosen the two extend chain 5. Install the rear boom cover. adjustment locknuts (11). If the third to second boom separation distance cannot be achieved, contact your local JLG service distributor. 3-34 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 125 (279 mm) with the boom fully retracted and the chains Chain Tension Check”. properly tensioned. A distance of less than 8.5 in (216 mm) could result in interference and cause damage to boom components. 6036, 6042, 8042, 10042, 10054 31211015 3-35...
  • Page 126 If the chain sag measurement (19) is less than 2.85 in (72 mm), tighten the extend chain adjustment locknut (1). If the chain sag measurement (19) is more than 3.85 in (98 mm), loosen the extend chain adjustment locknut (1). 3-36 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 127 12.36 in (313 mm). Follow the instructions in cannot be achieved, contact your local authorized service Section 3.7.7, d. “Component/Assembly Verification distributor. (10054)”. 5. Recheck chain tension. Refer to Section 3.7.5, “Boom Chain Tension Check”. 6036, 6042, 8042, 10042, 10054 31211015 3-37...
  • Page 128 Boom 3.7.8 Extend Chains Removal and Replacement (6036, 6042, 8042 & 10042) 1. Park the machine on level ground. Place the transmission in (N) NEUTRAL, engage the parking brake switch, level the boom and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.
  • Page 129 Boom 3.7.9 Retract Chain Removal and Replacement (6036, 6042, 8042 & 10042) 1. Park the machine on level ground. Place the transmission in (N) NEUTRAL, engage the parking brake switch, level the boom and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.
  • Page 130 . key switch and the steering wheel. 12. Remove the string from the old chain and attach it to the new clevis. 13. Coat the threads of the threaded clevis with multi-purpose grease. 3-40 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 131 SH1811 7. At the front of the first boom section, remove the capscrews (17) and locknuts holding the extend chain clevis’ to the yoke plates. 6036, 6042, 8042, 10042, 10054 31211015 3-41...
  • Page 132 23. Coat the capscrews with anti-seize compound. Insert the capscrews through the yoke plates and clevis’ and secure in place with locknuts. Tighten each locknut securely, but the chain clevis’ must pivot freely. 3-42 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 133 Remove the wire from the clevis, but not from inside the boom. 12. Coat the threads of the threaded clevis with multi-purpose grease. 6036, 6042, 8042, 10042, 10054 31211015 3-43...
  • Page 134 8. At the rear of the boom, locate the two retract chain anchor plates. Remove the locknut and shoulder bolt (8) holding the retract chain clevis to the anchor plates. The two anchor plates can remain in place on the third boom section. 3-44 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 135 Section 3.7.5, “Boom Chain Tension Check”. tension on the retract chain is relieved. Shut the engine 18. Install the boom rear cover. OFF. 19. Properly connect the battery. Refer Section 9.8, “Battery”, for procedure. 6036, 6042, 8042, 10042, 10054 31211015 3-45...
  • Page 136 MH5991 MH6510 19. Guide the threaded end of the clevis through the hole in the tab (16) on the second boom section. 3-46 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 137 MH2671 26. Insert the shoulder bolt (17) through the plates and clevis and secure in place with a locknut. Tighten the locknut securely. 6036, 6042, 8042, 10042, 10054 31211015 3-47...

  • Page 138: Boom Wear Pads

    Lubrication of the boom wear surfaces is also recommended when the machine is stored, to help prevent rusting. • Clean and lightly grease the hose carrier guide bar pathways with Mystik Tetrimoly grease. 3-48 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 139: Quick Coupler

    Insert the quick coupler head pin through Maximum difference in height of fork tips is 3 percent of the quick coupler and boom head. Secure with the the length of the blade (19). previously removed bolt and nut (8). 6036, 6042, 8042, 10042, 10054 31211015 3-49...

  • Page 140: Troubleshooting

    2. Lift/lower hydraulic system not 2. Refer to Section 8.5.2, “Pressure operating properly. Specifications”. 3. Faulty lift/lower cylinder. 3. Repair cylinder. Refer to Section 8.9, “Hydraulic Cylinders”. 4. Seized boom pivot pin bearing. 4. Replace bearing. 3-50 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 141 Refer to Section 2.5, “Service and Maintenance Schedules”. Replace worn pins as needed. Refer to Section 8.9.1, “General Cylinder Instructions”. 2. Worn self-aligning bushing(s). 2. Replace bushing(s) and lubricate at regular intervals. Refer to Section 2.6, “Lubrication Schedules”. 6036, 6042, 8042, 10042, 10054 31211015 3-51...
  • Page 142 Section 2.5, “Service and Maintenance Schedules”. Repair or replace chain sheave(s) as needed. 4. Improper chain lubrication. 4. Lubricate at regular intervals. Refer to Section 2.5, “Service and Maintenance Schedules”. Replace chains as needed. 3-52 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 143: Cab And Covers

    Cab Installation ............. . . 4-14 6036, 6042, 8042, 10042, 10054 31211015...

  • Page 144: Operator Cab And Covers Component Terminology

    BOOM CONTROL/ HEATER AND A/C TILT JOYSTICK CONTROLS (OPTIONAL) STEERING WHEEL INSTRUMENT PANEL AUXILIARY HYDRAULIC CONTROL LEVER TRANSMISSION CONTROL LEVER PARK BRAKE FRAME LEVEL SWITCH CONTROL LEVER IGNITION SWITCH SERVICE BRAKE PEDAL MZ8440 ACCELERATOR PEDAL 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 145: Operator Cab

    3. Open the engine rear and side engine doors. Allow the 2. Place a Do Not Operate Tag on both ignition key switch system fluids to cool. and steering wheel. 3. Open engine covers. Allow system fluids to cool. 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 146 Refer to Section 8.5.1, “Pressure opening. Remove the steering column (9). Checks and Adjustments”. Note: DO NOT disassemble the steering valve. The steering valve is not serviceable and must be replaced in its entirety, if defective. 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 147 7. Properly connect the battery. Refer Section 9.8, “Battery”, for procedure. 8. Remove the Do Not Operate Tags from both the ignition M 8460 key switch and the steering wheel. 9. Close and secure the engine rear and side engine doors. 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 148 “Battery”, for procedure. bolts (17) securing the boom joystick to the cab. 5. Remove the Do Not Operate Tags from both the ignition 8. Remove the joystick assembly. key switch and the steering wheel. 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 149 7. Remove the clip and pin (20) from the main control valve control spool. 4. Remove the console panel in the cab. 8. Remove the bolts securing each cable bracket (21) to the main control valve. 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 150 7. Transfer the coolant to a container with a cover, and 5. Properly connect the battery. Refer Section 9.8, label as “Used Antifreeze”. Dispose of the used coolant “Battery”, for procedure. at an approved recycling facility. 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 151 6. Install the heater access panel and secure with the previously used hardware. 7. Install brackets (38 & 39) securing heater assembly to M 8530 cab. 8. Install heater ducts (37) to the heater assembly. 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 152 8. Wait for the engine to cool and check the coolant level. 9. Remove the heater access panel. Add coolant as required to bring the coolant to the proper level. 9. Check the operation of cab heater. 10. Shut the engine OFF. 4-10 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 153 10. Label and disconnect hoses (41) attached to the system and all air is purged. condenser assembly (42). 11. Label and disconnect all electrical connections attached to the condenser assembly (42). 6036, 6042, 8042, 10042, 10054 31211015 4-11...
  • Page 154 16. Check the operation of cab heater and A/C. 17. Shut the engine OFF. 18. Close and secure the engine cover. 19. Remove Do Not Operate Tag from ignition key switch and steering wheel. 4-12 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 155: Cab Removal

    “Used Antifreeze”. Dispose of the used coolant wiring, hydraulic hoses and fasteners are disconnected at an approved recycling facility. and removed. 8. Close the radiator drain plug or petcock. 9. Remove the transmission covers. 6036, 6042, 8042, 10042, 10054 31211015 4-13...

  • Page 156: Cab Installation

    Connect the previously labeled connectors. 9. If equipped, install the cab heater hoses. Refer to Section 4.3.8, “Heater System (if equipped)”. 10. Install the heater access panel. 4-14 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 157: Axles, Drive Shafts, Wheels And Tires

    Axle Replacement (6036 & 6042) ........

  • Page 158: Axle, Drive Shaft And Wheel Component Terminology

    5.1.1 6036 & 6042 ENGINE-TO-TRANSMISSION DRIVE SHAFT REAR AXLE ASSEMBLY REAR STEERING CYLINDER FRONT STEERING CYLINDER REAR DRIVE SHAFT REAR AXLE WHEEL HUBS FRONT DRIVE SHAFT FRONT AXLE ASSEMBLY MAQ1780 FRONT AXLE WHEEL HUBS 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 159 Axles, Drive Shafts, Wheels and Tires 5.1.2 8042 ENGINE-TO-TRANSMISSION DRIVE SHAFT REAR AXLE ASSEMBLY REAR STEERING CYLINDER FRONT STEERING CYLINDER REAR DRIVE SHAFT REAR AXLE WHEEL HUBS FRONT DRIVE SHAFT FRONT AXLE ASSEMBLY MAQ1770 FRONT AXLE WHEEL HUBS 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 160 5.1.3 10042 & 10054 ENGINE-TO-TRANSMISSION DRIVE SHAFT REAR AXLE ASSEMBLY REAR STEERING CYLINDER FRONT STEERING REAR DRIVE SHAFT REAR AXLE CYLINDER WHEEL HUBS FRONT DRIVE SHAFT FRONT AXLE ASSEMBLY MAQ1790 FRONT AXLE WHEEL HUBS 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 161: General Information

    Supply information from the axle serial number plate when communicating about an axle assembly or axle components. 5.3.2 Axle Specifications General axle specifications are found in Section 2.3, “Fluid Specifications”. 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 162 “Used Oil”. Dispose of used oil at an approved recycling facility. 5.3.5 Axle Replacement (6036 & 6042) a. Axle Removal The front and rear axle assemblies differ in that the front axle assembly is equipped with a parking brake mechanism and a limited-slip feature;...
  • Page 163 Ensure that the machine will Note: ALWAYS use new o-rings when servicing the machine. remain in place during axle installation. 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 164 3. Open the engine rear and side engine doors. Allow the system fluids to cool. 4. Properly disconnect the battery. Refer Section 9.8, “Battery”, for procedure. 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 165 Block up or support necessary. the assembly so that it does not move or fall. 13. Inspect the pivot bearing (9). Replace the bearing if worn or damaged. 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 166 Transfer used axle oil into a suitable covered container, and label container as “Used Oil”. Dispose of used oil at an approved recycling facility. 5-10 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 167 Align the driveshaft yoke on hoist. Place suitable supports beneath the frame and the axle in the same plane as the yoke on the lower the machine onto the supports, allowing enough transmission. 6036, 6042, 8042, 10042, 10054 31211015 5-11...

  • Page 168: Axle Assembly And Drive Shaft Troubleshooting

    6. Replace gears as needed. 7. Contamination in the axle. 7. Drain axle and/or wheel end housings and fill to correct level. Refer to Section 2.3, “Fluid Specifications”. 8. Axle housing damaged. 8. Replace damaged parts. 5-12 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 169 6. Axle housing mounting nuts and 6. Tighten housing nuts and capscrews loose. capscrews to 288 lb-ft (390 Nm). 7. Differential and/or axle housing(s) 7. Replace housing(s) as needed. damaged. 6036, 6042, 8042, 10042, 10054 31211015 5-13...
  • Page 170 10. Excessive noise when brakes are 1. Brake discs worn. 1. Check brake discs for wear. Refer engaged. to Section 5.7.1, “Brake Disc Inspection”. 2. Brake discs damaged. 2. Replace brake discs. 5-14 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 171 Section 5.7.1, “Brake Disc reduced. Inspection”. 2. Brake (hydraulic) system not 2. Refer to Section 8.5.2, “Pressure operating properly. Specifications”. 3. Brake piston o-rings and seals 3. Replace o-rings and seals. damaged (leaking). 6036, 6042, 8042, 10042, 10054 31211015 5-15...

  • Page 172: Drive Shafts

    4. Install the four bolts (5) securing the engine output flange to the engine. Torque bolts to 60 lb-ft (81 Nm). 5. Install four new bolts (5) securing the engine output flange to the engine. Torque as required. 5-16 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 173: Wheels And Tires

    7. Remove the wheel and tire assembly from the machine. 6036, 6042, 8042, 10042, 10054 31211015 5-17...

  • Page 174: Brakes

    “Used Oil”. Dispose of OY1220 3. Tighten lug nuts in an alternating pattern as indicated in figure. Refer to Section 2.2.5, “Tires, ” for proper torque value. 4. Remove machine from supports. 5-18 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 175: Towing A Disabled Machine

    JLG distributor for specific instructions for your particular frame on the left side next to the transmission. situation. 6. Turn the key switch to the ON position, release the park brake, and have an operator seated in the seat. 6036, 6042, 8042, 10042, 10054 31211015 5-19...
  • Page 176 Only the rear service brakes will function when the brake pedal is depressed. Steering is not possible and the machine will only travel in the direction that the wheels were last turned. Tow or push the machine at a very slow speed. 5-20 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 177: Transmission Assembly Component Terminology

    Transmission Troubleshooting ..........6036, 6042, 8042, 10042, 10054...
  • Page 178 The following illustration identifies the components that are referred to throughout this section. OIL FILL TUBE AND DIPSTICK VALVE BLOCK (CONTROL CIRCUIT 1) OIL FILTER VALVE BLOCK (CONTROL CIRCUIT 2) OUTPUT SHAFT MAQ0741 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 179 8. Thoroughly clean the transmission and surrounding area, including all hoses and fittings. Model Publication Type Publication # 6036, 6042, 8042, Service Manual 8990455 10042,10054 6036, 6042 31211016 Parts Manual 8042, 10042, 31211017 10054 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 180 DO NOT raise the transmission at this time. 20. Place blocks under the transmission to help support it during removal. MH3391 13. Label and disconnect the transmission temperature switch connector (2) and shift solenoid wiring harness connectors (3). 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 181 29. Remove the transmission oil filter and dispose of properly. Clean the filter mounting surface. Cover or cap the oil filter mount. MH3411 Note: The lifting ring (3) must be repositioned to allow the covers to be installed. 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 182 “HOT” zone mark on the dipstick. 18. Install the transmission covers. 12. Recheck all drain plugs, lines, connections, etc., for leaks, and tighten where necessary. 19. Properly connect the battery. Refer Section 9.8, “Battery”, for procedure. 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 183: Transmission Troubleshooting

    “Fluid Specifications”. 3. Pump suction pipe screen 3. Clean, repair and/or replace clogged. suction pipe. 4. Central shaft damaged. 4. Replace central shaft. 5. Pump worn or damaged. 5. Repair or replace pump assembly. 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 184 4. Stop and idle the engine. 5. Restriction in oil cooler hoses. 5. Replace cooler hoses. 6. Pump worn or damaged. 6. Repair or replace pump assembly. 7. Engine thermostat stuck. 7. Replace engine thermostat. 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 185 7. Replace converter and/or input (possible converter leak and/or shaft seal. input shaft seal damage). 8. Oil leaking at output shaft (output 8. Replace output shaft seal. shaft seal damaged). 9. Housing damaged. 9. Replace housing as needed. 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 186 Transmission This Page Intentionally Left Blank 6-10 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 187: Engine

    Air Cleaner Assembly Installation ......... . . 7-21 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 188 Isolation Coupler Installation ..........7-24 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 189 140° F (60° C). Extended light-load operation during early life of the engine is not recommended. DO NOT run the engine at high, no-load speeds. DO NOT apply an overload to the engine. 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 190 IF EQUIPPED FOR LS IF EQUIPPED FOR ULS TURBOCHARGER TURBOCHARGER STARTER STARTER ALTERNATOR ALTERNATOR THERMOSTAT THERMOSTAT FUEL INJECTOR FUEL INJECTOR PUMP PUMP WATER PUMP FUEL FILTER MAQ1820 MAQ1180 FUEL FILTER WATER PUMP OIL FILTER OIL FILTER 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 191: Engine Cooling System

    Tighten the radiator drain petcock. 6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 7. Loosen upper radiator hose clamp and remove the radiator hose from the thermostat housing. 6036, 6042, 8042, 10042, 10054 31211015...

  • Page 192: Engine Electrical System

    7. Place a funnel at base of radiator to channel drained coolant into a container. Loosen drain petcock and slowly allow coolant to drain. Transfer coolant into a properly labeled container. Dispose of properly if 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 193: Fuel System

    The fuel/hydraulic oil tank is a one-piece unit and cannot be disassembled. The fuel level indicator and hydraulic filters can be removed and reused on the new replacement tank. Dispose of the old tank according to local regulations concerning 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 194 1 - 1.5 psi (7 - 10 kPa) of air pressure through elbow. Check reservoir for leaks by applying a soap solution to the exterior and look for bubbles to appear at cracked or damaged area. 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 195 2. Install DEF tank and secure to frame with the previously removed straps (4). 3. Remove plugs and/or caps from the previously labeled DEF tank DEF hoses (6) and connect to their appropriate locations. 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 196 Note: Verify the orientation of the header for reassembly. b. DEF Header Cleaning 1. Refer to Diesel Exhaust Fluid (DEF) System Cleaning – (if equipped for ULS 85hp or 110hp (63kW or 82kW)) for detailed DEF header cleaning. 7-10 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 197 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel. 3. Open the engine doors. Allow the system fluids to cool. 4. Properly disconnect the battery(s). Refer to Section 9.8, “Battery”, for procedure. 6036, 6042, 8042, 10042, 10054 31211015 7-11...
  • Page 198 Refractometer (pn 70011925). The DEF solution must meet the requirements International Standard ISO 22241-1 for diesel engines. There is no acceptable substitute. For engines using Selective Catalytic Reduction (SCR) Systems, operating in 7-12 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 199 2. Install DEF tank and secure to frame with the previously removed straps (4). 3. Remove plugs and/or caps from the previously labeled DEF tank DEF hoses (6) and connect to their appropriate locations. 6036, 6042, 8042, 10042, 10054 31211015 7-13...
  • Page 200 DEF header must be discarded and replaced. Refer to Section 7.6.11, “Cummins Diesel Exhaust Fluid (DEF) System Cleaning – (if equipped for ULS 110hp (82kW)) (S/N 0160082087 to Present)”for DEF system cleaning. 7-14 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 201 Filter – (if equipped for ULS 85hp or 110hp (63kW or Note: The following procedures are only to be performed when 82kW))” for DEF pump filter cleaning procedure. warranty is expired. 6036, 6042, 8042, 10042, 10054 31211015 7-15...
  • Page 202 DEF coolant valve (5). Secure with the two previously removed clamps. Orient clamps as shown. 12. Tighten and torque clamps to 40 in-lb (4,5 Nm). 13. Remove hose pliers from the DEF coolant supply hose. 7-16 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 203: Engine Exhaust System

    1. Install muffler and tailpipe on muffler mounting plate (12) using proper clamps in proper position. 2. Lift muffler mounting plate up and slide mounting plate bolts (13) through slot in right side of frame. 6036, 6042, 8042, 10042, 10054 31211015 7-17...
  • Page 204 13. Remove the Do Not Operate Tags from both the ignition 10. Be sure to properly support muffler mounting plate and key switch and the steering wheel. muffler for removal. 11. Drop muffler mounting plate down on left side. 7-18 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 205 3. Lift left side of muffler mounting plate up and re-install mounting plate bolts (6). 4. Tighten all mounting plate bolts. 5. Tighten band clamp (8) enough to hold the muffler in place. 6036, 6042, 8042, 10042, 10054 31211015 7-19...
  • Page 206 11. Place mounting plate on level surface and replace connections. Adjust or repair as needed. muffler, clamps and tailpipe. Note position of muffler for re-installation purposes. 11. Close and secure the engine cover. 7-20 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 207: Air Cleaner Assembly

    6. Loosen clamps securing air cleaner hose (23) to air cleaner assembly and remove elbow/hose from air cleaner assembly. 7. Remove cap screws and lock washers (24) securing mounting band to air cleaner bracket. Remove air cleaner assembly. 6036, 6042, 8042, 10042, 10054 31211015 7-21...

  • Page 208: Engine Replacement

    12. Loosen the clamps on the sleeve reducer at the engine and on the air suction pipe. 13. Remove air intake hoses and pre-cleaner. It is not necessary to remove air cleaner assembly before engine is removed from frame. 7-22 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 209 Section 7.4.3, “Radiator/Oil Cooler and Replacement”. 17. Properly connect the battery. Refer Section 9.8, “Battery”, for procedure. 18. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 6036, 6042, 8042, 10042, 10054 31211015 7-23...

  • Page 210: Isolation Coupler

    8. Remove the cap screws securing the coupler (4) to the flywheel. Note: The coupler is heavy and requires two people, one on each side, to remove. 9. Remove the coupler assembly. 7-24 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 211: Hydraulic Section

    Cylinder Torque Specifications..........8-54 6036, 6042, 8042, 10042, 10054 31211015...

  • Page 212: Hydraulic Component Terminology

    The following illustration identifies the components that are referred to throughout this section. 6036 & 6042 (85 HP) LIFT/LOWER CYLINDER(S) COMPENSATION CYLINDER(S)
  • Page 213 STABILIZER CYLINDER FRAME LEVEL CYLINDER JOYSTICK STEERING CYLINDER (REAR) STEERING ORBITROL VALVE SERVICE SECONDARY BRAKE VALVE FUNCTION VALVE OUTRIGGER VALVE (10042 & 10054 ONLY) STEERING OUTRIGGER CYLINDER CYLINDERS (FRONT) (10042 & 10054 ONLY) MAQ1271 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 214 Always use OEM filters to assure the necessary filtration requirements are met. 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 215: Hydraulic Circuits

    Section 8.5.2, “Pressure Specifications”. If the reading is not as specified, turn the engine OFF and check other components in the system. Verify that all related hydraulic components and electrical switches, sensors, solenoids, etc. are operating correctly. 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 216 Hydraulic Section 8.5.2 Pressure Specifications 6036 - 85 hp (63 kW) (PRH1) (PRH2) SECONDARY FUNCTION MANIFOLD (PARK BRAKE MAIN CONTROL VALVE GAUGE) MAQ1510 MAQ1500 (BRAKE VALVE (MAIN PUMP GAUGE) (LOAD SENSE RELIEF PRESSURE) VALVE) SERVICE BRAKE VALVE Prior to SN 0160074878, excluding...
  • Page 217 8. Block tire, connect gauge to D Service Brake port. Start engine and run at low 0 psi (0 bar) Park Brake - OFF (low idle) idle. Do Not apply brake pedal pressure. 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 218 Run engine at low idle, Service Brake 80 psi (5,5 bar) transmission in (N) Neutral, turn Park Brake - OFF (low idle) Minimum engine OFF, wait 3 seconds, apply maximum brake pedal effort. 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 219 STABIL-TRAK ADJUSTMENT PRESSURE SCREW MAQ1530 SERVICE BRAKE VALVE Prior to SN 0160074878, excluding SN 0160074878 to Present, including 0160074813 0160074818 and 0160074882 0160074813 0160074818 and 0160074882 (AXLE BRAKE (AXLE BRAKE PRESSURE) PRESSURE) MAE14330 MAQ1520 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 220 Connect gauge to PBG port, run Manifold engine at high idle, fully retract 380-390 psi PRH1(C) Park Brake - OFF (Park Brake extend/retract cylinder, switch park (26,2-26,8 bar) Pressure) brake off. (high idle) 8-10 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 221 - 50 psi (3,4 bar) 50 psi (3,4 bar) Valve No Adjustment. Pressure under Park Brake - ON Minimum (low idle) 50 psi (3,4 bar) indicates a Stabil-Trak Valve or cylinder failure 6036, 6042, 8042, 10042, 10054 31211015 8-11...
  • Page 222 B. Slowly apply the service brake - the Stabil-Trak light must be ON with a service brake pressure of 200 - 300 psi (13,7 - 20,6 bar) Adjust service brake switch if required. 8-12 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 223 Hydraulic Section c. 6036 - 74 hp (55 kW) MAIN CONTROL VALVE (PRH1) (PRH2) (MAIN PUMP PRESSURE) SECONDARY FUNCTION MANIFOLD (PARK BRAKE GAUGE) MAQ1510 (BRAKE VALVE MAQ1500 GAUGE) HYDRAULIC PUMP (LOAD SENSE RELIEF PUMP LOAD VALVE) SENSE PORT STANDBY PRESSURE...
  • Page 224 Mode Selected Secondary Function Connect gauge to BVG port, run Manifold 550-560psi engine at high idle, fully retract PRH2(B) Park Brake ON (Service (37,9-38,6 bar) extend/retract cylinder. Brake) (high idle) 8-14 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 225 Run engine at low idle, 80 psi (5,5 bar) Brake transmission in (N) Neutral, turn Park Brake - OFF Minimum (low idle) engine OFF, wait 3 seconds, apply maximum brake pedal effort. 6036, 6042, 8042, 10042, 10054 31211015 8-15...
  • Page 226 MAQ1540 PRESSURE MAQ1530 SCREW SERVICE BRAKE VALVE Prior to SN 0160074878, excluding SN 0160074878 to Present, including 0160074813 0160074818 and 0160074882 0160074813 0160074818 and 0160074882 (AXLE BRAKE PRESSURE) (AXLE BRAKE PRESSURE) MAE14330 MAQ1520 8-16 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 227 Mode Selected Secondary Function Connect gauge to BVG port, run Manifold 550-560psi engine at high idle, fully retract PRH2(B) Park Brake ON (Service (37,9-38,6 bar) extend/retract cylinder. Brake) (high idle) 6036, 6042, 8042, 10042, 10054 31211015 8-17...
  • Page 228 (SAE-4 O-Ring Boss 7/16-20 UNF 75-150 psi Valve PRV (E) Park Brake - ON 2B) and connect pressure gauge. (5,1-10,3 bar) (low idle) Start machine with boom lowered, frame leveled left at low idle. 8-18 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 229 B. Slowly apply the service brake - the Stabil-Trak light must be ON with a service brake pressure of 200 - 300 psi (13,7 - 20,6 bar) Adjust service brake switch if required. 6036, 6042, 8042, 10042, 10054 31211015 8-19...
  • Page 230 PRESSURE MAQ1540 MAQ1530 SCREW SERVICE BRAKE VALVE Prior to SN 0160074878, excluding SN 0160074878 to Present, including 0160074813 0160074818 and 0160074882 0160074813 0160074818 and 0160074882 (AXLE BRAKE PRESSURE) (AXLE BRAKE PRESSURE) MAE14330 MAQ1520 8-20 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 231 Mode Selected Secondary Function Connect gauge to BVG port, run Manifold 550-560psi engine at high idle, fully retract PRH (D) Park Brake - ON (service (37,9-38,6 bar) the extend/retract cylinder. brake) (high idle) 6036, 6042, 8042, 10042, 10054 31211015 8-21...
  • Page 232 Test Port Fitting 75-150 psi Valve (SAE-4 O-Ring Boss 7/16-20 UNF PRV (F) Park Brake - ON (5,1-10,3 bar) (low idle) 2B) and connect pressure gauge. Start machine with boom lowered at low idle. 8-22 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 233 B. Slowly apply the service brake - the Stabil-Trak light must be ON with a service brake pressure of 200 - 300 psi (13,7 - 20,6 bar) Adjust service brake switch if required. 6036, 6042, 8042, 10042, 10054 31211015 8-23...
  • Page 234 Hydraulic Section 8.5.3 Hydraulic Schematics a. 6036 (Prior to SN 0160074884, excluding 0160074882) MAQ1280C 8-24 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 235 Hydraulic Section b. 6036 (SN 0160074884 to Present, including 0160074882) MAE4440A 6036, 6042, 8042, 10042, 10054 31211015 8-25...
  • Page 236 Hydraulic Section c. 6036 - 74 hp (55 kW) Engine (Prior to SN 0160074884, excluding 0160074882) MAQ2090B 8-26 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 237 Hydraulic Section d. 6036 - 74 hp (55 kW) Engine (SN 0160074884 to Present, including 0160074882) 4450 6036, 6042, 8042, 10042, 10054 31211015 8-27...
  • Page 238 Hydraulic Section e. 6042 (Prior to SN 0160074884, excluding 0160074882) MAQ1290C 8-28 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 239 Hydraulic Section 6042 (SN 0160074884 to Present, including 0160074882) MAE4460A 6036, 6042, 8042, 10042, 10054 31211015 8-29...
  • Page 240 Hydraulic Section g. 6042 - 74 hp (55 kW) Engine (Prior to SN 0160074884, excluding 0160074882) MAQ2100B 8-30 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 241 Hydraulic Section h. 6042 - 74 hp (55 kW) Engine (SN 0160074884 to Present, including 0160074882) MAE4470B 6036, 6042, 8042, 10042, 10054 31211015 8-31...
  • Page 242 Hydraulic Section 8042 (Prior to SN 0160074878, excluding 0160074813 and 0160074818) MAQ1300C 8-32 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 243 Hydraulic Section 8042 (SN 0160074878 to Present, including 0160074813 and 0160074818) MAE4480B 6036, 6042, 8042, 10042, 10054 31211015 8-33...
  • Page 244 Hydraulic Section k. 10042 (Prior to SN 0160074878, excluding 0160074813 and 0160074818) MAQ1310C 8-34 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 245 Hydraulic Section 10042 (SN 0160074878 to Present, including 0160074813 and 0160074818) MAE4490B 6036, 6042, 8042, 10042, 10054 31211015 8-35...
  • Page 246 Hydraulic Section m. 10054 (Prior to SN 0160074878, excluding 0160074813 and 0160074818) MAQ1320C 8-36 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 247 Hydraulic Section n. 10054 (SN 0160074878 to Present, including 0160074813 and 0160074818) MAE4500B 6036, 6042, 8042, 10042, 10054 31211015 8-37...

  • Page 248: Hydraulic Reservoir

    75 lb-in (8.5 Nm). container, and label as “Used Oil”. Dispose of used oil at 7. Install the previously removed access cover (2). an approved recycling facility. Clean and reinstall the drain plug (4). 8-38 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 249: Hydraulic System Pump

    8. Label, disconnect and cap the hydraulic hoses attached to the pump. 9. Remove the bolts (2), lockwashers and washers securing the pump to the transmission (3). 6036, 6042, 8042, 10042, 10054 31211015 8-39...

  • Page 250: Valves And Manifolds

    (1). the tie rods. 9. Wipe up any hydraulic fluid spillage in, on, near and 2. Disassemble each section assembly as required. around the machine and the work area. 8-40 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 251 2. Install the control spool being careful not to nick or scratch the valve section bore or the control spool. 3. Install the end caps on each end of the valve section. 6036, 6042, 8042, 10042, 10054 31211015 8-41...
  • Page 252 Tighten all the tube and hose clamps. 6. Fill the hydraulic fluid reservoir. Refer to Section 8.6.2, “Hydraulic Oil Reservoir Filling”. 8-42 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 253 7. Inspect the service brake valve and connections for leaks, and check the level of the hydraulic fluid in the reservoir. Shut the engine OFF. 6036, 6042, 8042, 10042, 10054 31211015 8-43...
  • Page 254 Close the brake bleeder when brake pedal is fully depressed. Repeat the procedure until oil is not aerated further. Remove the tubing from the brake bleeder. 5. Repeat steps 2, 3 and 4 for remaining brake bleeders. 8042, 10042, 10054 MAQ1850 8-44 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 255 This distance should be 73 mm (2.88 in). Verify the correct operation of the steer select valve solenoids before considering replacement of the valve. The housing of the steer select valve is not serviceable and must be replaced if defective. 6036, 6042, 8042, 10042, 10054 31211015 8-45...
  • Page 256 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. 8-46 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 257 6. Install previously removed reducing valve(s) and test 6. Remove the transmission covers. ports. Torque as required. 6036 & 6042 SECONDARY MANIFOLD SHOWN MAQ1510 7. Label, disconnect and cap hydraulic hoses and electrical plugs connected to secondary manifold. 6036, 6042, 8042, 10042, 10054 31211015 8-47...
  • Page 258 4. Open the engine cover. Allow the system fluids to cool. surfaces within the valve block. 5. Properly disconnect the battery. Refer Section 9.8, “Battery”, for procedure. 8-48 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 259 8. Remove nut and bolt securing extend lockout valve to the frame. Remove the valve from the machine. 9. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools. 6036, 6042, 8042, 10042, 10054 31211015 8-49...
  • Page 260 2. Install bolt and nut securing valve to frame. 3. Connect all the previously labeled hydraulic hoses, fittings, solenoid wire terminal leads, etc., to the extend lockout valve. 8-50 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 261: Hydraulic Cylinders

    The sealant often leaves a white, powdery residue on threads and other parts, which must be MAQ2060 removed by brushing with a soft brass wire brush prior to reassembly. 6036, 6042, 8042, 10042, 10054 31211015 8-51...
  • Page 262 BEFORE the piston head. 3. Fasten the rod eye in a soft-jawed vise, and place a padded support under and near the threaded end of the rod to prevent any damage to the rod. 8-52 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 263 The steer cylinder is attached to each axle center housing. The steer cylinder assembly can be found in Section 5.3, “Axle Assemblies”. The steer cylinder is covered in the appropriate manufacturer’s axle literature. STEERING CYLINDER AXLE CENTER SECTION MAQ2070 6036, 6042, 8042, 10042, 10054 31211015 8-53...
  • Page 264 3 - 4 lb-ft 35 - 40 lb-ft 25 - 30 lb-ft (407 - 475 Nm) (1593 - 1898 Nm) (27 - 34 Nm) (4 - 5 Nm) (47 - 54 Nm) (34 - 41 Nm) 8-54 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 265 (41 - 47 Nm) Outrigger Cylinder Model Head Locknut Valves 10042, 10054 250 - 350 lb-ft 1650 - 1800 lb-ft 30 - 35 lb-ft (339 - 474 Nm) (2237 - 2440 Nm) (41 - 47 Nm) 6036, 6042, 8042, 10042, 10054 31211015 8-55...
  • Page 266 Hydraulic Section This Page Intentionally Left Blank 8-56 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 267: Electrical System

    Cab Heater Controls............9-26 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 268 Engine Fault Codes ............9-54 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 269: Electrical Component Terminology

    INSTRUMENT TEMPERATURE PANEL SENDER PARK BRAKE STARTER SWITCH IGNITION SWITCH TRANSMISSION SERVICE SOLENOID BRAKE VALVES SWITCH ACCELERATOR DIAGNOSTIC PEDAL LOCATION BOOM ANGLE SENSOR BOOM EXTEND (FOUR SECTION BOOM SHOWN) INTERLOCK SENSOR (10054 ONLY) MAQ0363 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 270 35 Amp DEF Heater Suction Relay 35 Amp DEF Heater Diagnostic Relay 35 Amp DEF Heater Pressure Relay 35 Amp DEF Heater Supply Module Relay 15 Amp Supply Module Heater 15 Amp DEF Heater 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 271 Electrical System 9.4.2 Cab Harness Fuses and Relays 6036, 6042, 8042 & 10042 BLANK MAQ1461 10054 BLANK BLANK MAQ1561 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 272 40 Amp Main BLANK 30 Amp Work Lights (if equipped) 30 Amp Road Lights (if equipped) 35 Amp Boom Switch (Removed on 6036) 35 Amp Park Brake Switch 35 Amp Neutral Relay 35 Amp Back-Up Relay 35 Amp Relay 2...

  • Page 273: Electrical System Schematics

    Electrical System ELECTRICAL SYSTEM SCHEMATICS 9.5.1 Cab Schematic MAQ1590F 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 274 Electrical System 9.5.2 Chassis - Engine Schematic (85 hp (63 kW), 110 hp (82 kW) if equipped for ULS) MAQ1600F 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 275 Electrical System 9.5.3 Chassis - Engine Schematic (85 hp (63 kW), 110 hp (82 kW) if equipped for LS) MAQ1660H 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 276 Electrical System 9.5.4 Chassis - Engine Schematic (74 hp (55 kW) if equipped) MAQ2080D 9-10 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 277 Electrical System 9.5.5 Cab O/R Option Schematic (10042 only) MAQ1610F 6036, 6042, 8042, 10042, 10054 31211015 9-11...
  • Page 278 Electrical System 9.5.6 Cab O/R Option Schematic (10054 only) MAQ1620F 9-12 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 279 Electrical System 9.5.7 HVAC Option Schematic MAQ1630F 6036, 6042, 8042, 10042, 10054 31211015 9-13...
  • Page 280 Electrical System 9.5.8 Road Light Option Schematic MAQ1640F 9-14 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 281 Electrical System 9.5.9 Worklights/Beacon Option Schematic MAQ1650F 6036, 6042, 8042, 10042, 10054 31211015 9-15...
  • Page 282 Electrical System 9.5.10 Telematics Option MAQ4850 9-16 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 283: Dielectric Grease Application

    (wire inserted in the wrong cavity during assembly and the corrected). MAE3240 The Deutsch connector system is widely used for harsh environment interconnect. Follow the general guidance for installation. 6036, 6042, 8042, 10042, 10054 31211015 9-17...
  • Page 284 Once contaminated, there is no practical way to remove the dielectric grease (replacement of female contacts required). 9-18 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 285 To meet criteria, the enclosure must be rated to at least IP66 (dust tight; protected from powerful jets of water). The enclosure must be fitted with a high quality, continuous gasket and all wiring must pass through cable entrances. 6036, 6042, 8042, 10042, 10054 31211015 9-19...

  • Page 286: Engine Start Circuit

    Check for the cause of the blown fuse. 7. Remove the starter from the machine. 2. There may be a defect in the ignition key switch, ignition wiring or starter solenoid. 9-20 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 287: Battery

    4. Disconnect Negative battery cable (2). 4. Visually inspect the battery (1). 5. Disconnect Positive battery cable (3). 5. Check terminals for corrosion. 6. Replace the battery if it has a cracked, melted or damaged case. 6036, 6042, 8042, 10042, 10054 31211015 9-21...

  • Page 288: Charging Circuit

    Operation & Safety Manual). Allow the 2. Align the lower alternator mount hole with the lower engine to run, which will enable the mounting bracket on the engine, and insert the lower alternator (2) to charge the battery. 9-22 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 289: Window Wiper/Washer Windshield Wiper Motor

    (4) nuts and washer from the motor shaft. 10. Disconnect the washer hose from the hose connector. 11. Remove the wiper arms, knurled driver and rubber cap from the motor shaft. 6036, 6042, 8042, 10042, 10054 31211015 9-23...
  • Page 290 MA8361 5. Remove the wiper arm (5) from the wiper motor shaft. 6. Disconnect the washer hose from the top hose fitting. 7. From inside the cab, remove screws from top locknut plate. 9-24 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 291 10. Close and secure the engine rear and side engine doors. 7. Rotate the washer reservoir, label and remove the cab harness connectors from the washer reservoir connectors. 8. Remove the windshield washer hose from the reservoir. 6036, 6042, 8042, 10042, 10054 31211015 9-25...

  • Page 292: Cab Heater And Fan

    9. If removing the temperature control knob, disconnect the cable connector and remove control knob. 10. Remove the locknut from the suspect control shaft. 9-26 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 293: Solenoids, Sensors And Senders

    2. Connect previously labeled wiring connector to switch. 3. Properly connect the battery. Refer Section 9.8, “Battery”, for procedure. 4. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 6036, 6042, 8042, 10042, 10054 31211015 9-27...
  • Page 294 If the sender is not defective, the problem could be elsewhere; possibly in a shorted wire, damaged transmission, improper or low fluid, etc. 6. Install the transmission covers. 7. Close and secure the engine rear and side engine doors. 9-28 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 295 Stabil-TRAK system engages. If the Service Brake Switch is suspect in the proper operation of the Stabil-TRAK system, refer to Section 10.7, “Stabil-TRAK™ System Test”. 6036, 6042, 8042, 10042, 10054 31211015 9-29...
  • Page 296 Refer to Section 9.12.5, “Boom Angle Sensor”. 11. Shut off the engine. 12. Remove the blocks from the front tires. 13. Remove the pressure gauge. 14. Install the lower access panel. 9-30 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 297 5. Make note of wire tie locations and clip wire ties where 6. Close and secure the engine rear and side engine doors. necessary. MH6121 6. Disconnect the boom interlock sensor electrical connector (16). 6036, 6042, 8042, 10042, 10054 31211015 9-31...
  • Page 298 4. Remove the Do Not Operate Tags from both the ignition 4. Properly disconnect the battery. Refer Section 9.8, key switch and the steering wheel. “Battery”, for procedure. 5. Close and secure the engine rear and side engine doors. 9-32 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 299: Display Monitor

    4. Properly connect the battery. Refer Section 9.8, “Battery”, for procedure. 5. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 6. Close and secure the engine doors. 6036, 6042, 8042, 10042, 10054 31211015 9-33...
  • Page 300 4. Properly connect the battery. Refer Section 9.8, “Battery”, for procedure. 5. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 6. Close and secure the engine doors. 9-34 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 301 Inspection and Replacement Inspect the switch terminals for continuity and shorting in both the engaged and disengaged positions. Replace a defective or faulty switch with a new switch. 6036, 6042, 8042, 10042, 10054 31211015 9-35...

  • Page 302: Machine Data

    Section 9.18.2, “Offboard 6. Left and Right Arrow Keys: Used to move between Top Diagnostics”. Level, Sub Levels and Item Menus. For more information, contact the local JLG dealer. 9-36 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 303 4. Up/Down Arrow Keys: Change adjustable values. 5. Left and Right Arrow Keys: Used to move between Top Level, Sub Levels and Item Menus. 6. Disconnect: To disconnect the connection of the mobile from the system. 6036, 6042, 8042, 10042, 10054 31211015 9-37...
  • Page 304 Electrical System 9.15.4 Analyzer Software Version P1.2 MAQ42OO 9-38 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 305: Analyzer Software Accessibility

    Access Level 2 System Displays the parameter related to the frame leveling. Access Level 2 Displays the version of the software, hardware and constant data of Versions Access Level 2 control modules in the machine 6036, 6042, 8042, 10042, 10054 31211015 9-39...
  • Page 306 Access Level 2, 3 Engine for the telehandler 8042 55KW 10042 82KW HRC 10042 82KW LRC 10042 55KW 10054 82KW HRC 10054 82KW LRC 10052 55KW Note: Settings in BOLD are default values. 9-40 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 307 Personalities Menu/ Default Values (Range) Sub- Access Function Description menu Level 6036, 6042, 8042, 10042, 10052, 10054 Items Accel Up: x.xS (0.0 – 5.0S) Decel Up: x.xS (0.0 – 5.0S) Accel Down: x.xS (0.0 – 5.0S) Fork tilt screen allows Decel Down: x.xS...
  • Page 308 Press the ESC key to exit from the menu. The control system will display this message if Failed the procedure is failed. Press the ESC key to exit from the menu. 9-42 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 309: Telematics Gateway

    When Fuel Level 2 (SPN 38) is not used, Fuel Level 1 represents total fuel in all fuel storage containers. When Fuel Level 2 is used, Fuel Level 1 represents fuel level in primary or left side fuel storage container. DM1 Engine Faults Shows actual engine fault codes. 6036, 6042, 8042, 10042, 10054 31211015 9-43...
  • Page 310 3. Not Used 9. CAN-LO 2 4. IGNITION 10. CAN-HI 2 5. Not Used 11. Not Used MAQ4810 6. Not Used 12. Not Used 1. Gateway Module 3. Telematics-Ready (TCU) Plug 2. Diagnostics Plug 9-44 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 311 Electrical System 9.17.3 Telematics Gateway Harness Breakdown a. 2D Harness View 6036, 6042, 8042, 10042, 10054 31211015 9-45...
  • Page 312 X1116 (D) 16 AWG X1116 (H) S1115 16 AWG S1119 (I) CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET CANL1 18 AWG CO1117-J1 (9) CANL1 18 AWG X1149 (B) CANL1 18 AWG X1106 (B) 9-46 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 313 S1139 (2) CANL2 16 AWG X1145 (9) CANL2 18 AWG X1132 (B) X1132 (CAN2 TERMINATOR CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET CANH2 18 AWG S1142 (2) CANL2 18 AWG S1141 (2) 6036, 6042, 8042, 10042, 10054 31211015 9-47...
  • Page 314 Electrical System c. 3D Harness View 9-48 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 315 It also provides the technician with the capability to turn on certain drivers such as the grid heaters and lift pump as well as running diagnostic tests such as single cylinder cutout. 6036, 6042, 8042, 10042, 10054 31211015 9-49...

  • Page 316: Machine Fault Codes

    Fork Tilt Up Valve prevented Tilt Cal OK is NO; refer to Fork Tilt Calibration OK Tilt Cal OK is YES (calibration JOYSTICK CALIBRATION 23195  functionality completed) FAULTY Fork Tilt Down Valve prevented 9-50 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 317 All of the following occur for 500mS: Torque-Based or ANTI-STALL VALVE – Speed-Based Anti-Stall enabled 33428 Anti-Stall Valve prevented Power cycled SHORT TO GROUND Anti-Stall Valve Actual (mA) > Anti-Stall Valve Short to Ground Limit (mA) 6036, 6042, 8042, 10042, 10054 31211015 9-51...
  • Page 318 Accel Pedal A (%) and Accel Pedal B (%) differ by more VOLTAGE 4338 Power cycled Throttle RPM than 6% DISAGREEMENT Machine Setup’s MODEL is 6036 55KW, 6042 55KW, WRONG ENGINE Engine speed set to Closed 4367  8042 55KW, 10042 55KW, or 10054 55KW; Power cycled SELECTED Throttle RPM SPN166EngRatedPower >...
  • Page 319 Personality setting outside adjustment limits changed to trigger defaults; CHECK ALL SETTINGS power-cycled Low-Side Fault Relay de- Calibration setting outside calibration limits energized Engine speed set to Closed Non-volatile storage checksum issue Throttle RPM 6036, 6042, 8042, 10042, 10054 31211015 9-53...

  • Page 320: Engine Fault Codes

    Accelerator Pedal or Lever Position Sensor 1 - Data Accelerator Pedal Position 1 valid but above normal operational range - Most Severe Level Accelerator Pedal or Lever Position Sensor 1 - Data 1242 Accelerator Pedal Position 1 erratic, intermittent or incorrect 9-54 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 321 Water in Fuel Indicator - Data Valid But Above Normal 1852 Water In Fuel Indicator Operating Range - Moderately Severe Level Engine Oil Level - Data valid but below normal Engine Oil Level operational range - Most Severe Level 6036, 6042, 8042, 10042, 10054 31211015 9-55...
  • Page 322 Intake Manifold 1 Pressure - Data Valid But Above Normal Operating Range - Moderately Severe Level Pressure Engine Intake Manifold #1 Intake Manifold 1 Pressure - Data Valid But Below Normal Operating Range - Moderately Severe Level Pressure 9-56 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 323 Engine Air Filter Differential Pressure - Data Valid But 5576 Engine Air Filter 1 Differential Pressure Above Normal Operating Range - Least Severe Level Barometric Pressure Sensor Circuit - Voltage above Barometric Pressure normal, or shorted to high source 6036, 6042, 8042, 10042, 10054 31211015 9-57...
  • Page 324 Coolant Level Sensor 1 Circuit - Voltage above normal, Engine Coolant Level or shorted to high source Coolant Level Sensor 1 Circuit - Voltage below normal, Engine Coolant Level or shorted to low source 9-58 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 325 Engine Injector Metering Rail 1 Below Normal Operating Range - Moderately Severe Pressure Level Engine Injector Metering Rail 1 Injector Metering Rail 1 Pressure - Mechanical system Pressure not responding or out of adjustment 6036, 6042, 8042, 10042, 10054 31211015 9-59...
  • Page 326 Engine Fuel Temperature - Data valid but above Engine Fuel Temperature 1 normal operational range - Most Severe Level Engine Fuel Temperature - Data erratic, intermittent or Engine Fuel Temperature 1 incorrect 9-60 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 327 Transmission Output Shaft Speed - Data Valid But Transmission Output Shaft Speed Above Normal Operating Range - Moderately Severe Level Transmission Output Shaft Speed - Data Valid But Transmission Output Shaft Speed Below Normal Operating Range - Moderately Severe Level 6036, 6042, 8042, 10042, 10054 31211015 9-61...
  • Page 328 But Above Normal Operating Range - Moderately Temperature Severe Level Auxiliary Temperature Sensor Input 1 - Special Auxiliary Temperature 1 Instructions Auxiliary Temperature Sensor Input 1 Circuit - Voltage Auxiliary Temperature 1 above normal, or shorted to high source 9-62 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 329 Brake Switch Circuit - Voltage below normal, or Brake Switch shorted to low source Cruise Control Set Switch - Data erratic, intermittent or 2721 Cruise Control Set Switch incorrect 6036, 6042, 8042, 10042, 10054 31211015 9-63...
  • Page 330 J1939 Network #1 - Data erratic, intermittent or Network (previously SAE J1939 Data incorrect Link) J1939 Network #1, Primary Vehicle Network (previously SAE J1939 Data SAE J1939 Datalink - Abnormal update rate Link) 9-64 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 331 Fan Control Circuit - Voltage above normal, or shorted 6263 Driver to high source Engine Fan Clutch 1 Output Device Fan Control Circuit - Voltage below normal, or shorted 6264 Driver to low source 6036, 6042, 8042, 10042, 10054 31211015 9-65...
  • Page 332 Injector Solenoid Driver Cylinder 7 Circuit - Current 1548 Engine Injector Cylinder #7 below normal or open circuit Injector Solenoid Driver Cylinder 8 Circuit - Current 1549 Engine Injector Cylinder #8 below normal or open circuit 9-66 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 333 Auxiliary Input/Output 2 Circuit - Current above 4725 Auxiliary I/O #02 normal or grounded circuit Auxiliary Input/Output 3 Circuit - Voltage above Auxiliary I/O #03 normal, or shorted to high source 6036, 6042, 8042, 10042, 10054 31211015 9-67...
  • Page 334 SAE J1939 Multiplexing Remote Accelerator Pedal or Remote Accelerator Pedal Position Lever Position Sensor System - Received Network Data In Error Auxiliary Intermediate (PTO) Speed Switch Validation - 6563 PTO Governor State Data erratic, intermittent or incorrect 9-68 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 335 Engine Wait to Start Lamp Engine Wait to Start Lamp - Condition Exists Engine Protection System Engine Protection System Approaching Shutdown - 1109 3931 Approaching Shutdown Data valid but above normal operational range - Most 6036, 6042, 8042, 10042, 10054 31211015 9-69...
  • Page 336 Turbocharger 1 Compressor Intake Pressure - Data 1176 Intake Pressure erratic, intermittent or incorrect Turbocharger 1 Compressor Intake Pressure - Data Engine Turbocharger 1 Compressor 1176 3348 valid but below normal operational range - Most Intake Pressure Severe Level 9-70 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 337 Engine Misfire for Multiple Cylinders - Condition Exists 1323 1654 Engine Misfire Cylinder #1 Engine Misfire Cylinder 1 - Condition Exists 1324 1655 Engine Misfire Cylinder #2 Engine Misfire Cylinder 2 - Condition Exists 6036, 6042, 8042, 10042, 10054 31211015 9-71...
  • Page 338 Auxiliary Pressure Sensor Input 2 Circuit - Voltage 1388 Auxiliary Pressure #2 above normal, or shorted to high source Auxiliary Pressure Sensor Input 2 Circuit - Voltage 1388 Auxiliary Pressure #2 below normal, or shorted to low source 9-72 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 339 Fan Speed – Data Erratic, Intermittent, or Incorrect J1939 Network #4 - Data erratic, intermittent or 1668 4437 J1939 Network #4 - Data erratic incorrect Engine Starter Mode Overcrank Protection - Condition 1675 3737 Engine Starter Mode Exists 6036, 6042, 8042, 10042, 10054 31211015 9-73...
  • Page 340 Battery Temperature - Data Valid But Above Normal 1800 2263 Battery 1 Temperature Operating Range - Moderately Severe Level Battery Temperature - Data Valid But Below Normal 1800 2264 Battery 1 Temperature Operating Range - Moderately Severe Level 9-74 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 341 EGR Valve Controller - Out of Calibration (EGR1) Valve Control EGR Valve Control Circuit Over Temperature - Data Engine Exhaust Gas Recirculation 1 2791 1961 Valid But Above Normal Operating Range - Least (EGR1) Valve Control Severe Level 6036, 6042, 8042, 10042, 10054 31211015 9-75...
  • Page 342 Tank Temperature Temperature - Root Cause Not Known Aftertreatment 1 Diesel Exhaust Fluid Tank Aftertreatment 1 Diesel Exhaust Fluid 3031 6559 Temperature Sensor - Voltage below normal, or Tank Temperature shorted to low source 9-76 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 343 Aftertreatment 1 Outlet NOx Sensor - Abnormal 3226 2771 Aftertreatment 1 Outlet NOx update rate Aftertreatment 1 Outlet NOx Sensor - Abnormal rate of 3226 3545 Aftertreatment 1 Outlet NOx change 6036, 6042, 8042, 10042, 10054 31211015 9-77...
  • Page 344 3242 3317 Filter Intake Gas Temperature shorted to high source Aftertreatment 1 Diesel Particulate Aftertreatment 1 Diesel Particulate Filter Intake 3242 3318 Filter Intake Gas Temperature Temperature - Data erratic, intermittent or incorrect 9-78 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 345 Filter Differential Pressure Range Aftertreatment 2 Intake NOx Sensor - Abnormal 3255 4145 Aftertreatment 2 Intake NOx update rate 3265 3988 Aftertreatment 2 Outlet NOx Aftertreatment 2 Outlet NOx - Abnormal Update Rate 6036, 6042, 8042, 10042, 10054 31211015 9-79...
  • Page 346 Voltage below normal, or shorted to low source Aftertreatment Diesel Exhaust Fluid Quality Sensor Aftertreatment 1 Diesel Exhaust Fluid 3364 1685 Circuit - Voltage below normal, or shorted to low Tank 1 Quality source 9-80 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 347 Valid But Below Normal Operating Range - Moderate Tank 1 Quality Severe Level Electronic Throttle Control Actuator Electronic Throttle Control Actuator Driver Circuit- 3464 6493 Driver Circuit Voltage above normal, or shorted to high source 6036, 6042, 8042, 10042, 10054 31211015 9-81...
  • Page 348 Aftertreatment Purge Air Actuator - Mechanical 3490 3225 Aftertreatment 1 Purge Air Actuator system not responding or out of adjustment Sensor Supply 1 Circuit - Voltage below normal, or 3509 Sensor supply voltage 1 shorted to low source 9-82 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 349 Sensor Circuit - Current below normal or open circuit Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment 1 Diesel Exhaust Fluid Temperature 2 3515 4744 Temperature 2 Sensor Circuit - Current above normal or grounded 6036, 6042, 8042, 10042, 10054 31211015 9-83...
  • Page 350 Below Normal Operating Range - Moderately Severe Level Aftertreatment 1 Diesel Particulate Filter Outlet Aftertreatment Diesel Particulate 3610 3133 Pressure Sensor Circuit - Voltage above normal, or Filter Outlet Pressure shorted to high source 9-84 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 351 Due to System Timeout - Condition Exists Timeout Diesel Particulate Filter 1 Conditions Diesel Particulate Filter 1 Conditions Not Met for 3750 3396 Not Met for Active Regeneration Active Regeneration - Condition Exists 6036, 6042, 8042, 10042, 10054 31211015 9-85...
  • Page 352 Gain Adjust Potentiometer Circuit - Voltage below 4184 3694 Gain Adjust Potentiometer Circuit normal, or shorted to low source Overspeed Shutdown Relay Driver Diagnostic has 4185 1427 Overspeed Shutdown Relay Driver detected an error - Condition Exists 9-86 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 353 Aftertreatment 1 Diesel Exhaust Fluid Dosing 4337 4249 Dosing Temperature Temperature - Abnormal Rate of Change Aftertreatment 1 SCR Feedback Aftertreatment 1 SCR Feedback Control Status - 4339 4586 Control Status Condition Exists 6036, 6042, 8042, 10042, 10054 31211015 9-87...
  • Page 354 Circuit - Voltage below normal, or shorted to low Line Heater 3 State source Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment Diesel Exhaust Fluid Line Heater 3 4344 3425 Line Heater 3 State Circuit - Current below normal or open circuit 9-88 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 355 - Most Severe Aftertreatment 1 SCR Outlet Temperature - Data Valid Aftertreatment 1 SCR Catalyst Outlet 4363 3235 But Above Normal Operating Range - Moderately Gas Temperature Severe Level 6036, 6042, 8042, 10042, 10054 31211015 9-89...
  • Page 356 Aftertreatment 1 Diesel Oxidation Catalyst Intake 4765 3315 Catalyst Intake Temperature Temperature - Data erratic, intermittent or incorrect Aftertreatment Diesel Oxidation Aftertreatment 1 Diesel Oxidation Catalyst Intake 4765 3325 Catalyst Intake Temperature Temperature Swapped - Out of Calibration 9-90 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 357 Aftertreatment 1 Diesel Oxidation Catalyst Missing - 4796 6726 Catalyst Missing Condition Exists Aftertreatment Warm Up Diesel Aftertreatment Warm Up Diesel Oxidation Catalyst 4809 3152 Oxidation Catalyst Intake Intake Temperature Sensor Circuit - Voltage above Temperature normal 6036, 6042, 8042, 10042, 10054 31211015 9-91...
  • Page 358 Engine Exhaust Gas Recirculation Outlet Pressure - 5019 3138 Outlet Pressure Data erratic, intermittent or incorrect Aftertreatment 1 Intake Gas NOx Aftertreatment 1 Intake NOx Sensor Heater - Abnormal 5024 3649 Sensor Heater Ratio rate of change 9-92 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 359 Engine Fuel Valve 1 Engine Fuel Valve 1 - Out of Calibration Aftertreatment Diesel Exhaust Fluid Aftertreatment Diesel Exhaust Fluid Dosing Valve - 5394 3567 Dosing Valve Current below normal or open circuit 6036, 6042, 8042, 10042, 10054 31211015 9-93...
  • Page 360 - Voltage above normal, or shorted to high source Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment Diesel Exhaust Fluid Line Heater Relay 5491 6478 Line Heater Relay - Voltage below normal, or shorted to low source 9-94 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 361 Regulator Position Sensor Circuit High Source Engine Exhaust Back Pressure Regulator Position Engine Exhaust Back Pressure 5625 5276 Sensor Circuit - Voltage Below Normal, or Shorted to Regulator Position Sensor Circuit Low Source 6036, 6042, 8042, 10042, 10054 31211015 9-95...
  • Page 362 Temperature Sensor Module - Voltage below normal, Module or Shorted to low source Aftertreatment Selective Catalytic Aftertreatment Selective Catalytic Reduction 5743 4166 Reduction Temperature Sensor Temperature Sensor Module - Data Valid But Above Module Normal 9-96 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 363 Aftertreatment Warm Up Diesel Aftertreatment Warm Up Diesel Oxidation Catalyst 5797 4255 Oxidation Catalyst Temperature Temperature Sensor Module - Voltage below normal, Sensor Module or shorted to low source 6036, 6042, 8042, 10042, 10054 31211015 9-97...
  • Page 364 Maintain ECU Power Lamp - Voltage Below Normal, or 6655 4952 ECU Power Lamp Shorted to Low Source Maintain ECU Power Lamp - Voltage Above Normal, or 6655 6511 ECU Power Lamp Shorted to High Source 9-98 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 365 5391 Catalyst Temperature Sensor Module Sensor Module - Abnormal Update Rate Aftertreatment Diesel Oxidation Aftertreatment Diesel Oxidation Catalyst Temperature 6882 5392 Catalyst Temperature Sensor Module Sensor Module - Bad Intelligent Device or Component 6036, 6042, 8042, 10042, 10054 31211015 9-99...
  • Page 366 Glow Plug Module - Bad intelligent device or 520435 3222 Glow Plug Module component Closed Crankcase Ventilation System Closed Crankcase Ventilation System Pressure Sensor - 520595 4286 Pressure Sensor Voltage Above Normal, or Shorted to High Source 9-100 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 367 Aftertreatment 1 Diesel Oxidation Aftertreatment 1 Diesel Oxidation Catalyst System- 524286 5617 Catalyst System Special Instruction 524286 9491 Reserved for temporary use - Condition Exists 524286 9999 Reserved for temporary use - Condition Exists 6036, 6042, 8042, 10042, 10054 31211015 9-101...
  • Page 368 Electrical System This Page Intentionally Left Blank 9-102 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 369: Stabil-Trak™ System And Boom Interlock System

    System Test Procedures ........... . 10-24 6036, 6042, 8042, 10042, 10054 31211015...
  • Page 370 Hydraulic Circuit Operation - Outrigger Interlock Mode ..... . 10-46 10.12.5 Hydraulic Troubleshooting - Outrigger Interlock Mode ..... . 10-46 10-2 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 371: Stabil-Trak™ System Component Terminology

    Stabil-TRAK system. The following illustration identifies the components that are referred to throughout this section. BOOM PROXIMITY SWITCH (RIGHT REAR CORNER OF BOOM) STABIL-TRAK MANIFOLD FRAME LEVEL STABIL-TRAK CYLINDER CYLINDER Model 10054 Shown 6036, 6042, 8042, 10042, 10054 31211015 10-3...

  • Page 372: Boom Extend Interlock System Component Terminology (10054 Only)

    The following illustration identifies the components that are referred to throughout this section. BOOM EXTEND SENSOR BOOM LOCKOUT VALVE OUTRIGGER CYLINDER PRESSURE SWITCH (2) 10-4 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 373: Stabil-Trak™ Description

    (approximately 40ft [12 m]) With the boom lowered to an angle of less than 40°, the free pivot mode is active and none of these functions will affect the Stabil-TRAK system. MH2980 MH2980 6036, 6042, 8042, 10042, 10054 31211015 10-5...

  • Page 374: Stabil-Trak™ Operation

    MODE and rear axle is locked so it is rigid with frame. Stabil- TRAK indicator (7) will be ON when • Engaging parking brake switch • Placing transmission in (N) NEUTRAL • Depressing and holding service brake pedal 10-6 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 375 R22 35 Amp Boom Extension Lock Out and hydraulic circuits should each be checked and the exact 24 7.5 Amp Outrigger 1 (Mini-Fuse) source of the problem diagnosed before any parts are 25 7.5 Amp Outrigger 2 (Mini-Fuse) replaced. 6036, 6042, 8042, 10042, 10054 31211015 10-7...
  • Page 376 7. Apply proper voltage to relay coil at terminal 86 (5) and attach the ground (-) probe to terminal 85 (6), ground. An audible click should be heard indicating that relay is functioning properly. 10-8 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 377 3. Properly connect the battery. Refer Section 9.8, “Battery”, for procedure. 4. Close and secure rear engine compartment door. 5. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 6036, 6042, 8042, 10042, 10054 31211015 10-9...

  • Page 378: Boom Extend Interlock System Description

    Stabil-TRAK system in LOCKED MODE. The Stabil-TRAK system will remain in LOCKED MODE, until boom has been retracted. (Refer to Section 10.4, “Stabil-TRAK Operation,” for more information.) 10-10 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 379: Boom Extend Interlock System Operation (10054 Only)

    It is important that you regularly check that this system is functioning properly. To check that Stabil-TRAK System is functioning properly, refer to Section 10.7, “Stabil-TRAK System Test,” for proper system function. 6036, 6042, 8042, 10042, 10054 31211015 10-11...

  • Page 380: Stabil-Trak™ System Test

    Stabil-TRAK system is not functioning properly and test should be stopped immediately. If the Stabil-TRAK system is not functioning properly, follow the procedures in Section 10.11, “Stabil-TRAK Hydraulic Circuit Operation and Troubleshooting, ” to repair the system. 10-12 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 381 With the transmission in (N) NEUTRAL, engage the parking brake switch. b. Move the transmission to the (F) FORWARD position. The Stabil-TRAK light should remain ON and the front left tire should remain off the ground. 6036, 6042, 8042, 10042, 10054 31211015 10-13...
  • Page 382 Frame level the machine back to 0°. k. Depress the service brake pedal. l. Place the transmission in(N) NEUTRAL. m. Lower the boom. 10-14 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 383: Stabil-Trak™ Electrical Circuit Operation And Troubleshooting (6042/8042/10042)

    Secondary Function Manifold Park Brake Solenoids Park Brake Disengage Relay Neutral Start Relay Definitions: PB = Park Brake SB = Service Brake DE = De-energized E = Energized C = Closed O = Open 6036, 6042, 8042, 10042, 10054 31211015 10-15...
  • Page 384 Stabil-TRAK™ System and Boom Interlock System FREE PIVOT MODE Ignition “ON” PB & SB Released 6042, 8042 and 10042 Stabil-TRAK Boom Below 40° Transmission in Fwd. or Rev. Electrical Circuit Conditions Boom Retracted FREE PIVOT Mode MAQ1920 10-16 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 385 Stabil-TRAK™ System and Boom Interlock System SLOW PIVOT MODE Ignition “ON” PB & SB Released 6042, 8042 and 10042 Stabil-TRAK Boom Above 40° Transmission in Fwd. or Rev. Electrical Circuit Conditions SLOW PIVOT Mode Boom Retracted MAQ1930 6036, 6042, 8042, 10042, 10054 31211015 10-17...
  • Page 386 Stabil-TRAK™ System and Boom Interlock System LOCKED MODE Ignition “ON” PB & SB Applied 6042, 8042 and 10042 Stabil-TRAK Boom Above 40° Transmission in Neutral Electrical Circuit Conditions Boom Retracted LOCKED MODE MAQ1940 10-18 31211015 6036, 6042, 8042, 10042, 10054...

  • Page 387: Stabil-Trak™ And Boom Interlock Electrical Circuit Operation And Troubleshooting (10054)

    Note: If an outrigger is raised or a pressure switch is defective, boom on the 10054 will not extend beyond the 42 Series extension limit. Definitions: Boom Retracted = Less than 42 Series extension limit 6036, 6042, 8042, 10042, 10054 31211015 10-19...
  • Page 388 Stabil-TRAK™ System and Boom Interlock System Boom Extended = Boom at 42 Series extension limit or greater (See Figure at Right). PB = Park Brake DE = De-energized E = Energized C = Closed O = Open MH6110 10-20 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 389 Stabil-TRAK™ System and Boom Interlock System MODE 1 Ignition “ON” PB Released 10054 Stabil-TRAK Electrical Circuit Boom Below 40° Transmission in Fwd. or Rev. Conditions Boom Extend Mode 1 Boom Retracted Outriggers Raised MAQ1951 6036, 6042, 8042, 10042, 10054 31211015 10-21...
  • Page 390 MODE 2 Ignition “ON” PB Released 10054 Stabil-TRAK Electrical Circuit Boom Below 40° Transmission in Fwd. or Rev. Boom Extend Mode 2 Conditions Boom Ext. To 42 Foot Ext. Limit Outriggers Raised MAQ1961 10-22 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 391 PB Applied By Interlock Sys. 10054 Stabil-TRAK Electrical Circuit Boom Below 40° Trans. in Neutral By Interlock Sys. Conditions Boom Extend Mode 3 Boom Ext. Beyond 42 Foot Ext. Limit Outriggers Lowered MAQ1971 6036, 6042, 8042, 10042, 10054 31211015 10-23...

  • Page 392: Boom/Outrigger Interlock System Test

    If any of these steps indicate that the Boom/Outrigger Interlock system is not functioning properly, follow the procedures in Section 10.12, “Boom Extend System Hydraulic Circuit Operation and Troubleshooting,” to repair the system. 10-24 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 393 Place the transmission in (N) NEUTRAL, move the neutral lock lever to the NEUTRAL LOCK position. b. Fully retract the boom. c. Raise the outriggers. d. Engage the parking brake switch, shut the engine OFF and remove the key. e. Exit the machine using both handholds. 6036, 6042, 8042, 10042, 10054 31211015 10-25...

  • Page 394: Stabil-Trak™ Hydraulic Circuit Operation And Troubleshooting

    Frame Level Right,” and Section Transmission is in (N) NEUTRAL, or Park 10.11.12, “Hydraulic Troubleshooting - brake ON or Service brake ENGAGED LOCKED MODE, Will Not Frame Level Right.” 10-26 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 395 Frame Level Left,” and Section Transmission is in (N) NEUTRAL, or Park 10.11.14, “Hydraulic Troubleshooting - brake ON or Service brake ENGAGED LOCKED MODE, Will Not Frame Level Left.” 6036, 6042, 8042, 10042, 10054 31211015 10-27...
  • Page 396 BASE OIL OUT flow will occur when the right side of the rear axle is lower than the left (right wheel in a pothole, or the left wheel passing over an obstruction), causing the cylinder to compress (2). MH2980 10-28 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 397 Stabil-TRAK™ System and Boom Interlock System This Page Intentionally Left Blank 6036, 6042, 8042, 10042, 10054 31211015 10-29...
  • Page 398 Because the volume of oil needed on the base side is greater than that needed on the rod side, the extra oil needed is supplied from the main hydraulic system through a 100 psi (7 bar) reducing cartridge (4) in the Stabil-TRAK manifold. 10-30 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 399 If OK Remove solenoid cartridges 12A and 12B from Stabil-TRAK manifold and inspect Clean passages or replace cartridge(s). for debris or damage. If OK Inspect check valves on Replace check valve(s). frame level cylinder. 6036, 6042, 8042, 10042, 10054 31211015 10-31...
  • Page 400 Because the volume of oil needed on the rod side is less than • Service brake DISENGAGED that needed on the base side, excess oil is returned to the tank through a 100 psi (7 bar) reducing cartridge (4) in the Stabil-TRAK manifold. 10-32 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 401 If OK Remove solenoid cartridges 12A Clean passages or replace and 12B from Stabil-TRAK manifold and cartridge(s). inspect for debris or damage. If OK Inspect check valves on Replace check valve(s). frame level cylinder. 6036, 6042, 8042, 10042, 10054 31211015 10-33...
  • Page 402 Stabil-TRAK cylinder (1), through solenoid-operated valve 4B (2), through a 0.060 inch orifice (3), through another 0.060 inch orifice (4), then through solenoid-operated valve 4A (5), then to the base end of the Stabil-TRAK cylinder. 10-34 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 403 If OK Remove solenoid cartridges 4A and 4B from Clean passages or replace cartridge(s). Stabil-TRAK manifold and inspect for debris or damage. If OK Inspect check valves on frame level cylinder. Replace check valve(s). 6036, 6042, 8042, 10042, 10054 31211015 10-35...
  • Page 404 Stabil-TRAK cylinder (1), through solenoid-operated valve 4A (2), through a 0.060 inch orifice (3), through another 0.060 inch orifice (4), then through solenoid-operated valve 4B (5), to the rod end of the Stabil- TRAK cylinder. 10-36 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 405 Remove solenoid coils 4A and 4B from Stabil- Clean passages or replace cartridge(s). TRAK manifold and inspect for debris or damage. If OK Inspect check valves on Replace check valve(s). frame level cylinder. 6036, 6042, 8042, 10042, 10054 31211015 10-37...
  • Page 406 4A (1), 4B (2), 12A (3) and 12B (4). At this time pilot pressure will cause the 100 psi relief valve (13) to change position, allowing the excess oil to vent to the reservoir. 10-38 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 407 If OK park brake ON or service brake ENGAGED Check solenoid cartridge 3 in the Replace cartridge. Stabil-TRAK manifold. If OK Inspect check valves 2A and 2B Replace check valve(s). on the Stabil-TRAK cylinder. 6036, 6042, 8042, 10042, 10054 31211015 10-39...
  • Page 408 4B (10), 12A (11), and 12B (12). At this time pilot pressure will (3) on the return side of the frame level cylinder, opening the cause the 100 psi relief valve (13) to change position, valve. allowing the excess oil to vent to the reservoir. 10-40 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 409 ON or (10054), ” If OK service brake ENGAGED Check solenoid cartridge 3 in Replace cartridge. the Stabil-TRAK manifold. If OK Inspect check valves 2A and 2B Replace check valve(s). on the Stabil-TRAK cylinder. 6036, 6042, 8042, 10042, 10054 31211015 10-41...

  • Page 410: Boom Extend System Hydraulic Circuit Operation And Troubleshooting

    Circuit Operation - Outrigger Interlock Ignition ON, engine running firm terrain, the boom will not Mode” and Section 10.12.5, “Hydraulic Both outriggers lowered onto firm terrain extend to its full limits. Troubleshooting - Outrigger Interlock Mode”. 10-42 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 411 Stabil-TRAK™ System and Boom Interlock System This Page Intentionally Left Blank 6036, 6042, 8042, 10042, 10054 31211015 10-43...
  • Page 412 (7-9 ohms). If OK Remove solenoid cartridge from boom lockout valve and inspect Clean passages or replace cartridge. for debris or damage. If OK Inspect check valves Replace check valve(s). on extend/retract cylinder. 10-44 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 413 BOOM LOCKOUT VALVE EXTEND/RETRACT CYLINDER OUTRIGGER VALVE MAIN CONTROL VALVE BYPASS CHECK VALVE HYDRAULIC RESERVOIR 1.2 DIA. PUMP HYDRAULIC OIL COOLER L.H. R.H. OUTRIGGER CYLINDER Pressure SOLENOID COIL Return STATE Suction DE-ENERGIZED ENERGIZED LoadSense MAQ2040 6036, 6042, 8042, 10042, 10054 31211015 10-45...
  • Page 414 If OK Remove solenoid cartridge from boom Clean passages or replace lockout valve and inspect cartridge. for debris or damage. If OK Inspect check valves on Replace check valve(s). extend/retract cylinder. 10-46 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 415 BOOM LOCKOUT VALVE EXTEND/RETRACT CYLINDER OUTRIGGER VALVE MAIN CONTROL VALVE BYPASS CHECK VALVE HYDRAULIC RESERVOIR 1.2 DIA. PUMP HYDRAULIC OIL COOLER L.H. R.H. OUTRIGGER CYLINDER Pressure SOLENOID COIL Return STATE Suction DE-ENERGIZED ENERGIZED LoadSense MAQ2050 6036, 6042, 8042, 10042, 10054 31211015 10-47...
  • Page 416 Stabil-TRAK™ System and Boom Interlock System This Page Intentionally Left Blank 10-48 31211015 6036, 6042, 8042, 10042, 10054...
  • Page 418 31211015 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 (717) 485-5161(Corporate) (800) 554-5438(Service) (717) 485-6417 JLG Worldwide Locations JLG Industries JLG Ground Support Oude JLG Latino Americana LTDA Oshkosh-JLG (Tianjin) 358 Park Road Bunders 1034 Rua Antonia Martins Luiz, 580 Equipment Technology LTD Regents Park Breitwaterstraat 12A...

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