Sky Trak

Service Manual
Models
6036, 6042, 8042,
10042 & 10054
6036 & 6042
S/N 0160045066 & After including
0160042742, 0160042747 & 0160042755
8042, 10042 & 10054

S/N 0160045250 & After including
0160042754, 0160042762, 0160042877,
0160042911, 0160043185, 0160043220
& 0160043244 excluding 0160045255
31200796
Revised
October 10, 2014
An Oshkosh Corporation Company

EFFECTIVITY PAGE
September 28, 2012 - A - Original Issue Of Manual

March 17, 2014 - B - Revise pages 2-2 thru 2-12, 2-17, 2-18, 5-8, 7-8, 8-6, 8-8, 8-10, 8-11, 8-20, 8-22, 9-4, 9-31 thru
9-40.
October 10, 2014 - C - Revise pages 1-4, 4-6, 7-2, 7-13, 7-14.
31200796 6036, 6042, 8042, 10042, 10054 i

READ THIS FIRST
Modifications
Modifications to this machine may affect compliance with Industry Standards and/or Governmental Regulations.
Any modification must be approved by JLG.
Machine Configuration
Two configurations of each machine are included in this manual. Determine if machine is equipped with Ultra Low Sulfur
Fuel Decal (1) as indicated below.
• If equipped with the Ultra Low Sulfur decal, all specific references to this machine configuration will be referred to as
Ultra Low Sulfur (ULS) from this point forward.
• If not equipped with the Ultra Low Sulfur decal, all specific references to this machine configuration will be referred to
as Low Sulfur (LS) from this point forward.
ULTRA LOW
SULFUR DIESEL
FUEL ONLY
S < 15 mg/kg
1001125387 A
OH4912
ii 6036, 6042, 8042, 10042, 10054 31200796

SECTION CONTENTS
Section Subject Page
Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.5 Fluid Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.6 Fluid and Lubricant Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
2.7 Service and Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2.8 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Section 3
Boom ........................................................... 3-1
3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 Boom System - Three Section (6036, 6042, 8042 & 10042) . . . . . . . . . . . . . . . . . . . . . 3-4
3.4 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.5 Boom System - Four Section (10054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.6 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.7 Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3.8 Quick Attach Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3.9 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3.10 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
3.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Section 4
Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
6036, 6042, 8042, 10042, 10054 i

Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Axle, Drive Shaft and Wheel Component Terminology (6036). . . . . . . . . . . . . . . . . . . . 5-2
5.4 Axle, Drive Shaft and Wheel Component Terminology (10042 & 10054) . . . . . . . . . . . 5-5
5.5 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.6 Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.7 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.8 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.9 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.10 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.11 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Section 6
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Transmission Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.5 Transmission Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Section 7
Engine ........................................................... 7-1
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.8 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.10 Isolation Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.5 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.6 Hydraulic System Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
8.7 Valves and Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
8.8 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
ii 6036, 6042, 8042, 10042, 10054

Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.4 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.5 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.6 Engine start circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
9.7 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
9.8 Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
9.9 Cab Heater and Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
9.10 Solenoids, Sensors and Senders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
9.11 Display Monitor and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
9.12 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
9.13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Section 10
Stabil-TRAK™ System and Boom Interlock System . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.1 Stabil-TRAK™ System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
10.2 Boom Extend Interlock System Component Terminology (10054 Only) . . . . . . . . . . . . 10-4
10.3 Stabil-TRAK™ Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
10.4 Stabil-TRAK™ Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
10.5 Boom Extend Interlock System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
10.6 Boom Extend Interlock System Operation (10054 Only) . . . . . . . . . . . . . . . . . . . . . . . . 10-10
10.7 Stabil-TRAK™ System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
10.8 Stabil-TRAK™ Boom Interlock Electrical Circuit Operation and Troubleshooting
(6042/8042/10042). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
10.9 Stabil-TRAK™ Boom Interlock Electrical Circuit Operation and Troubleshooting (10054) 10-18
10.10 Boom/Outrigger Interlock System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
10.11 Stabil-TRAK™ Hydraulic Circuit Operation and Troubleshooting . . . . . . . . . . . . . . . . . 10-25
10.12 Boom Extend System Hydraulic Circuit Operation and Troubleshooting . . . . . . . . . . . . 10-40
6036, 6042, 8042, 10042, 10054 iii

iv 6036, 6042, 8042, 10042, 10054

Section 1
Safety Practices
Contents
PARAGRAPH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5.1 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
6036, 6042, 8042, 10042, 10054 1-1

Safety Practices
1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS

This service manual provides general directions for Place Do Not Operate Tags on the ignition key switch and
accomplishing service and repair procedures. Following the steering wheel before attempting to perform any
the procedures in this manual will help assure safety and service or maintenance. Remove key and disconnect
equipment reliability. battery leads.
Read, understand and follow the information in this
manual, and obey all locally approved safety practices, 1.5 SAFETY INFORMATION
procedures, rules, codes, regulations and laws.
To avoid possible death or injury, carefully read,
These instructions cannot cover all details or variations in understand and comply with all safety messages.
the equipment, procedures, or processes described, nor
provide directions for meeting every possible contingency In the event of an accident, know where to obtain medical
during operation, maintenance, or testing. When additional assistance and how to use a first-aid kit and fire
information is desired consult your local authorized service extinguisher/fire suppression system. Keep emergency
distributor. telephone numbers (fire department, ambulance, rescue
squad/paramedics, police department, etc.) nearby. If
Many factors contribute to unsafe conditions: carelessness, working alone, check with another person routinely to
fatigue, overload, inattentiveness, unfamiliarity, even help assure personal safety.
drugs and alcohol, among others. For optimal safety,
encourage everyone to think, and to act, safely.
1.5.1 Safety Alert System and Signal Words
Appropriate service methods and proper repair
procedures are essential for the safety of the individual
doing the work, for the safety of the operator, and for the
safe, reliable operation of the machine. All references to
DANGER
the right side, left side, front and rear are given from the
operator seat looking in a forward direction. DANGER indicates an imminently hazardous situation
Supplementary information is available from JLG in the which, if not avoided, will result in death or serious injury.
form of Service Bulletins, Service Campaigns, Service
Training Schools, the manufacturer website, other
literature, and through updates to the manual itself. WARNING
1.2 DISCLAIMER
WARNING indicates a potentially hazardous situation
All information in this manual is based on the latest which, if not avoided, could result in death or serious
product information available at the time of publication. injury.
The manufacturer reserves the right to make changes
and improvements to its products, and to discontinue the
manufacture of any product, at its discretion at any time CAUTION
without public notice or obligation.
1.3 OPERATION & SAFETY MANUAL CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
The mechanic must not operate the machine until the injury.
Operation & Safety Manual has been read and
understood, training has been accomplished and
operation of the machine has been completed under the
supervision of an experienced and qualified operator.
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.
1-2 6036, 6042, 8042, 10042, 10054

Safety Practices
1.6 SAFETY INSTRUCTIONS 1.6.3 General Hazards

SOLVENTS: Only use approved solvents that are known
Following are general safety statements to consider before
to be safe for use.
performing maintenance procedures on the telehandler.
Additional statements related to specific tasks and HOUSEKEEPING: Keep the work area and operator cab
procedures are located throughout this manual and are clean, and remove all hazards (debris, oil, tools, etc.).
listed prior to any work instructions to provide safety FIRST AID: Immediately clean, dress and report all injuries
information before the potential of a hazard occurs. (cuts, abrasions, burns, etc.), no matter how minor the
For all safety messages, carefully read, understand and injury may seem. Know the location of a First Aid Kit, and
follow the instructions before proceeding. know how to use it.
CLEANLINESS: Wear eye protection, and clean all
1.6.1 Personal Hazards components with a high-pressure or steam cleaner
PERSONAL SAFETY GEAR: Wear all the protective before attempting service.
clothing and personal safety gear necessary to perform When removing hydraulic components, plug hose ends
the job safely. This might include heavy gloves, safety and connections to prevent excess leakage and
glasses or goggles, filter mask or respirator, safety shoes contamination. Place a suitable catch basin beneath the
or a hard hat. machine to capture fluid run-off.
LIFTING: NEVER lift a heavy object without the help of at It is good practice to avoid pressure-washing electrical/
least one assistant or a suitable sling and hoist. electronic components. In the event pressure-washing
the machine is needed, ensure the machine is shut down
1.6.2 Equipment Hazards before pressure-washing. Should pressure-washing be
utilized to wash areas containing electrical/electronic
LIFTING OF EQUIPMENT: Before using any lifting
components, it is recommended a maximum pressure of
equipment (chains, slings, brackets, hooks, etc.), verify
750 psi (52 bar) at a minimum distance of 12 in (30,5 cm)
that it is of the proper capacity, in good working order, and
away from these components. If electrical/electronic
is properly attached.
components are sprayed, spraying must not be direct and
NEVER stand or otherwise become positioned under a for brief time periods to avoid heavy saturation.
suspended load or under raised equipment. The load or
Check and obey all Federal, State and/or Local
equipment could fall or tip.
regulations regarding waste storage, disposal and
DO NOT use a hoist, jack or jack stands only to support recycling.
equipment. Always support equipment with the proper
capacity blocks or stands properly rated for the load.
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 1-3

Safety Practices
1.6.4 Operational Hazards FLUID FLAMABILTITY: DO NOT service the fuel or

hydraulic systems near an open flame, sparks or smoking
ENGINE: Stop the engine before performing any service
materials.
unless specifically instructed otherwise.
NEVER drain or store fluids in an open container. Engine
VENTILATION: Avoid prolonged engine operation in
fuel and hydraulic fluid are flammable and can cause a
enclosed areas without adequate ventilation.
fire and/or explosion.
SOFT SURFACES AND SLOPES: NEVER work on a
DO NOT mix gasoline or alcohol with diesel fuel. The
machine that is parked on a soft surface or slope. The
mixture can cause an explosion.
machine must be on a hard level surface, with the wheels
blocked before performing any service. PRESSURE TESTING: When conducting any test, only
use test equipment that is correctly calibrated and in good
FLUID TEMPERATURE: NEVER work on a machine
condition. Use the correct equipment in the proper
when the engine, cooling or hydraulic systems are hot.
manner, and make changes or repairs as indicated by the
Hot components and fluids can cause severe burns.
test procedure to achieve the desired result.
Allow systems to cool before proceeding.
LEAVING MACHINE: Lower the forks or attachment to
FLUID PRESSURE: Before loosening any hydraulic or
the ground before leaving the machine.
diesel fuel component, hose or tube, turn the engine
OFF. Wear heavy, protective gloves and eye protection. TIRES: Always keep tires inflated to the proper pressure
NEVER check for leaks using any part of your body; use to help prevent tipover. DO NOT over-inflate tires.
a piece of cardboard or wood instead. If injured, seek NEVER use mismatched tire types, sizes or ply ratings.
medical attention immediately. Diesel fluid leaking under Always use matched sets according to machine
pressure can explode. Hydraulic fluid and diesel fuel specifications.
leaking under pressure can penetrate the skin, cause
MAJOR COMPONENTS: Never alter, remove, or
infection, gangrene and other serious personal injury.
substitute any items such as counterweights, tires,
Engine fuel lines are pressurized. DO NOT attempt batteries or other items that may reduce or affect the
repairs unless specific training has been completed. overall weight or stability of the machine.
Refer to the engine manufacturers’ manual for specific
BATTERY: DO NOT charge a frozen battery.Charging a
details concerning the fuel system.
frozen battery may cause it to explode. Allow the battery
Relieve all pressure before disconnecting any to thaw before jump-starting or connecting a battery
component, part, line or hose. Slowly loosen parts and charger.
allow release of residual pressure before removing any
part or component. Before starting the engine or applying 1.7 SAFETY DECALS
pressure, use components, parts, hoses and pipes that
are in good condition, connected properly and are Check that all safety decals are present and readable on
tightened to the proper torque. Capture fluid in an the machine. Refer to the Operation & Safety Manual
appropriate container and dispose of in accordance with supplied with machine for information.
prevailing environmental regulations.
RADIATOR CAP: The cooling system is under pressure,
and escaping coolant can cause severe burns and eye
injury. To prevent personal injury, NEVER remove the
radiator cap while the cooling system is hot. Wear safety
glasses. 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.
1-4 6036, 6042, 8042, 10042, 10054

Section 2
General Information and Specifications
Contents

2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.3.3 Hydraulic Hose Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.4.1 Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.4.2 Hydraulic Cylinder Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.4.3 Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.4.4 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.4.5 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.5 Fluid Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.6 Fluid and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
2.7 Service and Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2.7.1 10 & 1st 50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2.7.2 50, 250 & 1st 500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.7.3 500 & 1000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2.7.4 2000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
2.8 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2.8.1 50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2.8.2 250 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
2.8.3 1000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
6036, 6042, 8042, 10042, 10054 2-1

2.1 REPLACEMENT PARTS AND 2.2 THREAD LOCKING COMPOUND

WARRANTY INFORMATION
JLG P/N Loctite® ND Industries Description
0100011 242TM Vibra-TITETM121 Medium Strength (Blue)
1001095650 243TM Vibra-TITETM122 Medium Strength (Blue)
0100019 271TM Vibra-TITETM140 High Strength (Red)
0100071 262TM Vibra-TITETM131 Medium - High Strength (Red)
Note: Loctite® 243TM can be substituted in place of

Loctite® 242TM. Vibra-TITETM 122 can be substituted in
place of Vibra-TITETM 121.
1
OH0281
Before ordering parts or initiating service inquiries, make

note of the machine serial number. The machine serial
number plate (1) is located as indicated in the figure.
Note: The replacement of any part on this machine with
any other than JLG authorized replacement parts can
adversely affect the performance, durability, or safety of
the machine, and will void the warranty. JLG disclaims
liability for any claims or damages, whether regarding
property damage, personal injury or death arising out of
the use of unauthorized replacement parts.
A warranty registration form must be filled out by the JLG
distributor, signed by the purchaser and returned to JLG
when the machine is sold and/or put into use.
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.
2-2 6036, 6042, 8042, 10042, 10054

2.3 TORQUE CHARTS
2.3.1 SAE Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)
SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque
Torque
Tensile Clamp Torque Torque (Loctite® 242TM or 271TM
Size TPI Bolt Dia (Loctite® 262TM or
Stress Area Load (Dry) Lubricated or Vibra-TITETM
Vibra-TITETM 131)
111 or 140)
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604 380 8 0.9 6 0.7
48 0.1120 0.00661 420 9 1.0 7 0.8
6 32 0.1380 0.00909 580 16 1.8 12 1.4
40 0.1380 0.01015 610 18 2.0 13 1.5
8 32 0.1640 0.01400 900 30 3.4 22 2.5
36 0.1640 0.01474 940 31 3.5 23 2.6
10 24 0.1900 0.01750 1120 43 4.8 32 3.5
32 0.1900 0.02000 1285 49 5.5 36 4
1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12
28 0.2500 0.0364 2320 120 13.5 86 10 135 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22
24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23
3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38
24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43
7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61
20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68
1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92
20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108
9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133
18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148
5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183
18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207
3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325
16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363
7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523
14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576
1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785
12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858
1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968
12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087
1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368
12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516
1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792
12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042
1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379
12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676
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 2-3

2.3.1 SAE Fastener Torque Chart (Continued)
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Torque Torque
Torque
Tensile Stress (Loctite® 242TM or 271TM or (Loctite® 262TM or
Size TPI Bolt Dia Clamp Load (Dry or Loctite® 263)
Area Vibra-TITETM 111 or 140) Vibra-TITETM 131)
K=0.20
K=0.18 K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 43 5
10 24 0.1900 0.01750 1580 60 7
32 0.1900 0.02000 1800 68 8
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 770 1045 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625
2-4 6036, 6042, 8042, 10042, 10054

Values for Magni Coating Fasteners (Ref 4150701)

SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque Torque
Torque
Size TPI Bolt Dia Clamp Load (Dry)
K=0.17
K=0.16 K=0.15
4 40 0.1120 0.00604 380 7 0.8
48 0.1120 0.00661 420 8 0.9
6 32 0.1380 0.00909 580 14 1.5
40 0.1380 0.01015 610 14 1.6
8 32 0.1640 0.01400 900 25 2.8
36 0.1640 0.01474 940 26 2.9
10 24 0.1900 0.01750 1120 36 4.1
32 0.1900 0.02000 1285 42 4.7
1/4 20 0.2500 0.0318 2020 86 9.7 80 9
28 0.2500 0.0364 2320 99 11.1 95 11
5/16 18 0.3125 0.0524 3340 15 20 14 19 15 20
24 0.3125 0.0580 3700 15 20 15 21 15 20
3/8 16 0.3750 0.0775 4940 25 35 25 34 25 34
24 0.3750 0.0878 5600 30 40 28 38 25 34
7/16 14 0.4375 0.1063 6800 40 55 40 54 35 48
20 0.4375 0.1187 7550 45 60 44 60 40 54
1/2 13 0.5000 0.1419 9050 65 90 60 82 55 75
20 0.5000 0.1599 10700 75 100 71 97 65 88
9/16 12 0.5625 0.1820 11600 90 120 87 118 80 109
18 0.5625 0.2030 12950 105 145 97 132 90 122
5/8 11 0.6250 0.2260 14400 130 175 120 163 115 156
18 0.6250 0.2560 16300 145 195 136 185 125 170
3/4 10 0.7500 0.3340 21300 225 305 213 290 200 272
16 0.7500 0.3730 23800 255 345 238 324 225 306
7/8 9 0.8750 0.4620 29400 365 495 343 466 320 435
14 0.8750 0.5090 32400 400 545 378 514 355 483
1 8 1.0000 0.6060 38600 545 740 515 700 480 653
12 1.0000 0.6630 42200 600 815 563 765 530 721
1 1/8 7 1.1250 0.7630 42300 675 920 635 863 595 809
12 1.1250 0.8560 47500 755 1025 713 969 670 911
1 1/4 7 1.2500 0.9690 53800 955 1300 897 1219 840 1142
12 1.2500 1.0730 59600 1055 1435 993 1351 930 1265
1 3/8 6 1.3750 1.1550 64100 1250 1700 1175 1598 1100 1496
12 1.3750 1.3150 73000 1420 1930 1338 1820 1255 1707
1 1/2 6 1.5000 1.4050 78000 1660 2260 1560 2122 1465 1992
12 1.5000 1.5800 87700 1865 2535 1754 2385 1645 2237
6036, 6042, 8042, 10042, 10054 2-5


SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Torque Torque
Torque
Size TPI Bolt Dia Clamp Load (Dry or Loctite® 263)
K=0.17
K=0.16 K=0.15
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 37 4
10 24 0.1900 0.01750 1580 51 6
32 0.1900 0.02000 1800 58 7
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
2-6 6036, 6042, 8042, 10042, 10054


SOCKET HEAD CAP SCREWS
Torque Torque
Tensile Stress Clamp Load Torque (Loctite® 242TM or 271TM or (Loctite® 262TM or
Size TPI Bolt Dia
Area See Note 4 (Dry) K=0.17 Vibra-TITETM 111 or 140) or Vibra-TITETM 131)
Precoat® 85 K=0.16 K=0.15
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 415 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
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 2-7

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

SOCKET HEAD CAP SCREWS
Torque Torque
Tensile Stress Clamp Load Torque (Loctite® 242TM or 271TM or (Loctite® 262TM or
Size TPI Bolt Dia
Area See Note 4 (Dry) K=0.17 Vibra-TITETM 111 or 140) or Vibra-TITETM 131)
Precoat® 85 K=0.16 K=0.15
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 415 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
2-8 6036, 6042, 8042, 10042, 10054

2.3.2 Metric Fastener Torque Chart

CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS
Torque Torque
Tensile Stress Clamp Load Torque (Loctite® 262TM or (Loctite® 242TM or
Size Pitch Torque (Lub)
Area See Note 4 (Dry or Loctite® 263TM) 271TM or 271TM or Vibra-TITETM
Vibra-TITETM 131) 111 or 141)
Sq mm KN [N.m] [N.m] [N.m]

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4
3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3
4 0.7 8.78 3.82 3.1 2.3 2.8 3.4
5 0.8 14.20 6.18 6.2 4.6 5.6 6.8
6 1 20.10 8.74 11 7.9 9.4 12
7 1 28.90 12.6 18 13 16 19
8 1.25 36.60 15.9 26 19 23 28
10 1.5 58.00 25.2 50 38 45 55
12 1.75 84.30 36.7 88 66 79 97
14 2 115 50.0 140 105 126 154
16 2 157 68.3 219 164 197 241
18 2.5 192 83.5 301 226 271 331
20 2.5 245 106.5 426 320 383 469
22 2.5 303 132.0 581 436 523 639
24 3 353 153.5 737 553 663 811
27 3 459 199.5 1080 810 970 1130
30 3.5 561 244.0 1460 1100 1320 1530
33 3.5 694 302.0 1990 1490 1790 2090
36 4 817 355.5 2560 1920 2300 2690
42 4.5 1120 487.0 4090 3070 3680 4290
6036, 6042, 8042, 10042, 10054 2-9

2.3.2 Metric Fastener Torque Chart (Continued)

CLASS 10.9 METRIC (HEX HEAD) BOLTS,
CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*
Torque
Torque
Torque (Lub or Loctite®
Tensile Stress Clamp Load (Loctite® 262TM or
Size Pitch (Dry or Loctite® 263TM) 242TM or 271TM or
Area See Note 4 Vibra-TITETM 131)
K=0.20 Vibra-TITETM 111 or 140)
K=0.15
K=0.18
3 0.5 5.03 3.13
3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5
7 1 28.90 18.0 25 23 19
8 1.25 36.60 22.8 37 33 27
10 1.5 58.00 36.1 70 65 55
12 1.75 84.30 52.5 125 115 95
14 2 115 71.6 200 180 150
16 2 157 97.8 315 280 235
18 2.5 192 119.5 430 385 325
20 2.5 245 152.5 610 550 460
22 2.5 303 189.0 830 750 625
24 3 353 222.0 1065 960 800
27 3 459 286.0 1545 1390 1160
30 3.5 561 349.5 2095 1885 1575
33 3.5 694 432.5 2855 2570 2140
36 4 817 509.0 3665 3300 2750
42 4.5 1120 698.0 5865 5275 4395
2-10 6036, 6042, 8042, 10042, 10054

Values for Magni Coated Fasteners (Ref 4150701)*

CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS
Torque Torque
Torque (Lub or Loctite® (Loctite® 262TM or
Tensile Stress Clamp Load
Size Pitch (Dry or Loctite® 263TM) 242TM or 271TM or Vibra-TITETM 131)
Area See Note 4
K=0.17 Vibra-TITETM 111 or 140) K=0.15
K=0.16
3 0.5 5.03 2.19 1.1 1.1 1.0
3.5 0.6 6.78 2.95 1.8 1.7 1.5
4 0.7 8.78 3.82 2.6 2.4 2.3
5 0.8 14.20 6.18 5.3 4.9 4.6
6 1 20.10 8.74 9 8.4 7.9
7 1 28.90 12.6 15 14 13
8 1.25 36.60 15.9 22 20 19
10 1.5 58.00 25.2 43 40 38
12 1.75 84.30 36.7 75 70 66
14 2 115 50.0 119 110 105
16 2 157 68.3 186 175 165
18 2.5 192 83.5 256 240 225
20 2.5 245 106.5 362 340 320
22 2.5 303 132.0 494 465 435
24 3 353 153.5 627 590 555
27 3 459 199.5 916 860 810
30 3.5 561 244.0 1245 1170 1100
33 3.5 694 302.0 1694 1595 1495
36 4 817 355.5 2176 2050 1920
42 4.5 1120 487.0 3477 3275 3070
6036, 6042, 8042, 10042, 10054 2-11

Values for Magni Coated Fasteners (Ref 4150701)*

CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS,
CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE*
Torque
Torque
Torque (Lub or Loctite®
Tensile Stress Clamp Load See (Loctite® 262TM or
Size Pitch (Dry or Loctite® 263TM) 242TM or 271TM or
Area Note 4 Vibra-TITETM 131)
K=0.17 Vibra-TITETM 111 or 140)
K=0.15
K=0.18
3 0.5 5.03 3.13
3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5 13 12 11
7 1 28.90 18.0 21 20 19
8 1.25 36.60 22.8 31 29 27
10 1.5 58.00 36.1 61 58 55
12 1.75 84.30 52.5 105 100 95
14 2 115 71.6 170 160 150
16 2 157 97.8 265 250 235
18 2.5 192 119.5 365 345 325
20 2.5 245 152.5 520 490 460
22 2.5 303 189.0 705 665 625
24 3 353 222.0 905 850 800
27 3 459 286.0 1315 1235 1160
30 3.5 561 349.5 1780 1680 1575
33 3.5 694 432.5 2425 2285 2140
36 4 817 509.0 3115 2930 2750
42 4.5 1120 698.0 4985 4690 4395
2-12 6036, 6042, 8042, 10042, 10054

2.3.3 Hydraulic Hose Torque Chart Flats Method:

1. If equipped, lubricate o-ring with hydraulic oil. Hand
O-Ring Face Seal & JIC Torque Chart tighten the swivel nut until no lateral movement of
the swivel nut can be detected. Average hand torque
Size ORFS JIC Flats Method
is 3 lb-ft (4 Nm).
13 lb-ft 13 lb-ft 2. Mark a dot on one of the swivel nut flats and another
4 1.5 to 1.75
(18 Nm) (18 Nm) dot in line on the hex of the adapter it’s connecting
23 lb-ft 23 lb-ft to.
6 1 to 1.5
(31 Nm) (31 Nm) 3. Use the double wrench method while tightening to
40 lb-ft 40 lb-ft avoid hose twist.
8 1.5 to 1.75
(54 Nm) (54 Nm) 4. After the connection has been properly tightened,
mark a straight line across the connecting parts, not
60 lb-ft 60 lb-ft
10 1.5 to 1.75 covering the dots indicating that the connection has
(81 Nm) (81 Nm)
been properly tightened.
74 lb-ft 85 lb-ft
12 1.0 to 1.5
(100 Nm) (115 Nm)
115 lb-ft 115 lb-ft
16 0.75 to 1.0
(156 Nm) (156 Nm)
170 lb-ft 170 lb-ft
20 0.75 to 1.0
(230 Nm) (230 Nm)
200 lb-ft 200 lb-ft
24 0.75 to 1.0
(271 Nm) (271 Nm)
270 lb-ft
32 N/A 0.75 to 1.0
(366 Nm)
Note: By definition the “Flats Method” will contain some

variance. Use the “Flats Method” only when accessibility
with a torque wrench is not possible.
Torque Wrench:
1. Identify the appropriate application and refer to the
above chart for the correct torque value.
2. If equipped, lubricate o-ring with hydraulic oil. Hand
tighten the swivel nut until no lateral movement of
the swivel nut can be detected. Average hand torque
is 3 lb-ft (4 Nm).
3. Use the double wrench method while tightening to
avoid hose twist.
4. Torque wrench must be held at the center of the grip.
Apply constant force until it clicks.
5. After the connection has been properly tightened,
mark a straight line across the connecting parts
indicating that the connection has been properly
tightened.
6036, 6042, 8042, 10042, 10054 2-13

2.4 SPECIFICATIONS
2.4.1 Travel Speeds
6036 & 6042 8042 10042 & 10054

First Gear 3.3 mph (5,3 km/hr) 3.4 mph (5,5 km/hr) 3.5 mph (5,6 km/hr)
Second Gear 5.5 mph (8,9 km/hr) 5.6 mph (9,0 km/hr) 5.8 mph (9,3 km/hr)
Third Gear 13.8 mph (22 km/hr) 14.1 mph (23 km/hr) 14.5 mph (23 km/hr)
Fourth Gear 19.1 mph (31 km/hr) 19.9 mph (32 km/hr) 20.5 mph (33 km/hr)
2.4.2 Hydraulic Cylinder Performance

Note: Machine with no attachment or load, engine at full throttle, hydraulic oil above 130° F (54° C) minimum, engine
at operating temperature.
APPROXIMATE TIMES (seconds)

FUNCTION
6036 6042 8042 10042 10054
Boom Extend Less than 15.0 Less than 19.0 Less than 19.0 Less than 19.0 Less than 19.0
Boom Retract Less than 15.0 Less than 19.0 Less than 17.0 Less than 17.0 Less than 17.0
Boom Lift Retracted Less than 15.0 Less than 17.0 Less than 17.5 Less than 17.5 Less than 17.5
Boom Lower Retracted Less than 10.0 Less than 13.0 Less than 15.5 Less than 15.5 Less than 15.5
Attachment Tilt - Up 4.0–6.0 6.5 Less than 8.0 Less than 8.0 Less than 8.0
Attachment Tilt - Down 3.5–5.5 6.0 Less than 11.0 Less than 11.0 Less than 11.0
Frame Level Left to
3.0–6.0 12.0–15.0 12.0–15.0 12.0–15.0 12.0–15.0
Right with Boom Down
Frame Level Left to Right
with Boom Above 40°
— 23.0–3.03 23.0–33.0 23.0–33.0 23.0–33.0
and Emergency Brake
Engaged
Frame Level Right to
4.0-8.0 12.0–15.0 12.0–15.0 12.0–15.0 12.0–15.0
Left with Boom Down
Frame Level Right to Left
with Boom Above 40°
— 26.0–52.0 26.0–52.0 26.0–52.0 26.0–52.0
and Emergency Brake
Engaged
Outrigger - Left or Right,
— — — 4.0–9.0 4.0–9.0
UP or DOWN
Outrigger - Left and
— — — 4.0–10.0 4.0–10.0
Right, UP or DOWN
2-14 6036, 6042, 8042, 10042, 10054

2.4.3 Electrical System
Battery
Type, Rating 12 BCI, Negative (-) Ground, Maintenance Free
Quantity 3.3 Liter—1, 4.5 Liter - 2
Cold Cranking Amps 3.3 Liter—950 CCA @ 0° F (-18° C) If equipped for ULS
3.3 Liter—700 CCA @ 0° F (-18° C) if equipped for LS
Reserve Capacity 205 Minutes @ 80° F (27° C) If equipped for ULS
180 Minutes @ 80° F (27° C) if equipped for LS
Group/Series Group 31
Alternator 12V, 120 Amps
2.4.4 Engine Performance Specifications
Description 6036 & 6042 6036 & 6042

If Equipped for ULS If Equipped for LS
Engine Make/Model Cummins Turbo QSB3.3 Cummins Turbo QSB3.3
3
Displacement 199 in (3,3 liters) 199 in3 (3,3 liters)
Low Idle (no load) 1100 rpm 1100 rpm
High Idle (no load) 2600 rpm 2600 rpm
Horsepower 85 hp (63 Kw) @ 2600 rpm 99 hp (74 Kw) @ 2600 rpm
Peak Torque 277 lb-ft (375 Nm) @ 1600 rpm 306 lb-ft (415 Nm) @ 1600 rpm
Fuel Delivery Fuel Injection
Air Cleaner Dry Type, Replaceable Primary and Safety Elements
Description 8042, 10042 & 10054 8042, 10042 & 10054

If Equipped for ULS If Equipped for LS
Engine Make/Model Cummins Turbo QSB3.3 Cummins Turbo QSB3.3
Displacement 199 in3 (3,3 liters) 199 in3 (3,3 liters)
Low Idle 1100 rpm 1100 rpm
High Idle 2600 rpm 2600 rpm
Horsepower 100 hp (74 Kw) @ 2600 rpm 110 hp (82 Kw) @ 2400 rpm
Peak Torque 305 lb-ft (414 Nm) @ 1600 rpm 306 lb-ft (415 Nm) @ 1600 rpm
Fuel Delivery Fuel Injection
Air Cleaner Dry Type, Replaceable Primary and Safety Elements
6036, 6042, 8042, 10042, 10054 2-15

2.4.5 Tires
Note: Standard wheel lug nut torque is 430–470 lb-ft (583–637 Nm).
Note: Pressure for foam filled tires are for initial fill ONLY.
a. 6036
Size Tire Type Minimum Ply/ Fill Type Pressure

Star Rating
Pneumatic 55 psi (3,8 bar)
13.0 x 24 G-2/L-2 Bias Ply Traction 12 Ply
Foam - Approx 542 lb (246 kg) 65 psi (4,5 bar)
13.0 x 24 Solid Tires
370/75x28 DuraForce 14 Ply
Foam-Approx 464 lb (210 kg) 73 psi (5,0 bar)
b. 6042

Star Rating
13.0 x 24 Solid Tires
c. 8042

Star Rating
d. 10042 & 10054

Star Rating
2-16 6036, 6042, 8042, 10042, 10054

2.5 FLUID SPECIFICATIONS

If Equipped for ULS
Ambient
Temperature Range
Compartment or System Type and Classification Viscosities
°F °C
Min Max Min Max
SAE 0W-30 -20 0 -29 -18
SAE 5W-30 -15 70 -26 21
Engine Crankcase API CJ-4 Plus
SAE 10W-30 -9 70 -22 21
SAE 15W-40 5 120 -15 49
Transmission and Transfer Case Mobilfluid 424 10W-30 15 120 -10 49
Axle Differential and Wheel End MobilFluid 424 10W-30 15 120 -10 49
MobilFluid 424 10W-30 15 120 -10 49
Hydraulic System MobilFluid DTE-13 32 -8 80 -21 27
Exxon Univis HVI 26 -20 120 -29 49
Boom Wear Pad Grease Mystik Tetrimoly NLGI Grade 2 -4 104 -20 40
Cylinder and Axle Grease Multipurpose Grease NLGI Grade 2 -22 104 -30 40
Boom Chain Lubricant Schaffer 200S Silver Streak
Ethylene Glycol 50/50 Mix Standard
Engine Coolant
and Water 60/40 Mix Cold Weather
#2 Diesel
Standard
B20 Biodiesel
Ultra Low Sulfur
Fuel Blend of #1 diesel and #2 diesel fuels (S ≤ 15 mg/kg)
(“winterized” #2) Cold Weather
B20 Biodiesel with Winter Conditioner
6036, 6042, 8042, 10042, 10054 2-17

If Equipped for LS
Ambient
Temperature Range
Compartment or System Type and Classification Viscosities
°F °C
Min Max Min Max
SAE 0W-30 -20 0 -29 -18
SAE 5W-30 -15 70 -26 21
Engine Crankcase API CI-4 Multigrade
SAE 10W-30 -9 70 -22 21
SAE 15W-40 5 120 -15 49
Transmission and Transfer Case Mobilfluid 424 10W-30 15 120 -10 49
Axle Differential and Wheel End MobilFluid 424 10W-30 15 120 -10 49
MobilFluid 424 10W-30 15 120 -10 49
Hydraulic System MobilFluid DTE-13 32 -8 80 -21 27
Exxon Univis HVI 26 -20 120 -29 49
Boom Wear Pad Grease Mystik Tetrimoly NLGI Grade 2 -4 104 -20 40
Cylinder and Axle Grease Multipurpose Grease NLGI Grade 2 -22 104 -30 40
Boom Chain Lubricant Schaffer 200S Silver Streak
Ethylene Glycol 50/50 Mix Standard
Engine Coolant
and Water 60/40 Mix Cold Weather
#2 Diesel
Standard
B20 Biodiesel
Low Sulfur
Fuel Blend of #1 diesel and #2 diesel fuels (S ≤ 500 mg/kg)
(“winterized” #2) Cold Weather
B20 Biodiesel with Winter Conditioner
2-18 6036, 6042, 8042, 10042, 10054

2.6 FLUID AND LUBRICANT CAPACITIES
Engine Crankcase Oil

Capacity w/Filter Change 7.6 quart (7,2 liter)
Fuel Tank
Capacity 35.6 gallon (135 liter)
Cooling System
System Capacity
If equipped for ULS 3.8 gallon (14,4 liter)
If equipped for LS 4.0 gallon (15,1 liter)
Hydraulic System
System Capacity
6036 & 6042 57 gallon (216 liter)
8042 58 gallon (218 liter)
10042 & 10054 64 gallon (242 liter)
Reservoir Capacity to Full Mark 32 gallon (122 liter)
Transmission
Capacity with Filter Change 12.5 quart (11,8 liter)
Transfer Case
Capacity 2.1 quarts (2,0 liters)
Axles
Differential Housing Capacity 11.2 quart (10,6 liter)
Wheel End Capacity
6036, 6042 & 8042 1.85 quart (1,75 liter)
10042 &10054
Front Axle 2.2 quart (2,08 liter)
Rear Axle 1.85 quart (1,75 liter)
6036, 6042, 8042, 10042, 10054 2-19

2.7 SERVICE AND

MAINTENANCE SCHEDULES
2.7.1 10 & 1st 50 Hour
EVERY
10
Check Fuel Drain Fuel/ Air Filter Check Engine Check Hydraulic
Level Water Seprator Restriction Oil Level Oil Level
Indicator
Check Tire Check Check Engine

Condition & Transmission Coolant Level
Pressure Oil Level
1st
50
LB/F
T (N
m)
Change Change Check Wheel Check Boom

Transmission Hydraulic Lug Nut Chain Tension
Filter Filter Torque
MAQ0850
2-20 6036, 6042, 8042, 10042, 10054

2.7.2 50, 250 & 1st 500 Hour
EVERY
50
Check Boom Check Check Washer Lubrication

Wear Pads Battery Fluid Level Schedule
(if equipped)
EVERY
250
Change Engine Check Axle Check Wheel Change Air Check Boom
Oil and Oil Level End Oil Levels Filter Elements Chain
Filter*
Lubrication
Schedule
1st
500
Change Change Wheel

Axle Oil End Oil
OH4800
Note: Engine oil and filter service interval can be extended. See Engine Manual for details.
6036, 6042, 8042, 10042, 10054 2-21

2.7.3 500 & 1000 Hour
EVERY
500
LB/F
T (N
m)
Change Fuel Check Wheel

Filters Lug Nut
Torque
EVERY
1000
P
Change Change Change Change Wheel Check Axle

Transmission Hydraulic Axle Oil End Oil Brake Discs
Oil & Filter Fluid & Filters
Check Boom Check Boom Check Check Air Lubrication

Chain Tension Wear Pads Fan Belt Intake System Schedule
Lubricate
Boom Chain
OH4970
2-22 6036, 6042, 8042, 10042, 10054

2.7.4 2000 Hour
EVERY
1500
Change Crankcase
Vent Filter
(if equipped for ULS)
EVERY
2000
Change Engine
Engine Coolant Valve Lash
Adjustment
OH4961
Note: Valve Lash adjustment for QSB 3.3 engine ONLY. See Engine Manual for details.
6036, 6042, 8042, 10042, 10054 2-23

2.8 LUBRICATION SCHEDULES
2.8.1 50 Hour
a. 6036, 6042, 8042 & 10042
2-24 6036, 6042, 8042, 10042, 10054

EVERY
50
OH4162
6036, 6042, 8042, 10042, 10054 2-25

b. 10054
EVERY
50
OH4242
2-26 6036, 6042, 8042, 10042, 10054

2.8.2 250 Hour
a. 6036 & 6042
EVERY
250
6042 ONLY
OA1820
6036, 6042, 8042, 10042, 10054 2-27

b. 8042, 10042 & 10054
EVERY
250
OH4172
2-28 6036, 6042, 8042, 10042, 10054

2.8.3 1000 Hour
EVERY
1000
OH4181
6036, 6042, 8042, 10042, 10054 2-29

This Page Intentionally Left Blank
2-30 6036, 6042, 8042, 10042, 10054

Section 3
Boom
Contents

3.1 Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 Boom System - Three Section (6036, 6042, 8042 & 10042) . . . . . . . . . . . . . . . . . 3-4
3.3.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4.2 Third Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4.3 Second Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.4.4 First Boom Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.4.5 First Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.4.6 Second Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.4.7 Third Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.4.8 Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.5 Boom System - Four Section (10054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.5.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.6 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.6.1 Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.6.2 Third Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.6.3 Second Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.6.4 First Boom Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.6.5 First Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.6.6 Second Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.6.7 Third Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.6.8 Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.7 Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3.7.1 Boom Chain Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3.7.2 Inspection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3.7.3 Expose Chains for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.7.4 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.7.5 Boom Chain Tension Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3.7.6 Boom Chain Tension Adjustment (6036, 6042, 8042 & 10042) . . . . . . . . 3-32
3.7.7 Boom Chain Tension Adjustment (10054). . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3.7.8 Extend Chains Removal and Replacement (6036, 6042, 8042 & 10042). 3-37
3.7.9 Retract Chain Removal and Replacement (6036, 6042, 8042 & 10042) . 3-39
3.7.10 Extend Chains Removal and Replacement (10054) . . . . . . . . . . . . . . . . . 3-40
3.7.11 Retract Chain Removal and Replacement (10054) . . . . . . . . . . . . . . . . . 3-43
6036, 6042, 8042, 10042, 10054 3-1

Boom
3.8 Quick Attach Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

3.8.1 Quick Attach Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3.8.2 Quick Attach Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3.9 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3.9.1 Wear Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3.9.2 Wear Pad Installation and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3.10 Forks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
3.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
3-2 6036, 6042, 8042, 10042, 10054

Boom
3.1 BOOM SYSTEM COMPONENT

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

THIRD BOOM BOOM EXTEND CHAIN SECTION
SECTION
SECTION CHAINS
BOOM
PROXIMITY
EXTEND/RETRACT SENSOR
CYLINDER
COMPENSATION
CYLINDER
ATTACHMENT
TILT CYLINDER LIFT/LOWER
CYLINDER
QUICK ATTACH
FOUR SECTION BOOM (10054)
SECOND & THIRD THIRD BOOM

FOURTH BOOM BOOM SECTION SECTION
SECOND BOOM FIRST BOOM
SECTION EXTEND EXTEND CHAINS
SECTION SECTION
CHAIN FOURTH BOOM
SECTION RETRACT SECOND & THIRD
FOURTH BOOM CHAIN BOOM SECTION
SECTION RETRACT CHAIN
BOOM BOOM
PROXIMITY PROXIMITY
SENSOR SENSOR
EXTEND/RETRACT
CYLINDER
COMPENSATION
ATTACHMENT CYLINDER
TILT CYLINDER LIFT/LOWER
CYLINDER
MH4351
QUICK ATTACH
6036, 6042, 8042, 10042, 10054 3-3

Boom
3.2 SAFETY INFORMATION
WARNING WARNING
NEVER weld or drill the boom unless approved in
DO NOT service the machine without following all writing by the manufacturer. The structural integrity of
safety precautions as outlined in the “Safety the boom will be impaired if subjected to any repair
Practices” section of this manual. involving welding or drilling.
3.3 BOOM SYSTEM - THREE SECTION 3.4.1 Boom Removal

(6036, 6042, 8042 & 10042) 1. Remove any attachment from quick attach assembly.
Note: If replacing the third section boom, remove the
3.3.1 Boom System Operation
quick attach from the third section. Refer to Section
The three section boom assembly consists of first, 3.8.1, “Quick Attach Removal.”
second and third boom section assemblies with double
2. Park the machine on a hard, level surface, level the
top boom extend chains and a single retract chain. Boom
machine, fully retract the boom, lower the boom,
extension and retraction is accomplished via hydraulic
place the transmission control lever in
power and chain movement.
(N) NEUTRAL, engage the park brake and shut the
As the Extend/Retract hydraulic cylinder, which is engine OFF.
anchored at the rear of the second boom section and the
3. Place a Do Not Operate Tag on both the ignition key
rear of the first boom section, begins to extend, it forces
switch and the steering wheel, stating that the
the second boom section out of the first boom section.
machine should not be operated.
The second and third boom sections are connected by
4. Open the rear door. Allow the system fluids to cool.
extend and retract chains. These chains are routed
around sheaves on the second boom section. As the 5. Move the Attachment Tilt joystick in both directions
second boom section is forced out, the extend chain pulls to relieve any trapped pressure in the Attachment Tilt
the third boom section out of the second boom section. system. If the machine is equipped with Auxiliary
controls, move the Auxiliary hydraulic joystick in both
As hydraulic pressure is applied to the retract port on the
directions to relieve any trapped pressure in the
Extend/Retract cylinder, the second boom section is
Auxiliary hydraulic system.
pulled back into the first boom section, and retract chain
pulls the third boom section back into the second section. 6. Properly disconnect the battery.
This mechanical linkage formed by the chains and 7. Label, disconnect and cap the hydraulic hoses at the
supporting hardware extends and retracts the second rear of the boom. Cap all fittings to keep dirt and
and third boom sections at the same rate. debris from entering the hydraulic system.
The first boom section does not extend or retract, but lifts 8. Label and disconnect the boom proximity sensor at
and lowers via action of the lift/lower cylinder. the rear of the boom.
9. Remove the pin from the rod end of the
3.4 BOOM ASSEMBLY MAINTENANCE compensation cylinder being careful not to drop the
cylinder. Lower the cylinder onto the frame rails.
These instructions must be completed in sequence. The
10. Remove the pin from the rod end of the lift/lower
third boom section must be removed before removing the
cylinders. Lower the cylinders onto the frame rails.
second boom section. The third and second boom
section must be removed at one time before removing the 11. Confirm that the boom assembly is balanced with
first boom section. the sling and remove the boom assembly
pivot pin.
Before beginning, conduct a visual inspection of the
machine and work area, and review the task about to be 12. Lift the boom assembly from the machine and lower
undertaken. Read, understand and follow these onto suitable supports
instructions.
3-4 6036, 6042, 8042, 10042, 10054

Boom
3.4.2 Third Boom Section Removal

1. Remove any attachment from quick attach assembly.
1 2
Note: If replacing the third section boom, remove the
quick attach from the third section. Refer to Section
3.8.1, “Quick Attach Removal.”
engine OFF.
MH2841
11. Remove the stack clamps (1) and hose clamp
5. Move the Attachment Tilt joystick in both directions
support bracket (2) to the left side of the third boom
to relieve any trapped pressure in the Attachment Tilt
section.
system. If the machine is equipped with Auxiliary
6. Label, disconnect and cap the hoses attached to the
Attachment Tilt cylinder. Cap all fittings to keep dirt
and debris from entering the hydraulic system.
7. If the machine is equipped with Auxiliary hydraulics, 3
label, cap and remove the hoses from the bulkhead
fittings.
8. If replacing the third boom section with a new boom
section: Remove the female coupler, male nipple
and bulkhead fittings from the bulkhead plate inside
the boom head.
9. Remove the rear cover from the boom.
10. If equipped with Auxiliary hydraulics, inside the third
boom section, loosen, but DO NOT remove the
capscrews securing the left side wear pad and hose MH0871
clamp support bracket to the top of the third boom
section. 12. Pull the free ends of the hydraulic hoses (3) from the
inside the third boom section and out of the rear of
the boom. 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 3-5

Boom
4 6
MH0912
MH2551
14. At the rear of the boom, measure the amount of
threads protruding beyond each locknut (4) and
Note: Record the location of the shoulder bolt (6) to
record the measurement for reassembly. Remove
ensure correct installation.
the two locknuts and flat washers holding both
extend chain clevis’ to the anchor plate on the first 16. At the rear of the boom, locate the retract chain (7)
boom section. on the right side of the boom. In front of the retract
chain sheave, locate the shoulder bolt which holds
the retract chain to the anchor plates on the third
boom section. Remove the locknut from the shoulder
bolt. Allow the retract chain to hang out the rear of
the boom.
Note: If replacing the third boom section with a new
5 boom section, the quick attach assembly and the
Attachment Tilt cylinder should be removed at this time.
Refer to Section 3.8.1, “Quick Attach Removal.”.
If the third boom section is not to be replaced, the quick

attach assembly and Attachment Tilt cylinder can remain
in place.
MH0921
17. Using a sling or suitable support, pull the third boom
15. At the front of the second boom section, pull both section straight out of the second boom section.
extend chains (5) out from between the second and Reposition the slings as needed so the third boom
third boom sections. The extend chains can remain section balances when removed from the second
anchored between the yoke plates on the first boom boom section. Set the boom section down on a hard,
section. Loop both chains over the top of the chain level surface. Support the boom as needed to
sheave and lay the chains on top of the boom. prevent it from tipping over.
18. At the rear of the third boom section, remove the
remaining wear pads, shims and hardware. Label
and tag each set of wear pads being removed.
19. Inspect all wear pads for wear. Refer to Section 3.9,
“Boom Wear Pads.”
3-6 6036, 6042, 8042, 10042, 10054

Boom
3.4.3 Second Boom Section Removal Reassemble the capscrews, lockwashers and flat
washers to hold the lower wear pad in place for
1. At the front of the first boom section, remove the top,
second boom section removal.
bottom and side wear pads to the inside of the
boom. Label and tag each set of wear pads being 7. Remove hose reel side plate, lower left side wear
removed. pad and shims. Label and tag each set of wear pads
being removed.
2. Remove the capscrews and lockwashers holding the
center wear pad spacer mount to the front of the first 8. Pull the hose reel, with hoses, out the back of the
boom section. Label and tag each set of wear pads second boom section. Allow the hose reel assembly
being removed. to slide down the hoses and rest it on the floor.
9. Label and remove the hoses from the hose reel. The
center bolt can remain in place to hold the hose reel
and side plates together.
10
MH1021
MH1451
3. At the rear of the second boom section, remove the

10. Label, disconnect and cap the hydraulic hoses from
capscrew and lockwasher holding the retract chain
the bottom tube assemblies at the mounting plate
sheave pin (8) to the mounting plate inside the
(10).
boom.
11. Pull the hose ends out from between the second and
4. Remove the retract chain sheave pin from the mount
first boom sections and out the rear of the boom.
and the retract chain sheave. Remove the retract
chain sheave from the second boom section. 12. Using a suitable sling or support, secure the front of
the Extend/Retract cylinder.
5. Inspect the bushings inside the sheave. Replace the
bushings if there are any signs of wear. Inspect the
pin for wear or damage. Replace the pin if showing
signs of wear.
11
9
MH1051
13. Remove the retaining ring from one side of the

MH1501
Extend/Retract cylinder rod end mounting pin (11).
6. At the rear of the second boom section, remove the 14. Using a sling or suitable support, pull the second
hose reel assembly (9), lower wear pad and spacer. boom section straight out of the first boom section.
6036, 6042, 8042, 10042, 10054 3-7

Boom
Reposition the slings as needed so the second

boom section balances when removed from the first
boom section. Set the second boom section down
14
on blocks on a hard, level surface.
15. Remove the remaining wear pads. Label and tag
each set of wear pads being removed.
MH1131
4. Label, disconnect and cap the hydraulic hoses from

the bulkhead fittings on the mounting plate (14).
Remove the tubes from the bulkhead fittings.
5. At the rear right side of the boom, label, disconnect
and cap the boom Extend/Retract hoses from the
12
bulkhead fittings on the mounting plate. Cap the
fittings to keep dirt and debris from entering the
hydraulic system.
16
MH1091
17. Remove the extend chain sheave (12).

15
3.4.4 First Boom Section Removal
1. Use a suitable overhead lifting device and sling
attached to the Lift/Lower cylinder; remove slack
from the sling.
MH1151
6. Remove the tube clamps (15) and clamp covers to

the Extend and Retract tubes under the boom.
7. At the rear right side of the boom, label, disconnect
and cap the Extend and Retract tubes (16) from the
bulkhead fittings. Cap the fittings to keep dirt and
debris from entering the hydraulic system.
13
MH1111
2. At the underside of the boom, locate the retract

chain locknut (13). Measure the amount of threads
protruding beyond the locknut and record that
17
measurement for reassembly of the chain. 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 MH1201
surface.
3-8 6036, 6042, 8042, 10042, 10054

Boom
8. Label, disconnect and cap the hydraulic hoses 15. Lower the base end of the Extend/Retract cylinder
attached to both compensation cylinders (17). Cap and remove the rod end of the cylinder from the
all fittings to keep dirt and debris from entering the retainer at the front of the boom. Place the Extend/
hydraulic system. Retract cylinder on a clean, flat surface.
9. Support the compensation cylinder on the right side 16. At the front of the first boom section, remove rubber
of the machine. Remove the rod end pins securing bumper to the Extend/Retract cylinder retainer.
the cylinder in position. Move the cylinder to a clean, Inspect the rubber bumper. If it is in good condition,
flat surface. Repeat this procedure for the left side the rubber bumper can be reused. If the bumper is
compensation cylinder. showing signs of cracking or deterioration, it should
be replaced.
17. Remove the two yoke plates to the mount at the front
of the boom. Inspect the yoke plates for wear or
distortion. If any wear or distortion is detected, both
plates must be replaced. If no wear is detected, the
plates can remain assembled to the extend chain
clevis.
18
3.4.5 First Boom Section Installation

MH1221
1. On the rear of the boom, assemble the Extend and
10. Remove the boom proximity sensor (18) from the Retract bulkhead fittings to the mounting plate on the
right side boom pivot mounting plate. right side. Insert the fittings from the bottom up and
11. Securely block up or support the right Lift/Lower secure in place with the bulkhead fitting nuts on the
cylinder. Remove the rod end pin. Repeat this top side. Tighten securely. Repeat this procedure for
procedure for the left Lift/Lower cylinder. the Attachment Tilt fittings on the left side.
Note: Keep the caps on the threaded ends of the fittings
to protect the threads from damage and to keep dirt and
debris from entering the hydraulic system.
19
2. If equipped with Auxiliary hydraulics, assemble the
Auxiliary hydraulic bulkhead fittings to the mounting
plate on the left side. Insert the fittings from the
bottom up into the outer set of holes and secure in
place with the bulkhead fitting nuts on the top side.
Tighten securely.
MH1241 3. Using a sling, position the Extend/Retract cylinder to
its original orientation under the boom.
12. Remove the boom pivot pins (19) to the frame. While
removing the pins, note the location and quantity of 4. Coat the base end of the cylinder with anti-seize
shims between the outer boom and frame. compound. Insert the base end cylinder pin through
both mounting ears and the base end of the Extend/
13. Using a sling or suitable support, carefully lift the first Retract cylinder. Secure the pin in place with a
boom section away from the machine. Set the boom retaining ring on each side of the pin.
section down on a hard, level surface. Support the
boom as required to allow removal of the Extend/ 5. Lift the rod end of the Extend/Retract cylinder
Retract cylinder from the underside of the boom. enough to insert the threaded stud on the rubber
bumper into the hole in the Extend/Retract cylinder
14. Use a hoist and slings to support the Extend/Retract retainer. Secure the rubber bumper in place with a
cylinder. At the base end of the cylinder, remove a locknut. Tighten securely. Lower the rod end of the
retaining ring from one side of the cylinder base end Extend/Retract cylinder, and allow it to rest on the
pin. rubber bumper.
6036, 6042, 8042, 10042, 10054 3-9

Boom
6. Using a suitable hoist and slings, lift the boom 11. Use a hoist or suitable support to position the right
assembly and position the boom on the frame. Align side Compensation cylinder to its original orientation
the mounting plates on the frame between the onto the lower cylinder mount. Coat the entire
mounting hubs on each side of the boom assembly. Compensation cylinder pin with anti-seize
Lower the boom assembly until the holes in the compound. Insert the pin through the rod end of the
boom assembly and the mounting plates align. cylinder and the self-aligning bearing. Secure with
7. On the end of the boom pivot pin, closest to the lockbolt. Repeat procedure for left side
capscrew hole, mark the capscrew mounting hole Compensation cylinder.
location. Coat the entire pin with anti-seize 12. Install the boom proximity sensor on the right side
compound. mounting plate. With the boom properly shimmed,
8. Insert the pivot pin from the outside of the boom position the boom assembly all the way to the right
assembly, making sure the marks for the capscrew side.
mounting hole stay in line with the capscrew 2
mounting holes in the boom mounting hub.
1
20 MH1391
13. Insert the boom proximity sensor through the hole in

the right side mounting plate. Install the jam nut onto
the boom proximity sensor on the inside of the plate.
Adjust the inner and outer jam nuts on the sensor
until the gap (2) between the sensor and the boom is
0.12 in (3 mm). Torque the inside jam nut to 36 lb-in
MH1381 (4,1 Nm), to hold the sensor in position.
9. Shim the boom as required using the shims (20) to

maintain a 0.10” (2,5 mm) maximum gap (1)
between the boom mounting hub and the self 3
aligning bearing in the frame. If an additional shim is
required to maintain the maximum gap, the extra 4
shim MUST be inserted on the right side of the
boom.
10. Align the rod end of the right Lift/Lower cylinder with
the self-aligning bearing on the boom assembly.
Coat the entire Lift/Lower cylinder pin with anti-seize
compound. Insert the pin through the rod end of the
cylinder and the self-aligning bearing. Secure with
lock bolt. Repeat procedure with left Lift/Lower
cylinder. MH1151
14. Install the Extend and Retract tubes (3) to the inside
bulkhead fitting and the Extend/Retract cylinder.
15. Install the Extend and Retract tube clamp halves (4).
3-10 6036, 6042, 8042, 10042, 10054

Boom
16. Uncap and connect the hydraulic hoses and attach 3.4.6 Second Boom Section Installation
to their appropriate cylinder locations.
17. Install the Extend and Retract and Auxiliary (if
equipped) tube assemblies to their appropriate
bulkhead fittings. Secure with tube clamps.
6
18. Uncap and connect the previously labeled
Attachment Tilt and Auxiliary (if equipped) hydraulic
hoses to their appropriate bulkhead fittings.
MH1481
1. At the rear of the second boom section, assemble

the retract chain sheave (6) to the mounting ears on
the right side of the boom. Place the sheave
between the ears and insert the sheave pin from the
left side. Align the hole in the pin retainer plate with
5 the threaded hole in the left ear. Secure the pin.
2. Apply grease to the grease fitting in the pin. Spin the
sheave by hand to ensure the sheave spins freely on
the pin and to distribute grease evenly.
MH1461
19. Inside the rear of the boom, slide the threaded clevis
end (5) of the retract chain down the right side of the
boom. Guide the threaded part of the clevis out
through the hole in the tab on the bottom of the
boom. Pull threaded part of clevis all the way
through tab.
20. Coat the entire threaded portion of the clevis with
multi-purpose grease. Install a flat washer and
locknut onto the clevis. Thread the nut onto the 7
clevis until the threads are flush with the top of the
nut.
21. Install the bottom wear pads to the first boom section MH1501
with the previously used hardware. 3. Install the hose reel assembly (7), left side and
bottom wear pads to the rear of the second boom
section.
4. Install the boom side and top wear pads.
5. Grease the sections of the boom in areas where the
wear pads will slide.
6036, 6042, 8042, 10042, 10054 3-11

Boom
6. Before installing the second boom section into the 3.4.7 Third Boom Section Installation
first boom section, place a string (heavy enough to
pull the Attachment Tilt and Auxiliary hydraulic
0
hoses) down the inside of the boom. Allow the string 6.0 )
19 8 cm
(49
to hang out the rear of the boom. Pull the other end
out the opening on the left side of the boom where
the hoses will exit the boom. Position the strings all
the way to the left side of the first boom section.
7. Using a suitable sling, carefully slide the second
boom section into the first boom section. Leave MH1401
enough room at the front of the boom to install the
center wear pad. 1. Stretch the Attachment Tilt and Auxiliary (if
8. Install the center wear pad mount and wear pad to equipped) hoses out straight on a flat surface.
the bottom front of the first boom section. Measure from the male end of each hose back
196 in (498 cm) and apply tape around each hose at
9. Install the side and top wear pads to the front of the that point. The tape is for proper tensioning of the
first boom section. hoses during reassembly of the hose clamps.
2. Slide the elbow ends of the hoses down the third
boom section and out the boom head. Be careful not
to cross the hoses as you pull them out. Secure the
hoses in place with hose clamps. DO NOT tighten
the hose clamps at this time.
MH1091
10. Install the double extend chain sheave (8) to the

front of the second boom section.
11. With the sling still in place, install the rod end of the
Extend/Retract cylinder, pin and retaining ring. 10
12. Install the front, bottom wear pads in the second
boom section.
MH1631
3. Install the hose clamp support bracket (9) and top

left side wear pad to the third boom section
(Auxiliary hydraulics only).
4. Position the Attachment Tilt and Auxiliary hydraulic
hoses with the edge of the tape at the hose clamps
(10). Hold the hoses in this position, and tighten the
hose clamps.
3-12 6036, 6042, 8042, 10042, 10054

Boom
5. Install the top, bottom and side wear pads to the rear
of the third boom section. If the machine is equipped
with Auxiliary hydraulics, the top left wear pad is
already installed.
11
12
MH1651
MH1691
6. Lay the two extend chains (11) on the top of the third
boom section with the threaded clevis ends toward 12. Assemble the hoses to the hose reel (12) at the rear
the rear of the boom. Coat the threads on each of the boom.
clevis with multi-purpose grease and insert the
Note: Keep the hoses in the same order as they come
clevis’ through the holes in the anchor plate. Install a
from the hose clamps. DO NOT allow the hoses to cross.
washer and locknut onto each clevis. Tighten the
locknut enough so the threads are even with the top 13. Tie the strings (positioned inside the first boom
of the locknut. section) to the male end of the hydraulic hoses
7. At the rear of the third boom section, place the male coming off the bottom of the hose reel assembly.
ends of the hydraulic hoses in the third boom section 14. Working from the front of the boom, pull each hose
to prevent damage while installing the third boom through the boom assembly through the opening at
section into the second boom section. the bottom of the first boom section.
8. Grease the sections of the boom in areas where the 15. Remove the strings from the hoses.
9. Using a suitable sling, carefully slide the third boom
section into the second boom section. Leave enough
room at the front of the boom to install the remaining
wear pads.
10. Install the top and side wear pads to the inside of the
second boom section. 13
11. Pull the male ends of the hydraulic hoses out the
rear of the third boom section. Stretch the hoses out
straight behind the machine.
MH1451
16. At the front of the first boom section, assemble the

hose assemblies and tube assemblies to the
mounting plate (13).
Note: Where the hose assemblies come out of the outer
boom, lubricate the radius in the first boom section with
soap and water to allow proper tensioning of hoses.
17. Place the retract chain up around the retract chain
sheave on the right side of the boom. Stretch the
chain forward and place the clevis between the two
anchor plates. Align the hole in the clevis with the
second hole from the rear of the anchor plates.
6036, 6042, 8042, 10042, 10054 3-13
Boom
18. Insert the shoulder bolt from the top down and 3.4.8 Boom Installation
secure in place with a locknut.
15 machine, fully retract the boom, lower the boom,
engine OFF.
14 2. Using suitable slings, balance the boom assembly,
lift and guide the boom assembly into place. Align
the frame pivot bores with the boom assembly pivot
bores. Install the boom pivot pin.
3. Move the Attachment Tilt joystick in both directions
SH1871 to relieve any trapped pressure in the Attachment Tilt
system. If the machine is equipped with Auxiliary
19. Assemble the two extend chains to the mount if the
yoke plates (14) were removed from the extend
chains. Secure in place with a locknut. Tighten the
locknut securely; but the yoke plates must pivot
freely. 4. With the sling still in place, install the rod end of the
compensation cylinder, pin and bolt. Apply Loctite®
20. Align the holes in the yoke plates with the hole in the
242TM torque lock bolt to 100-110 lb-ft (135-149 Nm).
mount on the first boom section. Coat the shoulder
bolt (15) with anti-seize compound and insert the 5. With the sling still in place, install the rod end of each
shoulder bolt through the yoke plates and the mount lift/lower cylinder, pin and bolt. Apply Loctite® 242TM
on the boom. Secure in place with a locknut. Tighten torque lock bolt to 200-215 lb-ft (271-291 Nm).
the locknut securely; but the yoke plates must pivot 6. Uncap and connect the hydraulic hoses at the rear
freely. of the boom.
21. Install the quick attach and Attachment Tilt cylinder 7. Connect the boom proximity sensor at the rear of the
to the front of the boom. Refer to Section 3.8.2, boom.
“Quick Attach Installation.”
8. Recheck wear pad gaps to ensure they meet the
22. If necessary, install the Auxiliary hydraulic fittings to minimum gap requirement. Shim as necessary.
the front of the boom.
9. Ensure that the boom chains are properly adjusted.
23. Uncap and connect the previously labeled hoses to Refer to Section 3.7.6, “Boom Chain Tension
the Attachment Tilt cylinder. Adjustment (6036, 6042, 8042 & 10042).”
24. Properly connect the battery. 10. Properly connect the battery.
25. Remove the Do Not Operate Tags from both the 11. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel. ignition key switch and the steering wheel.
26. Start the engine and operate all boom functions 12. Start the engine and operate all boom functions
several times. Check the chain tension again and several times. Check for leaks, and check the
adjust as necessary. Check for leaks, and check the hydraulic fluid at the reservoir; add fluid if required.
hydraulic fluid level in the tank; add fluid if required.
27. Clean up all debris, hydraulic fluid, etc., in, on, near
and around the machine.
28. Install the rear cover to the boom.
29. Close and secure the rear door.
3-14 6036, 6042, 8042, 10042, 10054

Boom
3.5 BOOM SYSTEM - FOUR SECTION 3.6.1 Fourth Boom Section Removal
(10054) 1. Remove any attachment from quick attach assembly.
Note: If replacing the fourth section boom, remove the
3.5.1 Boom System Operation quick attach from the fourth section. Refer to Section
The four section boom consists of the fourth, third, 3.8.1, “Quick Attach Removal.”
second and first boom assemblies with double 2. Park the machine on a hard, level surface, level the
intermediate boom extend chains, a single inner boom machine, fully retract the boom, lower the boom,
extend chain, a single inner boom retract chain and a place the transmission control lever in
single intermediate boom retract chain. (N) NEUTRAL, engage the park brake and shut the
As the Extend/Retract hydraulic cylinder, which is engine OFF.
anchored at the front of the second boom section, and the 3. Place a Do Not Operate Tag on both the ignition key
rear of the first boom section begins to extend, it forces switch and the steering wheel, stating that the
the second boom section out of the first boom section. machine should not be operated.
The fourth, third, second and first boom sections are 4. Open the rear door. Allow the system fluids to cool.
connected by extend and retract chains. These chains
are routed around sheaves on the third and second boom 5. Move the Attachment Tilt joystick in both directions
sections. As the second and third boom sections are to relieve any trapped pressure in the Attachment Tilt
forced out, the extend chain pulls the fourth boom section system. If the machine is equipped with Auxiliary
out of the third. controls, move the Auxiliary hydraulic joystick in both
As hydraulic pressure is applied to the retract port on the Auxiliary hydraulic system.
Extend/Retract cylinder, the third boom section is pulled
back into the fourth boom section, and the retract chain 6. Label, disconnect and cap the hoses attached to the
pulls the third and fourth boom sections back into the Attachment Tilt cylinder. Cap all fittings to keep dirt
second boom section. and debris from entering the hydraulic system.
This mechanical linkage formed by the chains and 7. If the machine is equipped with Auxiliary hydraulics,
supporting hardware, extends and retracts the second, label, cap and remove the hoses from the bulkhead
third and fourth boom sections at the same rate. fittings.
If replacing the fourth boom section with a new boom
The first boom section does not extend or retract, but lifts section: Remove the female coupler, male nipple
and lowers via action of the Lift/Lower cylinders. and bulkhead fittings from the bulkhead plate inside
the boom head.
3.6 BOOM ASSEMBLY MAINTENANCE
8. Remove the rear cover from the boom.
These instructions must be completed in sequence. The
fourth boom section must be removed before removing
the third boom section. The third boom section must be
removed before removing the second boom section.The
fourth, third and second boom section must be removed
at one time before removing the first boom section.
Before beginning, conduct a visual inspection of the
16
machine and work area, and review the task about to be
undertaken. Read, understand and follow these
instructions.
MH1451
9. At the front of the first boom section, label and

WARNING remove the hydraulic hoses from the bottom tube
assemblies at the mounting plate (16). Cap the hose
NEVER weld or drill the boom unless approved in
ends.
writing by the manufacturer. The structural integrity of
the boom will be impaired if subjected to any repair
involving welding or drilling.
6036, 6042, 8042, 10042, 10054 3-15

Boom
17
MH1691 MH1791
10. Label and remove the hydraulic hoses from the hose 16. At the front of the boom, disconnect the fourth boom
reel (17). section extend chain clevis (1) from the anchor
plates on the third boom section. Pull the extend
chain clevis from between the plates and lay over the
18 front of the fourth boom section (2).
17. Remove the extend chain sheave.
18. Remove the top and side wear pads on the inside of
19 the third boom section. Label and tag each set of
wear pads being removed.
MH1781
3
11. At the rear of the boom, locate the fourth boom
section extend chain locknut (18). Measure the
amount of threads protruding beyond the locknut
and record the measurement for reassembly.
12. Loosen, but DO NOT remove the locknut.
13. At the rear of the boom, locate the two third boom MH1501
section extend chain locknuts (19). Measure the
amount of threads protruding beyond each locknut 19. At the rear of the boom, remove the hose reel
and record the measurements for reassembly. assembly (3). This requires removal of the bottom
14. Loosen, but DO NOT remove the locknuts. and side wear pads. Reinstall the wear pads for
second boom section removal.
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 6036, 6042, 8042, 10042, 10054

Boom
23. Remove the two capscrews and lockwashers holding

the hose carrier support (7) and the lower wear pad
to the third boom section.
24. Pull the hose carrier support with hose carrier
attached toward the rear of the boom. Reinstall the
capscrews and lockwashers to hold the wear pad in
place. DO NOT fully tighten the capscrews.
4
25. Remove the hose carrier support from the hose
carrier.
Note: If replacing the third boom section with a new
boom section, the quick attach assembly and the
Attachment Tilt cylinder should be removed at this time.
Refer to Section 3.8.1, “Quick Attach Removal.”.
MH2841 26. Using a sling or suitable support, pull the fourth
20. Inside the third boom section, remove the hose boom section straight out of the third boom section.
clamps and hose clamp support bracket (4). Reposition the slings as needed so the fourth boom
section balances when removed from the third boom
21. Return to the cab, start the engine and fully retract
section. Set the boom section down on a hard, level
the boom slowly. Shut the engine OFF.
surface. Support the boom as needed to prevent it
Note: Record the location of the shoulder bolt to ensure from tipping over.
correct installation.
5 8
6 MH1871
27. At the rear of the boom section, remove the extend

chain clevis (8) from the extend chain clevis anchor.
28. At the rear of the fourth boom section, remove the
remaining wear pads, shims and hardware. Label
MH4071
22. At the rear of the boom, remove the shoulder bolt (5) “Boom Wear Pads.”
to the fourth boom section retract chain (6). Let the
chain hang out the rear of the boom.
MH1861
6036, 6042, 8042, 10042, 10054 3-17

Boom
11
MH1901
MH1961
30. Inside the boom section, remove the hardware
securing the hose carrier (9) to the bottom of the 35. Remove the hose carrier assembly (11) from the
boom. boom by carefully pulling both the upper and lowers
portions through the rear of the boom at the same
31. On each side of the boom, remove the hardware
time.
securing the rear of the hose carrier guide in place.
36. Carefully slide the hose channel assembly out of the
rear of the boom.
3.6.2 Third Boom Section Removal

1. At the front of the second boom section, remove the
top and side wear pads. Label and tag each set of
10
wear pads being removed.
12
MH1911
32. Loosen, but DO NOT remove the hardware holding

the front of the hose carrier guide and the top wear
pad (10) to each side of the boom.
33. Tilt the back of the hose carrier guide up. Label all
hoses and their orientations. Pull the hoses from the
channels inside the boom. Lay the hoses out behind
the boom.
34. After the hoses are removed, remove the hose
carrier guide by pulling the guide out the rear of the
boom.
MH1991
2. Remove the shoulder bolt (12) 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 6036, 6042, 8042, 10042, 10054

Boom
3.6.3 Second Boom Section Removal

1. At the front of the first boom section, remove the top,
13 side and bottom wear pads. Label and tag each set
of wear pads being removed.
14
4. Remove the locknuts (13) holding the threaded

clevis of the extend chains to the anchor bracket on
the rear of the third boom section.
5. Pull both extend chains out from the front of the
boom. MH2121
6. At the rear of the third boom section, remove the
retract chain sheave. 2. Remove the retract chain sheave (14) from the
inside of the second boom section.
7. Remove the shoulder bolt. Let the retract chain hang
out the rear of the boom. 3. Using a suitable sling or support, secure the front of
the Extend/Retract cylinder.
8. Using a sling or suitable support, pull the third boom
section straight out of the second boom section. 4. Remove the retaining ring from one side of the
Reposition the slings as needed so the third boom Extend/Retract cylinder rod end mounting pin.
section balances when removed from the second
boom section. Set the boom section down on a hard,
level surface. Support the boom as needed to
prevent it from tipping over.
9. Remove the remaining wear pads, shims and
hardware. Label and tag each set of wear pads
being removed.
15
MH2171
5. On the left side of the first boom section, remove the

boom extend interlock proximity sensor (15) and
mounting bracket.
6. Using a sling or suitable support, pull the second
boom section straight out of the first boom section.
Reposition the slings as needed so the second
boom section balances when removed from the first
boom section. While pulling the second boom
section out of the first boom section, guide the
retract chain into the rear of the boom. Set the boom
boom as needed to prevent it from tipping over.
6036, 6042, 8042, 10042, 10054 3-19

Boom
7. Remove the remaining wear pads, shims and 5. Remove the retract chain by pulling it out the rear of
hardware. Label and tag each set of wear pads the boom.
being removed.
8. Inspect all wear pads for wear. Refer to Section 3.9, 18
MH1131
6. Label, disconnect and cap the Attachment Tilt and

Auxiliary (if equipped) hydraulic hoses on the
mounting plate (18).
7. Label, disconnect and cap the Attachment Tilt and
Auxiliary (if equipped) hydraulic tubes from the
bulkhead fittings.
8. Label, disconnect and cap the Extend/Retract
16 hydraulic hoses from the bulkhead fittings.
MH2141
9. At the underside of the second boom section,

remove the locknut (16) from the retract chain clevis. 19
Pull the retract chain out of the boom through the
rear of the boom. 1
3.6.4 First Boom Section Removal

1. Attach a suitable overhead lifting device and sling to
the Lift/Lower cylinder, and remove slack in the sling.
2. Securely support the first boom section.
3. Remove all wear pads, shims and hardware. Label
MH1151
9. Label, disconnect and cap the Extend/Retract

hydraulic tubes (19) from the bulkhead fittings.
Remove the tube clamps (1).
17
MH1111
4. At the underside of the boom, remove the retract MH1201
chain locknut (17). Measure the amount of threads 10. Label, disconnect and cap the hydraulic hoses
protruding beyond the locknut and record the attached to the Compensation cylinders (2).
measurement for reassembly of the chain.
3-20 6036, 6042, 8042, 10042, 10054

Boom
11. Use a hoist and a sling to hold the left Compensation 19. Remove the rubber bumper from the Extend/Retract
cylinder in position. Remove the lockbolt from the cylinder retainer. Inspect the rubber bumper. If it is in
Compensation cylinder rod end mounting pin. good condition, the rubber bumper can be reused. If
Remove the locknut from the base end of the bumper is showing signs of cracking or
Compensation cylinder. Lift the Compensation deterioration, it should be replaced.
cylinder away from the machine. Repeat procedure 20. Remove the Extend/Retract cylinder from the boom.
for the right Compensation cylinder.
3.6.5 First Boom Section Installation
1. Using a suitable hoist and sling, position the Extend/
Retract cylinder with the port elbows facing down.
3
Place the rod end of the cylinder through the cylinder
retainer at the front of the boom.
2. Coat the base end of the cylinder with anti-seize
compound. Insert the base end cylinder pin through
both mounting ears and the base end of the Extend/
Retract cylinder. Secure the pin in place with a
retaining ring on each side of the pin.
MH1221
3. Lift the rod end of the Extend/Retract cylinder
enough to insert the threaded stud on the rubber
12. On the right side boom pivot mounting plate, remove bumper into the hole in the Extend/Retract cylinder
the boom proximity sensor (3). retainer. Secure the rubber bumper in place with a
13. With the boom securely supported, block the Lift/ new locknut. Tighten securely. Lower the rod end of
Lower cylinders. Remove the lockbolts from the rod the Extend/Retract cylinder, and allow it to rest on
end of the cylinders and lower the cylinders onto the the rubber bumper.
machine. 4. Using a suitable hoist and slings, lift the boom
assembly and position the boom on the frame. Align
4 the mounting plates on the frame between the
mounting hubs on each side of the boom assembly.
Lower the boom assembly until the holes in the
boom assembly and the mounting plates align.
5. On the end of the boom pivot pin, closest to the
capscrew hole, mark the capscrew mounting hole
location. Coat the entire pin with anti-seize
compound.
MH1241
6. Insert the pivot pin from the outside of the boom
assembly, making sure the marks for the capscrew
14. Remove the boom pivot pins (4) and lockbolts. mounting hole stay in line with the capscrew
15. Using a sling or suitable support, carefully lift the first mounting holes in the boom mounting hub.
boom section away from the machine. Set the boom
boom as required to allow removal of the Extend/
Retract cylinder from the underside of the boom.
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 3-21

Boom
6 7
MH1391
11. Insert the boom proximity sensor through the hole in

the right side mounting plate. Install the jam nut onto
the boom proximity sensor on the inside of the plate.
Adjust the inner and outer jam nuts on the sensor
MH1381 until the gap (7) between the sensor and the boom is
7. Shim the boom as required using the shims (5) to 0.12 in (3 mm). Torque the inside jam nut to 36 lb-in
maintain a 0.10 in (2,5 mm) maximum gap (6) (4,1 Nm), to hold the sensor in position.
between the boom mounting hub and the self
aligning bearing in the frame. If an additional shim is
required to maintain the maximum gap, the extra 8
shim MUST be inserted on the right side of the
boom.
8. Align the rod end of the right Lift/Lower cylinder with 9
the self-aligning bearing on the boom assembly.
Coat the entire Lift/Lower cylinder pin with anti-seize
cylinder and the self-aligning bearing. Secure with
lock bolt. Repeat procedure with left Lift/Lower
cylinder.
9. Use a hoist or suitable support to position the right
side Compensation cylinder to its original orientation MH1151
onto the lower cylinder mount. Coat the entire 12. Install the Extend and Retract tubes (8) to the inside
Compensation cylinder pin with anti-seize bulkhead fitting and the Extend/Retract cylinder.
cylinder and the self-aligning bearing. Secure with 13. Install the Extend and Retract tube clamp halves (9).
lockbolt. Repeat procedure for left side 14. Uncap and connect the previously labeled hydraulic
Compensation cylinder. hoses and attach to their appropriate cylinder
10. Install the boom proximity sensor on the right side locations.
mounting plate. With the boom properly shimmed, 15. Install the Extend and Retract and Auxiliary (if
position the boom assembly all the way to the right equipped) tube assemblies to their appropriate
side. bulkhead fittings. Secure with tube clamps.
Attachment Tilt and Auxiliary (if equipped) hydraulic
hoses to their appropriate bulkhead fittings.
3-22 6036, 6042, 8042, 10042, 10054

Boom
side. Align the hole in the pin retainer plate with the
threaded hole in the left ear. Secure the pin.
2. Apply grease to the grease fitting in the pin. Spin the
sheave by hand to ensure the sheave spins freely on
the pin and to distribute grease evenly.
12
10
MH1461
17. Inside the rear of the boom, slide the threaded clevis
end (10) of the retract chain down the right side of MH1501
the boom. Guide the threaded part of the clevis out 3. Install the hose reel assembly (12), left side and
through the hole in the tab on the bottom of the bottom wear pads to the rear of the second boom
boom. Pull threaded part of clevis all the way section.
through tab.
4. Install the boom side and top wear pads of the
18. Coat the entire threaded portion of the clevis with second boom section.
multi-purpose grease. Install a flat washer and
locknut onto the clevis. Thread the nut onto the 5. Grease the sections of the boom in areas where the
clevis until the threads are flush with the top of the wear pads will slide.
nut. 6. Before installing the second boom section into the
19. Install the bottom wear pads to the first boom section first boom section, place a string (heavy enough to
with the previously used hardware. pull the Attachment Tilt and Auxiliary hydraulic
hoses) down the inside of the boom. Allow the string
3.6.6 Second Boom Section Installation to hang out the rear of the boom. Pull the other end
out the opening on the left side of the boom where
the hoses will exit the boom. Position the strings all
the way to the left side of the first boom section.
7. Using a suitable sling, carefully slide the second
boom section into the first boom section. Leave
11
enough room at the front of the boom to install the
center wear pad.
MH2261
1. At the rear of the second boom section, assemble

the retract chain sheave to the mounting ears on the
right side of the boom. Place the sheave between
the ears and insert the sheave pin (11) from the left
6036, 6042, 8042, 10042, 10054 3-23

Boom
3.6.7 Third Boom Installation

1. Install the bottom, side and top wear pads to the rear
of the third boom section.
15
13
MH2211
8. Install the center wear pad mount (13) and wear pad MH2021
to the bottom front of the first boom section.
2. At the rear of the third boom section, assemble the
9. Install the side and top wear pads to the front of the
retract chain sheave (15) to the mounting ears on
first boom section.
the left side of the boom. Place the sheave between
10. Install the double extend chain sheave to the front of the ears and insert the sheave pin from the right
the second boom section. side. Line up the hole in the pin retainer plate with
11. With the sling still in place, install the rod end of the the threaded hole in the right ear. Secure the pin.
Extend/Retract cylinder, pin and retaining ring. 3. Apply grease to the grease fitting in the pin. Spin the
12. Install the front, bottom wear pads in the second sheave by hand to ensure the sheave spins freely on
boom section. the pin and to distribute grease evenly.
4. Install the bottom front wear pads.
16
14
MH2171 MH2301
13. On the left side of the first boom section, reassemble 5. Lay the two extend chains (16) on the top of the third
the boom extend interlock sensor (14) with mounting boom section with the threaded clevis ends toward
bracket. Secure in place with the previously used the rear of the boom. Coat the threads on each
hardware. Tighten securely. clevis with multi-purpose grease and insert the
14. Secure the boom extend interlock sensor wire to the clevis’ through the holes in the anchor plate. Install a
Attachment Tilt tubes under the boom with new tie washer and locknut onto each clevis. Tighten the
wraps. locknut enough so the threads are even with the top
of the locknut.
3-24 6036, 6042, 8042, 10042, 10054

Boom
7. Using a suitable sling, carefully slide the third boom 3.6.8 Fourth Boom Section Installation
section into the second boom section. Leave enough
room at the front of the boom to install the remaining
0
wear pads. 6.0 )
19 8 cm
8. Install the top and side wear pads to the inside of the (49
second boom section.
9. Place the two extend chains up through the double
sheave mounting bracket on the front of the second
boom section.
10. Assemble the two extend chains to the mount if the
yoke plates were removed from the extend chains.
Secure in place with a locknut. Tighten the locknut
securely; but the yoke plates must pivot freely.
11. Install the double extend chain sheave. Apply grease
MH2381
to the sheave. Turn the sheave by hand to distribute
the grease evenly. 1. Lay the hose carrier assembly out flat on a level
17 surface. Stretch the four male ends of the hoses out
straight from the hose carrier assembly. Measure
from the male end of each hose back toward the
hose carrier assembly 196 in (498 cm) and apply
tape around each hose at that point. The tape is for
proper tensioning of the hoses during reassembly of
the hose clamps.
2. Insert the hose channel assembly into the rear of the
fourth boom section. Slide the hose channel
assembly into the boom and line up the holes for the
side wear pads.
3. Install the side, bottom and top wear pads.
MH1991 18
12. Align the holes in the yoke plates with the hole in the
mount on the first boom section. Coat the shoulder
bolt with anti-seize compound and insert the
shoulder bolt (17) through the yoke plates and the
mount on the boom. Secure in place with a locknut.
Tighten the locknut securely; but the yoke plates
must pivot freely.
13. Place the retract chain around the retract chain MH2441
sheave on the right side of the boom. Stretch the 4. Lay the fourth boom section extend chain (18) on the
chain forward and place the clevis between the two top of the fourth boom section with the threaded
anchor plates. Align the hole in the clevis with the clevis end toward the rear of the boom. Coat the
hole location recorded in the removal procedure. threads on the clevis with multi-purpose grease and
Insert the shoulder bolt and locknut, tighten securely. insert the clevis through the hole in the anchor plate.
Install a washer and locknut onto the clevis. 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 3-25

Boom
19
1
MH2411
5. Fold the hose carrier assembly in half, ensure the

female ends (19) of the hoses are on the bottom,
and carefully slide the folded hose carrier into the
fourth boom section.
6. Line up the lower mounting holes in the hose carrier
assembly with the holes in the bottom of the fourth
MH2471
boom section. Secure with the previously used
hardware. 9. With the hose guide tilted up in the back, insert the
7. Lift the upper part of the hose carrier assembly and female ends of the two left side hoses (from the hose
place the hose carrier guide under the hose carrier carrier) one at a time over the top of the angled
with the angled guides toward the front. Slide the guide (1) on the front side of the hose guide. Push
hose guide into the fourth boom section, and place the hoses into the hose channel on the left side of
the front notches onto the rear wear pad mounting the fourth boom section and down to the front of the
capscrew. Be sure the notch in the side of the hose boom section. Repeat this procedure for the two
guide is under the flat washer on each side of the right side hoses into the hose channel on the right
boom. side of the boom.
8. Rotate the back of the hose guide up toward the top 10. Insert a capscrew through the hole in the fourth
of the fourth boom section as far as it will go. Tighten boom section. Secure the hose guide in place with a
the rear wear pad mounting capscrews enough to flat washer and locknut. Torque to 28 - 34 lb-ft
hold the hose guide. (38 - 46 Nm).
11. Run the hose carrier out and in by hand to check for
interference.
Note: DO NOT allow the hydraulic hoses to cross inside
the boom.
12. At the front of the boom, pull the previously labeled
hydraulic hoses out the opening in the back of the
boom head. Let the hoses hang out of the boom
head.
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 6036, 6042, 8042, 10042, 10054

Boom
22. Place the extend chain clevis between the mounting

plates at the front of the second boom section. Coat
the shoulder bolt (4) with anti-seize compound and
insert through the plates and clevis. Secure the
shoulder bolt in place with a locknut. Tighten
2
securely, but the chain clevis should pivot freely.
Note: Keep the four hoses in line as they come out of
the hose carrier assembly at the rear of the boom. DO
MH1861 NOT allow the hoses to cross.
15. Reassemble the hose carrier support to the hose 23. Install the hose clamp support bracket and top left
carrier on the right side. Install the hose carrier side wear pad.
support (2) and lower wear pad with the previously 24. Position the hydraulic hoses with the edge of the
used hardware. tape at the hose clamps. Hold the hoses in this
16. Place the retract chain up around the retract chain position, and tighten the hose clamps.
sheave on the left side of the boom. Stretch the
chain forward and place the clevis between the two
anchor plates. Line up the hole in the clevis with the
anchor plate hole location recorded during removal.
17. Insert the shoulder bolt and secure in place with a
locknut. Tighten the locknut. 5
18. Install the side and top wear pads.
19. Place the fourth boom section extend chain sheave
(3) between the mounts at the front of the third boom
section. Insert the sheave pin through the mounts
and the sheave. Secure in place with the previously
used hardware.
20. After the sheave is assembled, apply a good grade
of multi-purpose grease to the grease fitting at the
MH1691
end of the pin. Turn the sheave by hand to distribute
grease evenly. 25. Assemble the hoses to the hose reel (5) at the rear
21. Place the fourth boom section extend chain up and of the boom.
around the sheave at the front of the third boom 26. Tie the strings (positioned inside the first boom
section. section during installation) to the male end of the
hydraulic hoses coming off the bottom of the hose
4
reel assembly.
27. Working from the front of the boom, pull each hose
through the boom assembly through the opening at
the bottom of the first boom section.
3 28. Remove the strings from the hoses.
MH2521
6036, 6042, 8042, 10042, 10054 3-27

Boom
3.7 BOOM EXTEND AND RETRACT

CHAINS
3.7.1 Boom Chain Inspection
WARNING
6 Worn pins, stretched or cracked links or corrosive
environments can cause chain failure. A chain failure
could result in uncontrolled boom movement, loss of
MH1451 load or machine instability.
29. At the front of the first boom section, assemble the Under normal operating conditions the boom extend
hose assemblies and tube assemblies to the chains will need to be inspected every 250 hours of
mounting plate (6). operation. The retract chains need to be exposed and
inspected every 1000 hours of operation. Environmental
Note: Where the hose assemblies come out of the outer
conditions and dynamic impulse/shock loads can
boom, lubricate the radius in the first boom section with drastically affect normal operating conditions and require
soap and water to allow proper tensioning of hoses. more frequent inspection intervals.
30. Install the quick attach and Attachment Tilt cylinder Environments in which material handling machines
to the front of the boom. Refer to Section 3.8.2, operate can vary widely from outdoor moisture to
“Quick Attach Installation.” temperature to mildly corrosive or highly corrosive
31. Uncap and connect the previously labeled hoses to industrial atmospheres, in addition to abrasive
exposures such as sand and grit. Some effects can be
the Attachment Tilt cylinder.
as follows:
32. Properly connect the battery.
• Moisture - Corrosive rusting reduces chain
33. Remove the Do Not Operate Tags from both the strength by pitting and cracking.
ignition key switch and the steering wheel.
• Temperature - Low temperature reduces chain
34. Start the engine and operate all boom functions strength by embrittlement. Going in and out of
several times. Check the chain tension again and cold storage results in moisture from
adjust as necessary. Check for leaks, and check the condensation.
hydraulic fluid level in the tank; add fluid if required. • Chemical Solutions or Vapors - Corrosive attack
35. Clean up all debris, hydraulic fluid, etc., in, on, near on the chain components and/or the mechanical
and around the machine. connections between the chain components.
Cracking can be (and often is) microscopic.
36. Install the rear cover to the boom. Going from microscopic cracking to complete
37. Close and secure the rear door. failure can be either abrupt or may require an
extended period of time.
• Abrasives - Accelerated wearing and scoring of
the articulating members of the chain (pins an d
plates), with a corresponding reduction in chain
strength. Due to the inaccessibility of the bearing
surfaces (pin surfaces and plate apertures),
wear and scoring are not readily noticeable to
the naked eye.
3-28 6036, 6042, 8042, 10042, 10054

Boom
Following are some examples of dynamic shock loading Edge Wear

which can impose abnormal loads above the endurance
limit of a leaf chain.
• High velocity movement of load, followed by
sudden, abrupt stops. 1 2
• Carrying loads in suspension over irregular

surfaces such as railroad tracks, potholes, and
rough terrain. MZ1463
• Attempting to “inch” loads which are beyond the

rated capacity of the machine. Check the chain for wear on the link plate edges
caused by running back and forth over the sheave.
The above load cycles and environmental conditions The maximum reduction of material should not
make it impossible to predict chain life. It is therefore exceed 5%. Measure and compare to a normal link
necessary to conduct frequent inspections until plate height by measuring a portion of chain that
replacement life can be predicted. does not run over the sheave. If the measured plate
height (1) is 5% less than the normal plate height
The boom chain’s normal life expectancy can be
expressed as a maximum percent of elongation. This is (2), discard and replace the chain.
generally 3%. As the chain flexes back and forth over the Elongation
sheave, the bearing joints (pins and inside link plates)
gradually incur wear due to articulation. It is important to measure the chain in the section
that moves over the sheaves because it receives the
3.7.2 Inspection Guidelines most frequent articulation. Measuring the chain near
its clevis terminals could give an inaccurate reading.
1. Park the machine on a firm, level surface, raise the The ends of the chains, near the clevis terminal, will
boom to a horizontal (level) position, place the not have flexed as frequently, if at all, as the middle
transmission control lever in (N) NEUTRAL, engage of the chains.
the park brake switch. It is best to measure in 12 pin increments from pin
2. Fully extend the boom until the extend chain is taut. center to pin center. For example, if the links are one
Shut the engine off. inch from pin center to pin center, the distance
should be 12 in (305 mm). If the links are 3/4 in
3. The extend chains will be visible for inspection with (19,0 mm) apart, the distance after 12 pins should
the machine in this state. be 9 in (228,6 mm).
4. While doing the chain inspection, check all chain
4
clevis ends for distortion or cracking and sheaves for
bearing wear or grooving from the chain. 3
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 3-29

Boom
Distorted or Battered Link Plates Cracked Plates

Inspect the chains very carefully, front and back as
85 well as side to side, for any evidence of cracked
plates. If any one crack is discovered, the chain
should be replaced in its entirety.
It is important, however to determine the cause of
the crack before installing a new chain so the
condition does not repeat itself.
The types of cracks are:
MZ1466
• Fatigue Cracking -
Fatigue cracks (9) are a 9
Distorted or battered link plates (5) on a leaf chain can result of repeated
cause tight joints and prevent flexing. cyclic loading beyond MZ1467
Turning or Protruding Pins the chain’s endurance

limit.
Highly loaded chain, operating with inadequate
lubrication can generate abnormal frictional forces • Stress Corrosion
between pin and link plates. When chain is allowed Cracking - The
outside link plates 10
to operate in this condition, a pin or series of pins,
can begin to twist out of a chain, resulting in failure. are particularly MZ1468
susceptible to stress
corrosion cracking (10).
• Corrosion Fatigue Cracking - Corrosion
6 7 fatigue cracks are very similar to fatigue
cracks in appearance. Corrosion fatigue is the
8 combined action of an aggressive
MZ1465 environment and cyclic stress.
Examine the pin head rivets to determine if the Other Modes of Failure
“VEE” flats are still in correct alignment (6). Chain • Ultimate Strength Failure -
with rotated/displaced heads (7) or abnormal pin These types of failures are
protrusion (8) should be replaced immediately. caused by overloads far in 1
excess of the design load. MZ1469
DO NOT attempt to repair the chain by welding or
driving the pin(s) back into the chain. Once the press Either fractured plates (1) or 2
fit integrity between outside plates and pins has enlarged holes (2) can
been altered, it cannot be restored. occur. If either of these
MZ1470
failures occurs, the chain
Any wear pattern on the pin heads or the sides of the should be replaced immediately.
link plates indicates misalignment in the system.
This condition damages the chain as well as • Tight Joints
increases frictional loading and should be corrected. - All joints in
the chain
should flex
freely. Tight
joints (3) 3 MZ1471
resist flexing.
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 6036, 6042, 8042, 10042, 10054

Boom
3.7.3 Expose Chains for Inspection 3.7.4 Chain Lubrication

After inspection and before being returned to service,
c. Extend Chains chains must be lubricated. Refer to Section 2.4, “Fluid
1. Park the machine on a firm, level surface. Place the Specifications,” for proper lubricant.
transmission control lever in (N) NEUTRAL, engage The lubricant must penetrate the chain joint to prevent
the park brake switch and raise the boom to a wear. Applying lubricant to the external surfaces will
horizontal (level) position. prevent rust, but the chains should be articulated to
2. Fully extend the boom and shut the engine OFF. make sure the lubricant penetrates to the working
surfaces between the pins and links.
The extend chains will be visible for inspection with the
machine in this state. To prepare the chain for lubrication, the chain plates
should be brushed with a stiff brush or wire brush to
While doing the chain inspection, check all chain clevis clear the space between the plates so that lubricant can
ends for distortion or cracking and sheaves for bearing penetrate to the working surfaces.
wear or grooving from the chain.
Lubricant may be applied with a narrow paint brush or
If during the inspection, any chain is found to be damaged directly poured on, but the chain should be well flooded
or stretched, the chain must be replaced. It is with lubricant and the boom should be extended and
recommended that when any chain is replaced, that all retracted to be sure that the lubricant penetrates to the
the chains and clevises be replaced at the same time. working surfaces. All surplus lubricant should be wiped
away from the external surfaces. DO NOT use a solvent
d. Retract Chains for this wiping operation.
Regular application of lubricant is necessary to make
The retract chains are only partially visible through the
sure that all working surfaces are adequately lubricated.
rear of the boom with all the sections retracted. It is In extremely dusty conditions, it may be necessary to
possible to see a section of the retract chain as the boom lubricate the chains more often. Refer to Section 2.7,
is slowly extended. If there is ANY question that one or all “Service and Maintenance Schedules,” and Section 2.8,
the retract chains are damaged, the boom should be “Lubrication Schedules,” for detailed information.
removed and disassembled with the retract chains being
Lubrication of chains on machines working consistently
inspected and replaced if necessary.
in extreme hot or cold conditions requires special
Note: DO NOT attempt to repair a chain. Replace a consideration. It is important that a reputable lubrication
stretched or damaged chain with a new part. Always specialist or a JLG distributor be consulted for guidance.
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 3-31

Boom
3.7.5 Boom Chain Tension Check 3.7.6 Boom Chain Tension Adjustment
1. Make sure the attachment is attached to the boom
(6036, 6042, 8042 & 10042)
head before doing the tension check. Note: Always perform Section 3.7.5, “Boom Chain Ten-
2. Park the machine on level ground. Place the sion Check” before adjusting the boom chain tension.
transmission control lever in (N) NEUTRAL, engage
the parking brake switch and level the boom.
2
3. Slowly, fully extend the boom and retract it about
halfway. Fully extend the boom, then retract it 2 in
(51 mm) (one inch per section). Turn the
engine OFF.
1
OH0241
1. Adjust the two boom extend chains (2).
OA0493
4. Measure the sag (1) in each of the boom extend

chains between the bottom of the extend chains and
the top of the boom at their closest point. Acceptable
boom chain sag is between 1.5 in (38 mm) and MH1752
2.5 in (64 mm) for the 6036, 6042, 8042 & 10042
If the chain sag measurement (1) is less than 1.5 in
and between 2.85 in (72 mm) and 3.85 in (98 mm)
(38 mm), tighten the two extend chain adjustment
for the 10054.
locknuts (3).
If the measurement is either less than, or greater If the chain sag measurement is more than 2.5 in
than the range given, the boom chains need to (64 mm), loosen the two extend chain adjustment
be adjusted. Continue with Section 3.7.6, “Boom locknuts.
Chain Tension Adjustment (6036, 6042, 8042 &
2. Tighten or loosen the two extend chain adjustment
10042)” or Section 3.7.7, “Boom Chain Tension
locknuts located at the rear of the boom. Be sure
Adjustment (10054),” to adjust the chain system.
each of the locknuts are adjusted equally so that
5. Start the engine, retract the boom completely and each extend chain maintains the same tension.
turn the engine OFF. Equal chain tension can be checked by the position
of the yoke (4) on the outer boom. The front of the
yoke should be parallel with the front edge of the
outer boom.
3-32 6036, 6042, 8042, 10042, 10054

Boom
a. Component/Assembly Verification
9
5
8
7
OH1091
OA0513
The third (7) to second (8) boom section separation
3. If there is no adjustment left on the extend chains, should be checked when assembling new boom sections
tighten the retract chain locknut (5) at the front on or chains, or when the rear retract chain clevis has been
the underside of the outer boom. moved forward on the anchor plate.
4. Recheck chain tension. Refer to Section 3.7.5, Measure the separation (9) between the third and second
“Boom Chain Tension Check.” boom section top plates. The distance should be at least
8.5 in (216 mm) and not greater than 11 in (279 mm) with
the boom fully retracted and the chains properly
6 tensioned. A distance of less than 8.5 in (216 mm) could
result in interference and cause damage to boom
components.
If the distance is less than 8.5 in (216 mm) or greater than
11 in (279 mm):
1. Verify that the retract chain clevis (6) is not mounted
in the last hole in the anchor plate.
2. Make sure that the chain system is properly
tensioned. Refer to Section 3.7.5, “Boom Chain
Tension Check.”
MA9451
3. To increase the separation distance: Loosen the
retract chain locknut (5) on the bottom of the boom
5. Further chain adjustment can be achieved by
one or two turns and tighten the two extend chain
loosening all three chain locknuts and moving the
locknuts equally the same number of turns. A
rear retract chain clevis (6) from the original
minimum of one full thread on the clevis must
mounting hole in the anchor plate to the next hole.
protrude beyond the collar of the locknut.
This is only acceptable when boom chain sag cannot
be acquired and the chain elongation measurement 4. To decrease the separation distance: Loosen the
is still less than 12.36 in (313 mm). Follow the extend chain locknuts at the rear of boom equally
instructions in Section 3.7.6, a. “Component/ one or two turns and tighten the retract chain locknut
Assembly Verification.” (5) the same number of turns. A minimum of one full
thread on the clevis must protrude beyond the collar
6. Recheck chain tension. Refer to Section 3.7.5,
of the locknut.
“Boom Chain Tension Check.”
5. Install the rear boom cover.
6. If the third to second boom separation distance
cannot be achieved, contact your local JLG service
distributor.
6036, 6042, 8042, 10042, 10054 3-33

Boom
3.7.7 Boom Chain Tension Adjustment

(10054)
a. Outer Boom Chains Tension Adjustment

Note: Always perform Section 3.7.5, “Boom Chain
Tension Check.” before adjusting the boom extend chain
tension.
10
12
OH0552
2. Tighten or loosen the two extend chain adjustment

locknuts (11) located at the rear of the boom. Be
OA0493 sure each of the locknuts are adjusted equally so
that each extend chain maintains the same tension.
11 Equal chain tension can be checked by the position
of the yoke (12) on the first boom section. The front
of the yoke should be parallel with the front edge of
the outer boom.
13
MH1781
1. Adjust the two second and third boom section

extend chains.
If the chain sag measurement (10) is less than
2.85 in (72 mm), tighten the two extend chain OA0513
adjustment locknuts (11).
3. If there is no adjustment left on the extend chains,
If the chain sag measurement (10) is more than tighten the retract chain locknut (13) at the front on
3.85 in (98 mm), loosen the two extend chain the underside of the boom.
adjustment locknuts (11).
4. Recheck chain tension. Refer to Section 3.7.5,
3-34 6036, 6042, 8042, 10042, 10054

Boom
If the distance is less than 8.5 in (216 mm) or greater than

11 in (279 mm):
14 1. Verify that the retract chain clevis is not mounted in
the last hole in the anchor plate.
2. Make sure that the chain system is properly
tensioned. Refer to Section 3.7.5, “Boom Chain
Tension Check.”.
18
MA9451
5. Further chain adjustment can be achieved by

loosening all three chain locknuts and moving the
rear retract chain clevis (14) from the original
mounting hole in the anchor plate to the next hole.
This is only acceptable when boom chain sag cannot
be acquired and the chain elongation measurement
MH1781
is still less than 12.36 in (313 mm). Follow the
instructions in Section 3.7.7, b. “Component/ 3. To increase the separation distance: Loosen the
Assembly Verification.” retract chain locknut (13) on the bottom of the boom
6. Recheck chain tension. Refer to Section 3.7.5, one or two turns and tighten the two extend chain
“Boom Chain Tension Check.” locknuts (18) equally the same number of turns. A
b. Component/Assembly Verification protrude beyond the collar of the locknut.
The third to second boom section separation should be 4. To decrease the separation distance: Loosen the
checked when assembling new boom sections or chains, extend chain locknuts (18) at the rear of boom
or when the rear retract chain clevis has been moved equally one or two turns and tighten the retract chain
forward on the anchor plate. locknut (13) the same number of turns. A minimum
17 of one full thread on the clevis must protrude beyond
the collar of the locknut.
Note: If the third to second boom section separation
distance cannot be achieved, contact your local
authorized service distributor.
16
15
OH2862
Measure the separation between the third (15) and

second (16) section boom top plates. The distance (17)
should be at least 8.5 in (216 mm) and not greater than
11 in (279 mm) with the boom fully retracted and the
chains 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 3-35

Boom
c. Inner Boom Chain Tension Adjustment

Note: Always perform the Section 3.7.5, “Boom Chain
Tension Check,” before adjusting the fourth boom
section extend chain tension.
19
2
OH0661
2. If there is no adjustment left on the extend chains,

tighten the retract chain locknut (2) on the bottom of
the second boom section several turns.
OA0493 3. Recheck chain tension. Refer to Section 3.7.5,
MH1781
1. Adjust the fourth boom section extend chain:

MH4071
If the chain sag measurement (19) is less than
2.85 in (72 mm), tighten the extend chain adjustment 4. Further chain adjustment can be achieved by
locknut (1). loosening both chain locknuts and moving the rear
If the chain sag measurement (19) is more than retract chain clevis (3) from the original mounting
3.85 in (98 mm), loosen the extend chain adjustment hole in the anchor plate to the next hole.
locknut (1). This is only acceptable when boom chain sag cannot
be acquired and the chain elongation measurement
is still less than 12.36 in (313 mm). Follow the
instructions in Section 3.7.7, d. “Component/
Assembly Verification.”
5. Recheck chain tension. (Refer to Section 3.7.5,
“Boom Chain Tension Check.”)
3-36 6036, 6042, 8042, 10042, 10054

Boom
d. Component/Assembly Verification 3.7.8 Extend Chains Removal and

The fourth to third boom section separation should be
Replacement
checked when assembling new boom sections or chains,
(6036, 6042, 8042 & 10042)
or when the rear retract chain clevis has been moved 1. Park the machine on level ground. Place the
forward on the anchor plate. transmission control lever in (N) NEUTRAL, engage
6 the parking brake switch, level the boom and shut
the engine OFF.
3. Properly disconnect the battery.
4. Remove the boom rear cover.
4 5
OH2871
Measure the separation between the third (4) and

fourth (5) boom section top plates. The distance (6)
should be at least 13.75 in (349 mm) and not greater than
14.25 in (362 mm) with the boom fully retracted and the
chains properly tensioned. A distance of less than MH1752
13.75 in (349 mm) could result in interference and cause
damage to boom components. 5. At the rear of the boom, locate the extend chain
locknuts (7). Record the amount of threads
If the distance is less than 13.75 in (349 mm) or greater
extending beyond both the locknuts. These
than 14.25 in (362 mm):
measurements will be the starting point for
1. Verify that the retract chain clevis is not mounted in adjustment of the extend chains after installation.
the last hole in the anchor plate.
6. Remove and replace the extend chains one at a
2. Make sure that the chain system is properly time. Remove the right side locknut and flat washer,
tensioned. Refer to Section 3.7.5, “Boom Chain holding the clevis to the anchor plate.
Tension Check”
8
3. To increase the separation distance: Loosen the
retract chain locknut on the bottom of the second
boom section one or two turns and tighten the
extend chain locknut the same number of turns. A
protrude beyond the collar of the locknut.
SH1811
4. To decrease the separation distance: Loosen the
extend chain locknut at the rear of boom one or two 7. At the front of the boom, remove the capscrew (8)
turns and tighten the retract chain locknut on the and locknut holding the right side extend chain clevis
bottom of the second boom section the same to the yoke plates. Replace the capscrew if damaged
number of turns. A minimum of one full thread on the or worn.
clevis must protrude beyond the collar of the locknut.
Note: If the fourth to third boom section separation
distance cannot be achieved, contact your local
authorized service distributor.
6036, 6042, 8042, 10042, 10054 3-37

Boom
10
11
MH6510
8. At the rear of the boom, attach one end of a wire to

the threaded clevis (9) on the right side extend chain
using a threaded eye or a flat washer tack welded to 12
a capscrew. The outside diameter of the eye or flat
washer must be smaller than the diameter of the SH1852
threads on the clevis. 14. Pull the extend chain forward and place over the
9. Have an assistant pull the chain from the front of the right side of the chain sheave (10). Guide the wire
boom while guiding the wires into the boom from the and the threaded clevis under the chain sheave, and
rear. Remove the wire from the clevis, but not from between the top of the third boom section (11) and
inside the boom. the second boom section (12).
10. Inspect wear and condition of the booms, chains, 15. Have an assistant guide the extend chain into the
clevis’, chain sheaves, Extend/Retract cylinder, front of the boom, while pulling on the wire from the
chain rods, clevis anchors and all mounting rear of the boom. Guide the threaded clevis into the
hardware. Replace any worn or damaged parts. DO hole in the anchor plate.
NOT attempt to make any repairs to the chain. 16. Assemble the flat washer and locknut to the
Note: Chains and clevis’ are wear items and experience threaded clevis. Thread the locknut until the threads
the same stress. DO NOT attempt to repair a chain. are flush with the top of the nut.
Replace a stretched or damaged chain with a new part. 17. Pull the anchor clevis up around the double chain
Always replace both the chain and the clevis’. sheave and position the clevis between the yoke
11. Coat the threads of the threaded clevis with multi- plates.
purpose grease. 18. Coat the capscrew with anti-seize compound. Insert
12. Lay the new extend chain on top of the first boom the capscrew through the yoke plates and clevis and
section with the threaded clevis toward the front of secure in place with a locknut. Tighten securely; but
the boom. the chain must pivot freely.
13. Attach the wire to the threaded clevis of the new 19. Remove the wire from the clevis.
extend chain using a threaded eye or a flat washer 20. Repeat this procedure for the left side extend chain.
tack welded to a capscrew. The outside diameter of 21. At the rear of the boom, tighten the two locknuts on
the eye or flat washer must be smaller than the the extend chain clevis’ until the amount of threads
diameter of the threads on the clevis. protruding beyond each locknut is the same as the
measurement recorded during removal of the
chains.
22. Check and adjust boom chain tension. Refer to
Section 3.7.5, “Boom Chain Tension Check.”
23. Install the boom rear cover.
25. Remove the Do Not Operate Tags from both the
3-38 6036, 6042, 8042, 10042, 10054

Boom
3.7.9 Retract Chain Removal and washer must be smaller than the diameter of the
Replacement threads on the clevis. The wire or string will be used
(6036, 6042, 8042 & 10042) to pull the chain back through the boom during
reassembly.
1. Park the machine on level ground. Place the
transmission control lever in (N) NEUTRAL, engage 8. Remove the locknut and flat washer holding the
the parking brake switch, level the boom and shut retract chain threaded clevis to the mounting tab.
the engine OFF. Note: Record the location of the shoulder bolt to ensure
2. Place a Do Not Operate Tag on both the ignition key correct installation.
machine should not be operated. 15

13
MH2551
9. At the rear of the boom, locate the two retract chain

anchor plates holding the retract chain to the third
boom section just in front of the retract chain sheave.
Remove the locknut and shoulder bolt (15) holding
the retract chain clevis to the anchor plates. The two
OA0513
anchor plates can remain in place on the third boom
5. At the front underside of the boom, record the section.
amount of threads extending beyond the locknut 10. From the rear of the boom, pull the retract chain out
(13). This measurement will be the starting point for of the rear of the boom.
adjustment of the boom retract chain.
11. Inspect wear and condition of the booms, chains,
6. At the front underside of the boom, loosen the clevis’, chain sheaves, Extend/Retract cylinder, chain
locknut far enough that it can be removed by hand. rods, clevis anchors and all mounting hardware.
Replace a worn or damaged chain. DO NOT attempt
to make any repairs to the chain.
Note: Chains and clevis’ are wear items and experience
the same stress. DO NOT attempt to repair a chain.
Replace a stretched or damaged chain with a new part.
14 Always replace both the chain and the clevis’.
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.
MA9441
7. Attach a wire or string (14) to the threaded clevis

with a threaded eye or a flat washer tack welded to a
capscrew. The outside diameter of the eye or flat
6036, 6042, 8042, 10042, 10054 3-39

Boom
14. From the rear of the boom, have an assistant push 3.7.10 Extend Chains Removal and
the threaded clevis end of the chain under the chain Replacement (10054)
sheave and down between the second and first
boom sections. Pull the front clevis using the string a. Second and Third Boom Section Extend Chains
or wire. Keep the chain to the right side of the boom, Removal and Replacement
push the threaded clevis down to the tab at the front
underside of the first boom section.
15. Have an assistant guide the threaded end of the the parking brake switch, level the boom and shut
clevis through the hole in the tab. the engine OFF.
16. Remove the string or wire from the end of the clevis. 2. Place a Do Not Operate Tag on both the ignition key
17. Reassemble the flat washer and locknut onto the switch and the steering wheel, stating that the
threaded clevis. Tighten the locknut until the machine should not be operated.
threaded end of the clevis is flush with the top of the 3. Properly disconnect the battery.
locknut.
18. At the rear of the boom, place the retract chain up
and over the chain sheave. Place the clevis between 16
the two anchor plates.
19. If re-installing a used chain, insert the saved
shoulder bolt, in the same position in the plates and
clevis recorded during removal.
20. If installing a new chain, line up the hole in the clevis
with the second hole from the rear of the anchor
plates. Insert the shoulder bolt, saved during
removal of the old chain.
21. Secure the shoulder bolt in place with a locknut.
Tighten the locknut securely.
22. Tighten the locknut on the retract chain clevis until
MH1781
the amount of threads protruding beyond the locknut
is the same as the measurement recorded during 5. At the rear of the boom, locate the extend chain
removal of the retract chain. locknuts (16). Record the amount of threads
23. Check and adjust retract chain tension. Refer to extending beyond the locknuts. This measurement
Section 3.7.5, “Boom Chain Tension Check.” will be the starting point for adjustment of the extend
chains after installation.
6. Remove and replace the boom extend chains one at
a time. Remove the right side locknut and flat washer
26. Remove the Do Not Operate Tags from both the holding the right side chain clevis to the anchor
ignition key switch and the steering wheel. plate.
17
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.
3-40 6036, 6042, 8042, 10042, 10054

Boom
8. Inspect the capscrews for signs of wear or damage.

Replace with new capscrews if damaged or worn.
9. At the front of the second boom section, remove the
capscrew and lockwasher holding the extend chain
sheave pin to the sheave mount bracket. Remove
the pin from the mount bracket and the extend chain
19
sheave. Remove the extend chain sheave from the
mount.
18
MH2601
15. Pull the extend chain forward and place in between

MH6510 the chain sheave mounts. Guide the wire (19) and
10. At the rear of the boom, attach one end of a wire to the threaded clevis into the boom by placing the
the threaded clevis (18) on the right side extend threaded clevis between the top of the third boom
chain with a threaded eye or a flat washer tack section and the second boom section.
welded to a capscrew. The outside diameter of the 16. Have an assistant guide extend chain into the front
eye or flat washer must be smaller than the diameter of the boom while pulling the wire and threaded
of the threads on the clevis. clevis toward the rear of the boom. Guide the
11. Have an assistant pull the chain from the front of the threaded clevis into the hole in the anchor plate.
boom while guiding the wire into the boom from the 17. Place the flat washer onto the threaded end of the
rear. Remove the wire from the clevis, but not from threaded clevis and assemble the locknut. Thread
inside the boom. locknut onto the threaded clevis until the threads are
12. Coat the threads of the threaded clevis with multi- flush with the top of the nut.
purpose grease. 18. Remove the wire from the clevis.
13. Lay the new extend chain on top of the first boom 19. Repeat this procedure for the left side extend chain.
section with the threaded clevis toward the front of 20. After both of the chains are replaced inside the
the boom. boom, assemble the double sheave to the mount at
14. Attach the wire to the threaded clevis of the new the front of the second boom section.
extend chain using a threaded eye or a flat washer 21. Place the double extend chain sheave between the
tack welded to a capscrew. The outside diameter of mounts and under the extend chains at the front of
the eye or flat washer must be smaller than the the second boom section. Insert the sheave pin
diameter of the threads on the clevis. through the mounts and the double sheave. Line up
the mounting hole in the sheave pin with the
threaded hole in the sheave mount and secure in
place with the capscrew and the lockwasher. Tighten
securely.
22. Pull the anchor clevis’ up around the double chain
sheave and position the clevis’ one at a time
between the yoke plates.
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.
6036, 6042, 8042, 10042, 10054 3-41

Boom
24. At the rear of the boom, tighten the two locknuts on

the chain clevis’ until the amount of threads 2
protruding beyond each locknut is the same as the
measurement recorded during removal of the extend
chains.
25. Check and adjust the retract chain tension. Refer to
b. Fourth Boom Section Extend Chains Removal

and Replacement 3
1. Park the machine on level ground. Place the MH1791
the parking brake switch, level the boom and shut 7. At the front of the boom, disconnect the extend chain
the engine OFF. clevis from the anchor plates on the second boom
section. Remove the locknut holding the shoulder
2. Place a Do Not Operate Tag on both the ignition key bolt (2) to the anchor plates. Pull the extend chain
switch and the steering wheel, stating that the clevis from between the plates and lay over the front
machine should not be operated. of the fourth boom section (3).
3. Properly disconnect the battery. 8. Remove the locknut and capscrew holding the
4. Remove the boom rear cover. extend chain sheave to the front of the third boom
section.
1
9. Inspect the sheave pin for corrosion or damage. If
the pin is damaged, it should be replaced. Minor
corrosion can be repaired with fine emery cloth.
Save the chain sheave, pin and capscrew.
MH1781
5. At the rear of the boom, locate the extend chain MH6510

locknut (1). Record the amount of threads extending
beyond the locknut. This measurement will be the 10. At the rear of the boom, attach one end of a wire to
starting point for adjustment of the extend chain after the threaded clevis (4) on the extend chain with a
installation. threaded eye or a flat washer tack welded to a
6. Remove the locknut and flat washer holding the
washer must be smaller than the diameter of the
extend chain clevis to the anchor plate on the boom.
threads on the clevis.
11. Have an assistant pull the chain from the front of the
boom while guiding the wire into the boom from the
rear. Remove the wire from the clevis, but not from
inside the boom.
3-42 6036, 6042, 8042, 10042, 10054

Boom
12. Coat the threads of the threaded clevis with multi- 21. After the sheave is assembled, apply a good grade
purpose grease. of multi-purpose grease to the grease fitting at the
13. Lay the new extend chain on top of the fourth boom end of the pin. Turn the sheave by hand to distribute
section with the threaded clevis toward the front of the grease evenly.
the boom. 22. Pull the extend chain up and around the sheave at
14. Attach the wire to the threaded clevis of the new the front of the third boom section.
extend chain with a threaded eye or a flat washer 23. Place the extend chain clevis between the mounting
tack welded to a capscrew. The outside diameter of plates at the front of the third boom section. Coat the
the eye or flat washer must be smaller than the saved shoulder bolt with anti-seize compound and
diameter of the threads on the clevis. insert through the plates and clevis. Secure the
shoulder bolt in place with a locknut. Tighten
securely, but the chain clevis should pivot freely.
24. At the rear of the boom, tighten the locknut on the
extend chain clevis until the amount of threads
protruding beyond the locknut is the same as the
measurement recorded during removal of the extend
chain.
25. Check and adjust the extend chain tension. Refer to
5 Section 3.7.5, “Boom Chain Tension Check.”.
6
3.7.11 Retract Chain Removal and
MH5731 Replacement (10054)
15. Pull the extend chain forward and place in between c. Third Boom Section Retract Chain Removal and
the chain sheave mounts. Guide the wire and the Replacement
threaded clevis into the boom by placing the
threaded clevis between the third boom section (5) 1. Park the machine on level ground. Place the
and the top of the fourth boom section (6). transmission control lever in (N) NEUTRAL, engage
the parking brake switch, level the boom and shut
16. Have an assistant guide the extend chain into the
the engine OFF.
front of the boom while pulling the wire and threaded
clevis into the hole in the anchor plate. 2. Place a Do Not Operate Tag on both the ignition key
17. Place the flat washer onto the threaded end of the
threaded clevis and assemble the locknut. Thread
the locknut onto the threaded clevis until the threads 3. Properly disconnect the battery.
are flush with the top of the nut. 4. Remove the boom rear cover.
18. Remove the wire from the clevis.
19. After the chain is replaced inside the boom,
assemble the sheave to the mount at the front of the
third boom section.
20. Place the extend chain sheave between the mounts
at the front of the third boom section. Insert the
sheave pin through the mounts and the sheave.
Secure in place with the capscrew, saved, and a
locknut. Tighten securely.
6036, 6042, 8042, 10042, 10054 3-43

Boom
9. From the rear of the boom, pull the boom retract

chain out of the rear of the boom.
10. Disconnect the string or wire from the retract chain
clevis, and allow it to hang out the rear of the boom.
11. Coat the threads of the threaded clevis with multi-
7 purpose grease.
12. At the rear of the boom, attach the string or wire to
the new retract chain threaded clevis end with a
threaded eye or a flat washer tack welded to a
threads on the clevis.
13. From the rear of the boom, have an assistant push
the threaded clevis end of the new retract chain
OA0513
under the chain sheave and down between the
5. At the front underside of the boom, locate the retract second and first boom sections, while pulling the
chain locknut (7). Record the amount of threads retract chain through the boom using the previously
extending beyond the locknut. This measurement attached string or wire. Keep the retract chain to the
will be the starting point for adjustment of the retract right side of the boom, push and pull the threaded
chain after installation. clevis down to the tab at the front underside of the
boom.
6. At the front underside of the fourth boom section,
remove the locknut and flat washer holding the
retract chain threaded clevis to the mounting tab.
7. Attach a wire or string to the threaded clevis with a
threaded eye or a flat washer tack welded to a
threads on the clevis. The wire or string will be used
to pull the chain back through the boom during
reassembly.
Note: Record the location of the shoulder bolt to ensure
correct installation.
9
8
MH2561
14. Reassemble the flat washer and a locknut (9) onto

the threaded clevis. Tighten the locknut until the
threaded end of the clevis is flush with the top of the
locknut.
15. At the rear of the boom, place the retract chain up
and over the chain sheave. Place the clevis between
the two anchor plates. Line up the hole in the clevis
with the anchor plate hole position recorded during
removal.
MH2551
16. Insert the shoulder bolt through the plates and clevis
8. At the rear of the boom, locate the two retract chain and secure in place with a locknut. Tighten the
anchor plates. Remove the locknut and shoulder bolt locknut securely.
(8) holding the retract chain clevis to the anchor
plates. The two anchor plates can remain in place on 17. Check and adjust the retract chain tension. Refer to
the third boom section. Section 3.7.5, “Boom Chain Tension Check.”
3-44 6036, 6042, 8042, 10042, 10054

Boom
18. Install the boom rear cover. until all the tension on the retract chain is relieved.
19. Properly connect the battery. Shut the engine OFF.
20. Remove the Do Not Operate Tags from both the Note: Record the location of the shoulder bolt to ensure
ignition key switch and the steering wheel. correct installation.
11
d. Fourth Boom Section Retract Chain Removal
and Replacement
the parking brake switch, level the boom and shut
the engine OFF.
5. Start the engine and extend the boom until the MH2671
retract chain adjustment nut on the bottom of the

second boom section is visible. Shut the engine 9. At the rear of the boom, locate the two retract chain
OFF. anchor plates (11). The two anchor plates can
remain in place on the fourth boom section.
6. At the front underside of the boom, locate the retract
chain locknut. Record the amount of threads 10. Pull the retract chain clevis toward the rear of the
extending beyond the locknut. This measurement boom, through the middle of the two center hoses on
will be the starting point for adjustment of the retract the chain reel and over the top of the chain reel. Let
chain after installation. the clevis end of the retract chain hang out the rear
of the boom. Use a piece of wire that is
approximately 6 feet (1,8 m) long and tie it to the
clevis end of the retract chain. This wire will be used
to guide the chain back into the boom when the
boom is extended to expose the other end for
10 removal.
11. Have an assistant start the engine and slowly extend
the boom. Guide the retract chain with the wire
attached into the back of the boom. Extend the
boom until the retract chain adjustment nut on the
lower left side of the second boom section can be
accessed and removed. Turn the engine OFF.
12. Remove the locknut and flat washer holding the
threaded clevis on the retract chain to the tab in the
second boom section.
OH0661
7. Loosen the locknut (10) on the retract chain clevis.

12
DO NOT remove the locknut at this time, but loosen
the nut as far as possible to gain as much slack as
possible in the retract chain.
8. Return to the operator cab, start the engine and
slowly retract the boom all the way back, and then
extend the boom approximately 1 in (25 mm) or just
MH6510
6036, 6042, 8042, 10042, 10054 3-45

Boom
13. Attach a wire to the end of the retract chain clevis 19. Guide the threaded end of the clevis through the
(12) with a threaded eye or a flat washer tack welded hole in the tab (16) on the second boom section.
to a capscrew. The outside diameter of the eye or 20. Remove the wire from the end of the clevis.
flat washer must be smaller than the diameter of the
threads on the clevis. The wire must be long enough 21. Place the flat washer onto the threaded clevis.
to pull the clevis and chain through the boom. The Assemble a locknut onto the threaded clevis. Turn
wire must be heavy enough to pull the weight of the the locknut only 2 or 3 turns onto the clevis to allow
entire chain back through the boom during the assembly of the other end of the retract chain.
reassembly. 22. At the front of the boom, disconnect the extend chain
14. From the rear of the boom, using the wire attached clevis from the anchor plates on the second boom
to the rear anchor clevis, pull the retract chain section. Remove the locknut holding the shoulder
through the middle of the two center hoses on the bolt to the anchor plates. Pull the extend chain clevis
chain reel and over the top of the chain reel and out from between the plates and lay over the front of the
of the rear of the boom. fourth boom section.
15. Remove the wire still attached from the clevis on the 23. Return to the operator compartment and start the
old chain. engine and slowly retract the boom. To avoid having
the retract chain becoming entangled, keep tension
16. Install the wire still attached, to the new chain clevis. on the chain coming out the back of the boom.
17. Coat the threads of the threaded clevis on the new Retract the boom as far as possible with the Extend/
chain with multi-purpose grease. Retract cylinder. Turn the engine OFF.
24. The fourth boom section will not retract completely
13
and must be manually pushed in. To avoid having
14 the retract chain becoming entangled, keep tension
on the chain coming out the back of the boom while
the fourth boom section is pushed in.
Note: Care should be taken not to push the fourth boom
section in too far. If the fourth boom section is pushed in
too far it could damage the hose reel at the back of the
15 MH6021 boom.
18. From the front of the boom, have an assistant pull on 25. Remove the wire from the anchor clevis at the rear of
the tow wire while guiding the chain clevis between the boom. Place the retract chain up and over the
the two center hoses of the hose reel and under the chain sheave in front of the hose reel assembly.
chain sheave (13), on the left side of the boom and Place the clevis between the two anchor plates. Line
down the boom between the third (14) and second up the hole in the clevis with the anchor plate hole
(15) boom sections. Keep the retract chain lined up position recorded during removal.
squarely with the chain sheave and help feed the
retract chain in while pulling on the wire from the front of 17
the boom.
16
MH2671
MH5991
3-46 6036, 6042, 8042, 10042, 10054

Boom
26. Insert the shoulder bolt (17) through the plates and
clevis and secure in place with a locknut. Tighten the
locknut securely.
27. Pull the extend chain up and around the sheave at
the front of the third boom section.
28. Place the extend chain clevis between the mounting
plates at the front of the third boom section. Coat the
shoulder bolt with anti-seize compound and insert
through the plates and clevis. Secure the shoulder
bolt in place with a locknut. Tighten securely, but the
chain clevis should pivot freely.
29. Return to the operator compartment and start the
engine. Slowly extend the boom to gain access to
the retract chain adjustment nut on the lower left side
of the second boom section. Shut the engine OFF.
30. Tighten the adjustment nut until the threads of the
threaded clevis are flush with the top edge of the nut.
This will be a starting point for adjustment of the
fourth boom section retract chain.
31. Check and adjust the retract chain tension. Refer to
6036, 6042, 8042, 10042, 10054 3-47

Boom
3.8 QUICK ATTACH ASSEMBLY 3.9 BOOM WEAR PADS

The wear pads on this machine are flat rectangular wear
3.8.1 Quick Attach Removal pads with metal inserts.
1. Remove the lock bolt holding the Attachment Tilt A total of 32 wear pads are installed on the boom sections
cylinder rod end pin to the quick attach assembly. of the 6036, 6024, 8042 & 10042 machines and 47 wear
Remove the Attachment Tilt Cylinder pin. pads on the 10054 machines.
2. Support the quick attach assembly. Remove the
capscrew and locknut securing the quick attach pivot 3.9.1 Wear Pad Inspection
pin to the quick attach assembly. Remove the quick
1 1
attach assembly. Record the location and quantity of
the shim washers as the pin is being removed.
3. Inspect the above pins for nicks or surface corrosion.
Use fine emery cloth to fix minor nicks or corrosion.
If damaged or if it cannot be repaired the pin must be
replaced. Inspect all wear pads for wear. If the angle indicators (1)
on the ends of the wear pads are visible, the wear pads
3.8.2 Quick Attach Installation can be reused. If the pads show uneven wear (front to
1. Assemble the quick attach to the boom head. Line back), they should be replaced. Replace pads as a set if
up the quick attach between the mounts on the worn or damaged.
boom head. The quick attach should be centered in
the boom head. Reassemble the shims between the 3.9.2 Wear Pad Installation and Lubrication
quick attach and the boom head. Note: Inspect all wear pads. Replace as necessary.
2. Coat the quick attach head pin with an anti-seize The following wear pad procedure must be followed to
compound. Insert the quick attach head pin through insure the proper wear pad installation:
the quick attach and boom head. Secure with the
previous capscrew and locknut. • The wear pad inserts and mounting bolts MUST be
clean from any grease, oil or other contaminates
3. Align the quick attach with the Attachment Tilt before applying Loctite® 242TM and installing
cylinder rod end and insert the Attachment Tilt mounting bolts.
cylinder pin. Align the Attachment Tilt cylinder pin • Apply Loctite® 242TM to all wear pad mounting bolts.
and screw in the locking bolt. Torque as required.
4
3
2
MAQ0420
• A spacer (2) must be used before any shim (3) is

used.
• A shim (3) must be inserted between the spacer (2)
and wear pad support plate, block or boom section
(4).
• The number of shims can vary at each shim point.
• The bottom wear pads must be shimmed equally on
each side.
3-48 6036, 6042, 8042, 10042, 10054

Boom
3.10 FORKS
5
Forks should be cleaned and inspected prior to being
attached to carriage. If the following criteria is not met,
forks must be removed from service immediately.
Daily Inspection
10 8 7
• Maintain a total boom section clearance (5) of 5

0.070 - 0.130 in (1,78 - 3,30 mm) both the horizontal 4
and vertical directions. 14
A
B
13 11
MY3620 12 MH6460
• The length of the wear pad bolt depends on the

number of shims, spacers and washers being used. 1. Inspect forks (4) for cracks, paying special attention
to heel (5) and mounting tubes (6).
• The thickness of each threaded wear pad insert is
0.562 in (14,27 mm) (A). 2. Inspect forks for broken or bent tips (7) and twisted
• The bolt length should be determined by measuring blades (8) and shanks (9).
the distance from the face of the insert to the face of Yearly Inspection
the boom (B) including any spacer, shim(s) and
washer(s). 1. Straightness of the upper face of blade (8) and the
front face of shank (9) should not exceed 0.5 percent
• Bolt thread engagement in the wear pad insert
of the length of blade or height of shank.
should be 0.235 - 0.315 in (5,98 - 8,0 mm).
• One or two hardened washers are to be used on 2. Angle (10) between upper face of blade and front
each wear pad bolt except where noted otherwise. face of shank should not exceed 93 degrees.
DO NOT use more than two hardened washers. 3. Thickness of blade (13) and shank (14) should not
• Use only one hardened washer if mounting bolts are be reduced to 90 percent of original thickness.
recessed.
4. Ensure fork length (12) is adequate for intended
• Wear Pad Bolt Torque: 3/8-16 Bolt, 31 lb-ft (42 Nm) loads.
• Torque wear pad bolts after shimming is completed.
5. Fork markings should be legible, re-stamp if
• Lubricate the face and pockets of each wear pad required.
after being installed.
6. Compare fork tips (11) when mounted on a carriage.
Boom Section Wear Pad Pathway Lubrication:
Maximum difference in height of fork tips is 3 percent
• Clean and lightly grease all wear pad pathways with of the length of the blade (13).
Mystik Tetrimoly grease.
• Clean and lightly grease the hose carrier guide bar
pathways with Mystik Tetrimoly grease.
6036, 6042, 8042, 10042, 10054 3-49

Boom
3.11 TROUBLESHOOTING
This section provides an easy reference guide covering
the most common problems that occur during operation
of the boom.
Problem Cause Remedy

1. Boom will not extend or 1. Broken hydraulic hose(s) or 1. Locate break, replace hose(s)
retract tube(s) and/or connections or tube(s), tighten connections.
leaking.
2. Extend/retract hydraulic system 2. Refer to Section 8.4, “Hydraulic

not operating properly. Circuits.”
3. Faulty extend/retract cylinder. 3. Repair cylinder. Refer to Section

8.8.1, “General Cylinder
Instructions.”
4. Broken chains or anchors 4. Replace chains as needed
2. Boom shifts to right or left 1. Boom side wear pads 1. Shim wear pads to correct gap.
when extending. improperly shimmed or worn. Replace wear pads as needed.
Refer to Section 3.9, “Boom
Wear Pads.”
3. Excessive pivot pin noise 1. Insufficient lubrication. 1. Lubricate at regular intervals.

and/or wear. Refer to Section 2.8,
“Lubrication Schedules.”
Replace worn pins as needed.
2. Worn bearing(s). 2. Replace bearing(s) and

lubricate at regular intervals
Refer to Section 2.8,
4. Excessive Compensation 1. Insufficient lubrication. 1. Lubricate at regular intervals.

cylinder pivot pin noise and/ Refer to Section 2.8,
or wear. “Lubrication Schedules.”
2. Worn bushing(s). 2. Replace bushing(s) and

lubricate at regular intervals.
5. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes 1. Locate break, replace hose(s)
and/or connection leaks. or tube(s), tighten connections.
2. Lift/lower hydraulic system not 2. Refer to Section 8, “Hydraulic

operating properly. System.”
3. Faulty lift/lower cylinder. 3. Repair cylinder. Refer to Section

8.8, “Hydraulic Cylinders.”
4. Seized boom pivot pin bearing. 4. Replace bearing.
3-50 6036, 6042, 8042, 10042, 10054

Boom

6. Drooping chain, or jerky 1. Chain(s) tension not properly 1. Adjust chain(s).
boom extend or retract adjusted.
functions.
2. Chain(s) stretched or binding. 2. Replace chains as needed.
Refer to Section 3.7, “Boom
Extend and Retract Chains.”
3. Wear pads loose, contaminated, 3. Replace wear pad. Refer to

excessively worn or damaged. Section 3.9, “Boom Wear Pads.”
4. Contaminated, corroded or 4. Remove contamination and/or

rusted wear pad sliding corrosion from wear pad sliding
surfaces. surfaces and lubricate. If the
surfaces cannot be reconditioned,
replace the boom section(s).
5. Extend/Retract hydraulic system 5. Refer to Section 8.4, “Hydraulic

not operating properly. Circuits.”
6. Damaged boom section. 6. Replace the damaged boom

section. Refer to Section 3.4,
“Boom Assembly Maintenance.”
7. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes 1. Locate break, replace hose(s)
and/or connection leaks. or tube(s), tighten connections.
2. Lift/Lower hydraulic system not 2. Refer to Section 8.4, “Hydraulic

operating properly. Circuits.”
3. Faulty Lift cylinder. 3. Repair cylinder. Refer toSection

8.8.1, “General Cylinder
Instructions.”
4. Seized boom pivot pin bushing. 4. Replace bushing.
8. Excessive Lift/Lower cylinder 1. Insufficient lubrication. 1. Lubricate at regular intervals.

pivot pin noise and/or wear. Refer to Section 2.7, “Service
and Maintenance Schedules.”
Refer to Section 8.8.1, “General
Cylinder Instructions.”
2. Worn self-aligning bushing(s). 2. Replace bushing(s) and

lubricate at regular intervals.
Refer to Section 2.8,
6036, 6042, 8042, 10042, 10054 3-51

Boom

9. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and
correct as needed. Refer to
Section 3.9, “Boom Wear Pads.”
2. Rapid cycle times with heavy 2. Reduce cycle times.

loads.
3. Contaminated, corroded or 3. Remove contamination and/or

rusted wear pad sliding corrosion from wear pad sliding
surfaces. surfaces and lubricate. If the
surfaces cannot be
reconditioned, replace the boom
section(s).
4. Operating in extremely dusty/ 4. Clean equipment frequently.

abrasive conditions.
10. Auxiliary hydraulics will not 1. Auxiliary hydraulic system not 1. Refer to Section 8, “Hydraulic
operate. operating properly. System.”
11. Excessive chain wear. 1. Improper chain adjustment. 1. Adjust to correct tension. Refer
to Section 3.7.1, “Boom Chain
Inspection.”- Replace chains as
needed.
2. Chain sheave(s) not properly 2. Lubricate chain sheave. (Refer

lubricated. to Section 2.7, “Service and
Maintenance Schedules.”
3. Chain sheave(s) not rotating 3. Lubricate chain sheave. Refer

freely. to Section 2.7, “Service and
Maintenance Schedules.”
Repair or replace chain
sheave(s) as needed.
4. Improper chain lubrication. 4. Lubricate at regular intervals.

Refer to Section 2.7, “Service
and Maintenance Schedules.”
Replace chains as needed.
3-52 6036, 6042, 8042, 10042, 10054

Section 4
Cab and Covers
Contents

4.1 Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.1 Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.2 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3 Cab Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.1 Steering Column and Steering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.2 Service Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3.3 Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.4 Joystick Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.5 Windshield Wiper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.3.6 Heater/Defroster System (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
6036, 6042, 8042, 10042, 10054 4-1

Cab and Covers
4.1 OPERATOR CAB AND COVERS

COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance
information presented in this section, it is necessary that
the operator/mechanic be familiar with the names and
locations of the major assemblies of the machine cab and
covers. The following illustration identifies the
components that are referred to throughout this section.
HEATER AND A/C

CONTROLS (OPTIONAL)
INSTRUMENT
PANEL
STEERING WHEEL
TRANSMISSION
CONTROL LEVER
BOOM CONTROL
JOYSTICK
PARK BRAKE
SWITCH
ATTACHMENT TILT/
FRAME LEVEL
CONTROL JOYSTICK
AUXILIARY HYDRAULIC
IGNITION CONTROL JOYSTICK
SWITCH (IF EQUIPPED)
SERVICE BRAKE
PEDAL
MH6230
ACCELERATOR PEDAL
4-2 6036, 6042, 8042, 10042, 10054

Cab and Covers

WARNING machine should not be operated.

DO NOT service the machine without following all 4. Properly disconnect the battery.
safety precautions as outlined in the “Safety
Practices” section of this manual. 5. Remove the left, right and lower dash panels.
1
4.2 OPERATOR CAB
4.2.1 Cab Safety
WARNING 2
The protection offered by this ROPS/FOPS will be
impaired if subjected to any modification or structural
damage, at which time replacement is necessary.
ROPS/FOPS must be properly installed using
fasteners of correct size and grade, and torqued to
their specified value.
3
WARNING
DO NOT weld, grind, drill, repair or modify the cab in 4
any way. Any modification or damage to cab structural
components requires cab replacement. Refer to
Section 2.5 in the Operation & Safety Manual.
To help ensure optimum safety, protection and
performance, replace the cab if it is damaged. Refer to
the appropriate parts manual for ordering information.
MY0120
4.2.2 Serial Number Decal
6. Remove the steering wheel (1), disconnect and
The cab serial number decal is located on the left side of remove the travel select lever (2), disconnect the
the cab, behind the seat. Information specified on the instrument panel harness connector (3).
serial number plate includes the cab model number, the
cab serial number and other data. Write this information 7. Label, disconnect and cap the four hoses from the
down in a convenient location to use in cab side of the steering valve (4). Cap the fittings on the
correspondence. steering valve. Label, disconnect and plug the load
sense hose at the front of the steering valve. Cap the
fitting on the steering valve.
4.3 CAB COMPONENTS
8. Disconnect the horn button wire from the cab wiring
harness.
4.3.1 Steering Column and Steering Valve
9. Support the bottom of the steering valve, and
a. Steering Valve Removal remove the four capscrews and lockwashers.
Remove the steering valve through the lower dash
1. Park the machine on a firm, level surface, level the panel opening.
place the travel select lever in the (N) NEUTRAL
position, engage the parking brake and turn the
engine OFF.
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7. Install the travel select lever, connect the instrument

panel harness connector, install the steering wheel
assembly. Torque the steering wheel nut to 50 lb-ft
(68 Nm).
10. Start the engine and check the operation of steering
system. Check for hydraulic fluid leaks. Check the
hydraulic fluid level in the tank and add fluid as
required.
11. Install the left, right and lower dash panels.
c. Steering Test
Conduct a pressure check of the steering hydraulic
circuits at the main control valve. Refer to Section 8.3.1,
5 “Pressure Checks and Adjustments.”
MA8861 4.3.2 Service Brake Pedal

10. Remove the steering column (5), by pushing it down, a. Brake Valve Removal
and removing it through the lower dash panel
opening. Refer to Section 8.7.3, “Service Brake Valve,” for removal
information.
Note: DO NOT disassemble the steering valve. The
steering valve is not serviceable and must be replaced in b. Brake Valve Installation
its entirety, if defective.
Refer to Section 8.7.3, “Service Brake Valve,” for
b. Steering Valve Installation installation information.
1. Install the steering column and steering valve, by c. Service Brake Pedal Removal
inserting them through the lower dash panel
opening. Position steering valve in the cab to its 1. Park the machine on a firm, level surface, level the
original orientation. Secure the steering valve and machine, fully retract the boom, lower the boom,
column with the previously used hardware. Torque to place the travel select lever in the (N) NEUTRAL
13 lb-ft (18 Nm). position, engage the parking brake and turn the
engine OFF.
Note: ALWAYS use new o-rings when servicing the
machine.
switch and steering wheel, stating that the machine
2. Install new o-rings into the fittings. Lubricate the o- should not be operated.
rings with clean hydraulic oil. 3. Open the rear door. Allow the system fluids to cool.
3. Uncap and connect the previously labeled load 4. Properly disconnect the battery.
sense hose to the steering valve.
4. Install new o-rings into the steering valve fittings.
Lubricate the o-rings with clean hydraulic oil.
5. Uncap and connect the remaining previously labeled
four hoses to the steering valve.
6. Connect the horn button wire to the cab wiring
harness.
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4.3.3 Throttle Pedal
a. Throttle Pedal Removal

1. Park the machine on a firm, level surface, level the
position, engage the parking brake and turn the
engine OFF.
should not be operated.
MH6210 5
5. Remove the lower dash panel.
6. Remove the two capscrews, four flat washers, two
pivots and two nuts securing the service brake pedal
to the cab. 6
7. Remove the service brake pedal from the cab.
d. Service Brake Pedal Installation

1. Position the service brake pedal in its mounting
location within the cab.
2. Insert the two brake pedal pivots into mounting
locations on the service brake pedal.
MH6240
3. Install the service brake pedal with the previously
used hardware. 4. Disconnect the electrical harness connector (4).
4. Be sure the brake pedal has the correct range of motion. 5. Remove the bolts (5) securing the throttle pedal to
Secure pivot pin with bolt and lockwasher. the throttle pedal bracket (6).
5. Adjust the service brake as needed. Refer to Section 6. Remove the throttle pedal assembly from the cab.
9.10.5, c. “Service Brake Switch Adjustment.”
6. Install the lower dash panel. b. Throttle Pedal Installation
7. Properly connect the battery. 1. Position the throttle pedal in its mounting location
8. Remove the Do Not Operate Tags from both the within the cab.
ignition key switch and the steering wheel. 2. Secure the throttle pedal in place with previously
9. Close and secure the rear door. used hardware.
3. Reconnect the wire harness plug to the front of the
throttle pedal.
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4.3.4 Joystick Assemblies

These removal and installation instructions apply to
the boom control, attachment tilt/frame level and auxiliary 4
hydraulic joysticks.
a. Joystick Assembly Removal

1. Park the machine on a firm, level surface, level the MAQ0050
place the travel select lever in the (N) NEUTRAL 6. Remove the four capscrews (4) and remove the
position, engage the parking brake and turn the joystick assembly from the machine.
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key b. Joystick Assembly Installation
switch and steering wheel, stating that the machine 1. Secure the joystick to the cab with the previously
should not be operated. used hardware.
3. Properly disconnect the battery. 2. Connect the control cables at the joystick:
4. Remove the console panel in the cab. a. Install the end of the control cable into the slider
head (5) as recorded during removal. Tighten the
upper jam nut (3).
b. Loosely install the cable nut (2) into the slider
1 head.
c. Engage the control lever to expose the flats (1)
on the slider head. Place a wrench on the flats to
hold the slider head, and tighten the cable nut to
5 a maximum of 55 lb-ft (75 Nm).
d. Repeat steps for remaining cables.
Note: Refer to Section c, “Joystick Cable Adjustment,”
2
for detailed cable adjustment.
3 4. Remove the Do Not Operate Tags from both the
5. Test the joystick function:
Boom Control Joystick:
• Move the joystick handle rearward, activating the
boom lift function. The boom should RISE.
• Move the joystick handle forward, activating the
boom lower function. The boom should LOWER.
MA8521 • Move the joystick handle to the right, activating the
boom extend function. The boom should EXTEND.
Note: Record the location, and label all cables to ensure
correct installation. • Move the joystick handle to the left, activating the
boom retract function. The boom should RETRACT.
5. Disconnect control cables at the joystick:
Attachment tilt/frame level Control Joystick:
a. Push the control lever to expose the flats (1) on
the slider head. Place a wrench on the flats to • Move the joystick handle rearward, activating the
hold the slider head, and loosen the cable nut attachment tilt function. The boom should TILT UP.
(2). • Move joystick handle forward, activating attachment
b. Loosen the upper jam nut (3), and remove the tilt function. The boom should TILT DOWN.
cable from the bracket.
• Move joystick handle to right, activating frame level
c. Repeat steps for remaining control cables.
4-6 6036, 6042, 8042, 10042, 10054

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function. The boom should FRAME LEVEL RIGHT. 4.3.5 Windshield Wiper Assembly
• Move joystick handle to left, activating frame level Refer to Section 9.8, “Window Wiper/Washer Windshield
function. The boom should FRAME LEVEL LEFT. Wiper Motor,” for removal and installation information.
Auxiliary Control Joystick
4.3.6 Heater/Defroster System (If Equipped)
• Move the joystick handle to the right, the auxiliary
attachment should LOWER/OPEN. a. Heater Assembly Removal
• Move the joystick handle to the left, the auxiliary
attachment should RAISE/CLOSE.
6. Install console panel in the cab. place the travel select lever in the (N) NEUTRAL
position, engage the park brake and shut the engine
c. Joystick Cable Adjustment OFF.
A 2. Place a Do Not Operate Tag on both the ignition key
MAQ1470 5. Place a suitable container beneath the radiator drain
6 7 7 plug or petcock. Slowly turn the radiator cap to the
first stop, and allow any pressure to escape.
1. Park the machine on a firm, level surface, level the Remove the radiator cap.
machine, fully retract the boom, lower the boom, 6. Place a funnel at the base of the radiator to channel
place the travel select lever in the (N) NEUTRAL the drained coolant into the container. Loosen the
position, engage the parking brake and turn the drain plug or petcock and allow the coolant to drain.
engine OFF.
7. Transfer the coolant to a container with a cover, and
2. Place a Do Not Operate Tag on both the ignition key label as “Used Antifreeze.” Dispose of the used
switch and steering wheel, stating that the machine coolant at an approved recycling facility.
8. Close the radiator drain plug or petcock.
9. Remove the heater access panel.
4. Remove transmission covers.
10. Label, disconnect and cap the heater hoses. Pull the
5. Verify proper joystick cable dimension (A) hoses through the grommets.
0.94-1.06 in (23.9-27.0 mm) at the main control
valve.
6. With the joystick in the neutral position, the joystick
to main control valve spool pin (6) must spin freely. 10
7. If adjustment is required, loose lock nuts (7), adjust
joystick cable. 9
8. Tighten both lock nuts (7) using two wrenches.
9. Repeat step 7.
10. Torque lock nuts to 35-50 lb in (4-5.6 Nm).
11. Install transmission covers. 8
MA8371
6036, 6042, 8042, 10042, 10054 4-7

Cab and Covers
Note: The capscrew (8) at the lower rear position on 4.4 CAB REMOVAL
each side of the heater will be secured with an insert nut
(9).
11. Remove the eight capscrews, six nuts and six WARNING
lockwashers.
The protection offered by this ROPS/FOPS will be
12. Carefully pull the heater assembly forward. Label impaired if subjected to any modification or structural
and disconnect the wiring harness connections at damage, at which time replacement is necessary.
the blower. ROPS/FOPS must be properly installed using
13. Remove the heater assembly (10). fasteners of correct size and grade, and torqued to
their specified value.
14. If the heater assembly is to be replaced: Remove
the four hex-slotted capscrews, and remove the Note: To help ensure safety and optimum performance,
mounting bracket from the heater assembly. replace the cab if it is damaged. Refer to the appropriate
parts manual for ordering information.
b. Heater Assembly Installation
Inspect the cab, its welds and mounts. If modification,
1. Connect the wiring harness connections to the damage, a cracked weld and/or fatigued metal is
blower. discovered, replace the cab. Contact the local distributor
Note: The capscrew (8) at the lower rear position on with any questions about the suitability or condition of a
each side of the heater will be secured with an insert nut cab.
(9). Note: Remove and label cab components as needed
2. Slide the heater/mounting bracket assembly (9) into before removing the cab from the machine. Label,
the seat riser, and secure with the eight capscrews, disconnect and cap hydraulic hoses. Transfer cab parts
six lockwashers and six nuts. to the replacement cab after the replacement cab is
securely mounted on the machine.
3. Pull the hoses through the grommets. Uncap and
connect the previously labeled hoses to the heater. 1. Park the machine on a firm, level surface. Allow
sufficient overhead and side clearance for cab
4. Install the heater access panel and secure with the
removal. Level the machine, fully retract the boom,
previously used hardware.
lower the boom, place the travel select lever in the
5. Fill the cooling system completely with coolant, (N) NEUTRAL position, engage the park brake and
allowing time for the coolant to fill the engine block. shut the engine OFF.
The cooling system capacity is listed in Section 2.5,
2. Block all four wheels to help prevent the machine
“Fluid Specifications.”
from moving. Assure that there is sufficient overhead
6. Properly connect the battery. and side clearance for cab removal.
7. Remove the Do Not Operate Tags from both the 3. Open the rear door. Allow the system fluids to cool.
Note: When the engine is initially started, run it briefly at
Note: Steps 5 thru 10 apply to machines equipped with
low idle and check the machine for any visual sign of
cab heater.
fluid leakage. STOP the engine immediately if any
leakage is noted, and make any necessary repairs 5. Place a suitable container beneath the radiator drain
before continuing. plug or petcock. Slowly turn the radiator cap to the
first stop and allow any pressure to escape. Remove
8. Wait for the engine to cool and check the coolant
the radiator cap.
level. Add coolant as required to bring the coolant to
the proper level. 6. Place a funnel at the base of the radiator to channel
the drained coolant into the container. Loosen the
drain plug or petcock and allow the coolant to drain.
7. Transfer the coolant to a container with a cover, and
label as “Used Antifreeze.” Dispose of the used
coolant at an approved recycling facility.
8. Close the radiator drain plug or petcock.
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2 1
MA8501
MA8781
15. Working under the cab, label, disconnect and cap
the hydraulic hoses at the cab fittings (4). Cap all
9. Working under the cab, loosen the clamp screw (1) fittings to keep dirt and debris from entering the
and disconnect the heater control cable (2) from the hydraulic system.
heater control valve. Label, disconnect and cap the 16. If necessary, remove mirrors and other cab
heater hoses. components that may become damaged during cab
10. Remove the heater access panel. Label, disconnect removal.
and cap the heater hoses and route them through 6
the opening in the bottom of the cab.
11. Remove the console panel in the cab.
3 5
MA3331
17. Attach a clevis (5) to each of the cab lifting brackets.

Route a sling (16) with a minimum lifting capacity of
1000 lb (453 kg) to a hoist or overhead crane.
MA8471 Center the sling to ensure even lifting.
12. Label and disconnect the two cab-to-wiring harness 18. Remove the two upper cab-to-frame capscrews and
connectors (3). Push the connectors through the two flat washers.
opening at the bottom of the cab. 19. Remove the two lower cab-to-frame capscrews and
13. Remove the joystick assemblies from the cab. Refer two flat washers.
to Section 4.3.4, a. “Joystick Assembly Removal.” 20. Carefully begin to lift the cab. Stop and check that all
14. Route the joystick cables through the opening at the wiring, hydraulic hoses and fasteners are
bottom of the cab. disconnected and removed.
21. When all wiring, hydraulic hoses and fasteners are
disconnected or removed, carefully and slowly lift
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Cab and Covers
the cab and remove it from the frame. Readjust the

position of the sling as needed to help balance the
cab during removal.
22. When the cab is completely clear of the machine,
carefully lower it to the ground. Block up or support
the cab so that it does not move or fall. Assure that
no personnel enter the cab while it is being removed
from the machine.
23. Inspect the condition of the fittings, clamps,
hydraulic hoses, etc. Replace parts as indicated by
their condition.
4
24. Inspect and replace other machine parts that are
exposed with the cab removed. Repair or replace as MA8501
required.
7. Uncap and connect the previously labeled hydraulic
4.5 CAB INSTALLATION hoses at the cab fittings (4).
8. Route the joystick control cables through the
1. Block all four wheels to help prevent the machine opening at the bottom of the cab. Install the joystick
from moving. Assure that there is sufficient overhead assemblies. Refer to Section 4.3.4, b. “Joystick
and side clearance for cab installation. Assembly Installation.”
2. Attach a clevis (5) to each of the cab lifting brackets.
Route a sling (6) with a minimum lifting capacity of
1000 lb (453 kg) to carry the weight of the cab 3
through the clevis’ to a hoist or over head crane.
Make sure the sling is centered between the clevis’
to ensure even lifting.
3. Carefully begin to align the cab with the mounting
holes in the frame. Stop and check that wiring,
hydraulic hoses, cables, etc. will not be pinched or
damaged as the cab is positioned. Readjust the
position of the sling as needed to help balance the
cab during installation.
4. Install the two upper cab-to-frame capscrews and
washers. Torque to 480 lb-ft (651 Nm).
5. Install the two lower cab-to-frame capscrews and
washers. Torque to 480 lb-ft (651 Nm). MA8471
6. Under the cab, install new o-rings into the fittings. 9. Route the wiring harness connectors through the
Lubricate the o-rings with clean hydraulic oil. opening at the bottom of the cab. Connect the
previously labeled connectors (2).
10. Install the console panel.
11. Install the transmission covers.
12. Working under the cab, connect the coolant hoses to
the heater hoses.
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2 1
MA8781
13. Connect the heater control cable (2) to the heater

control valve (1).
14. Fill the cooling system completely with coolant,
allowing time for the coolant to fill the engine block.
The cooling system capacity is listed in Section 2.5,
16. Carefully examine all cab components, fasteners,
etc., one last time before engine start-up. Rectify any
faulty conditions.
17. Start the engine and check the operation of all controls.
Check for hydraulic fluid leaks. Check the hydraulic
fluid level in the tank and add fluid as required.
Note: When the engine is initially started, run it briefly at
low idle and check the machine for any visual sign of
fluid leakage. STOP the engine immediately if any
leakage is noted, and make any necessary repairs
before continuing.
18. Wait for the engine to cool and check the coolant
level. Add coolant to the overflow bottle as required
to bring the coolant to the proper level.
19. Install the mirrors and all other cab components as
needed, if removed.
20. Unblock the wheels.
6036, 6042, 8042, 10042, 10054 4-11

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4-12 6036, 6042, 8042, 10042, 10054

Section 5
Axles, Drive Shafts, Wheels and Tires
Contents

5.1 Axle, Drive Shaft and Wheel Component Terminology (6036) . . . . . . . . . . . . . . 5-2
5.4 Axle, Drive Shaft and Wheel Component Terminology (10042 & 10054) . . . . . . 5-5
5.5 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.6 Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.6.1 Axle Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.6.2 Axle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.6.3 Axle Internal Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.6.4 Axle Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.6.5 Axle Replacement (6036 & 6042) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.6.6 Axle Replacement (8042, 10042 & 10054) . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.7 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.8 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.8.1 Drive Shaft Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.8.2 Drive Shaft Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.8.3 Drive Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.8.4 Drive Shaft Cleaning and Drying. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.8.5 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.9 Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.9.1 Removing Wheel and Tire Assembly from Machine . . . . . . . . . . . . . . . . . 5-17
5.9.2 Installing Wheel and Tire Assembly onto Machine . . . . . . . . . . . . . . . . . . 5-18
5.10 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.10.1 Brake Disc Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.11 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
6036, 6042, 8042, 10042, 10054 5-1

5.1 AXLE, DRIVE SHAFT AND WHEEL

COMPONENT TERMINOLOGY (6036)
locations of the major assemblies of the axles, drive shafts,
wheels and tires. The following illustration identifies the
ENGINE-TO-TRANSMISSION
DRIVE SHAFT
REAR AXLE
REAR STEERING ASSEMBLY
CYLINDER
FRAME
LEVEL FRONT
CYLINDER STEERING
CYLINDER
FRONT DRIVE SHAFT REAR DRIVE SHAFT

FRONT AXLE
ASSEMBLY
MAQ0910
5-2 6036, 6042, 8042, 10042, 10054


ENGINE-TO-TRANSMISSION
DRIVE SHAFT
STABILIZER
CYLINDER
REAR AXLE
REAR STEERING ASSEMBLY
CYLINDER
FRAME
LEVEL FRONT
CYLINDER STEERING
CYLINDER
REAR DRIVE SHAFT
FRONT DRIVE SHAFT
FRONT AXLE
ASSEMBLY
MAQ0920
6036, 6042, 8042, 10042, 10054 5-3


ENGINE-TO-
TRANSMISSION DRIVE
SHAFT
STABILIZER
CYLINDER
FRAME
LEVEL
CYLINDER
REAR
STEERING
CYLINDER
REAR AXLE
ASSEMBLY
FRONT
STEERING
CYLINDER
REAR DRIVE SHAFT

FRONT DRIVE SHAFT
FRONT AXLE
MAQ0930
ASSEMBLY
5-4 6036, 6042, 8042, 10042, 10054


(10042 & 10054)
ENGINE-TO-
TRANSMISSION DRIVE
SHAFT
STABILIZER
CYLINDER
FRAME
LEVEL
CYLINDER
REAR
STEERING
CYLINDER
REAR AXLE
ASSEMBLY
FRONT
STEERING
CYLINDER
REAR DRIVE SHAFT

FRONT DRIVE SHAFT
FRONT AXLE
ASSEMBLY
MAQ0940
6036, 6042, 8042, 10042, 10054 5-5

5.5 GENERAL INFORMATION 5.6.3 Axle Internal Service

Detailed axle service instructions (covering the axle,
differential, brakes and wheel-end safety, repair,
WARNING disassembly, reassembly, adjustment and
troubleshooting information) are provided in the
DO NOT service the machine without following all
appropriate Axle Repair Manual.
safety precautions as outlined in Section 1, “Safety
Practices,” of this manual.
Machine ZF Model Axle P/N
Note: To help ensure optimum performance, the drive
6036,6042 MS-T 3045 II Both 31200694
shaft assemblies are specially balanced as a unit at the
factory. When servicing any flange yoke, slip yoke or 8042,10042 & MS-T 3060 II Front 31200695
drive shaft tube, order a complete assembly if 10054
components are bent or damaged. Refer to the
8042 MS-T 3045 II Rear 31200694
appropriate parts manual for ordering information.
10042,10054 MS-T 3055 II Rear 31200694
Before performing any inspection, maintenance or
service operation, thoroughly clean the unit. The axles
and drive shafts should be checked and repaired only by
experienced service technicians who are aware of all
safety instructions and particular component features.
Use suitable products to thoroughly clean all
disassembled mechanical parts to help prevent personal
injury to the worker and prevent damage to the parts.
Carefully inspect the integrity of all moving parts
(bearings, yokes, tubes, gears, shafts, etc.) and fasteners
(nuts, bolts, washers, etc.) as they are subject to major
stress and wear. Always replace any damaged, worn,
cracked, seized or otherwise improper parts that could
affect the safe and proper functioning of the machine,
axles and drive shafts.
5.6 AXLE ASSEMBLIES
5.6.1 Axle Serial Number Plate

The front axle serial number plate is located on a
mounting pad on the inboard portion of the right beam
trumpet. The rear axle serial number plate is located on a
mounting pad on the inboard portion of the left trumpet.
Information on the serial number plate is required in
correspondence regarding the axle.
Supply information from the axle serial number plate
when communicating about an axle assembly or axle
components.
5.6.2 Axle Specifications

General axle specifications are found in Section 2.5,
5-6 6036, 6042, 8042, 10042, 10054

5.6.4 Axle Maintenance Note: Clear the work area of all debris, unnecessary
personnel, etc. Allow sufficient space to raise the
CLEANING: Clean parts with machined or ground
machine and to remove the axle.
surfaces (such as gears, bearings and shafts) with
emulsion cleaners or petroleum-based cleaners. DO 1. Park the machine on a firm, level surface, level the
NOT steam clean internal components and the interior of machine, fully retract the boom, lower the boom,
the planetary hub and axle housing. Water can cause place the travel select lever in the (N) NEUTRAL
corrosion of critical parts. Rust contamination in the position, engage the parking brake, straighten all
lubricant can cause gear and bearing failure. Remove old wheels and shut the engine OFF.
gasket material from all surfaces. 2. Place a Do Not Operate Tag on both the ignition key
DRYING: Use clean, lintless towels to dry components switch and steering wheel, stating that the machine
after cleaning. DO NOT dry bearings by spinning them should not be operated.
with compressed air; this can damage mating surfaces 3. Open the rear door. Allow the system fluids to cool.
due to lack of lubrication. After drying, lightly coat
components with oil or a rust-preventive chemical to help 4. Properly disconnect the battery.
protect them from corrosion. If storing components for a
prolonged period, wrap them in wax paper.
PERIODIC OPERATION REQUIREMENT: Every two
weeks, drive the machine far enough to cause the drive-
train components to make several complete revolutions.
This will help ensure that internal components receive
lubrication to minimize deterioration caused by
environmental factors such as high humidity.
SUBMERSION: If the machine has been exposed to
water deep enough to cover the hubs, disassemble the
wheel ends and inspect for water damage and
contamination. If the carrier housing was submerged in
water, especially if the water level was above the vent MAQ0950
tube (breather), drain the axle and inspect internal parts 1

for water damage and contamination. Before assembling
and refilling the unit with the specified lubricant(s), clean, 5. If the axle will be disassembled after removal, place
examine and replace damaged parts as necessary. a suitable receptacle under the axle drain plug (1).
Remove the drain plug and allow the axle oil to drain
Note: Use a suitable puller for bearing removal. Clean, into the receptacle. Transfer the used axle oil into a
inspect and lubricate all bearings just prior to suitable covered container, and label the container
reassembly. If replacement of a damaged bearing cup or as “Used Oil.” Dispose of used oil at an approved
cone is necessary, replace the cup and cone as a set. recycling facility.
5.6.5 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; the rear axle has
neither. The following steps outline a typical axle removal
procedure, suitable for either the front or the rear axle
assembly. 2
Cleanliness is extremely important. Before attempting to

remove the axle, thoroughly clean the machine. Avoid
MA9091
spraying water or cleaning solution on the stabilizer
solenoids and other electrical components. If using a 6. Front Axle: Remove the front access panel (2) to
steam cleaner, seal all openings before steam cleaning. gain access to the front axle hose connections and
mounting bolts.
6036, 6042, 8042, 10042, 10054 5-7

Rear Axle: Open the right and left side engine and lower the machine onto the supports, allowing
compartment doors to gain access to the rear hose enough room for axle installation. Ensure that the
connections and mounting bolts. machine will remain in place during axle installation.
7. Label, disconnect and cap the steering and brake 3. Using a suitable jack, hoist or overhead crane and
lines at the axle. Cap all fittings to prevent dirt and sling, remove the axle from its support or holding
debris from entering the hydraulic system. Wipe up stand. Balance the axle and prevent it from tipping,
any spilled oil. turning or falling while positioning it beneath the
8. Block the front and rear of both tires on the axle that machine. DO NOT raise or otherwise disturb the
is not being removed. Ensure that the machine will machine while installing the axle. Keep the axle
remain in place during axle removal before supported and balanced on the jack, hoist or
proceeding. overhead crane and sling throughout the installation
procedure.
9. Raise the machine using a suitable jack or hoist.
Place suitable supports under both sides of the 4. Install the capscrews securing the axle to the frame.
frame and lower the machine onto the supports. Torque to 500-560 lb-ft (678-759 Nm).
Ensure that the machine will remain in place during 12
11 1
axle removal.
3 10 2
10. Support the axle that is being removed with a suitable
jack, hoist or overhead crane and sling. DO NOT 9 3
raise the axle or the machine. 4
8
11. Remove both wheel and tire assemblies from the 7 5
axle that is being removed. (Refer to Section 5.9.1, 6 MT0822
“Removing Wheel and Tire Assembly from

Machine.”) Note: If new frame level (front) or stabilizer (rear)
cylinder bearings (3) have been installed in the axles or
Note: The wheel and tire assemblies must be re-installed machine frame, the fracture in the bearing race must be
later with the directional tread pattern “arrows” facing in positioned at the 9 o’clock position as shown above.
the direction of forward travel.
5. Move the cylinder into position on the axle cylinder
12. Remove the drive shaft assembly. Refer to Section anchor. Insert a cylinder-mount pin through the
5.8.3, “Drive Shaft Removal.” cylinder and cylinder anchor. Secure the cylinder-
13. Remove the capscrew and locknut securing the mount pin with one capscrew and new locknut.
lower position cylinder-mount pin to the cylinder. Tap 6. Apply multi-purpose grease through the self-tapping
the cylinder mount pin out, and move the cylinder to lube fitting to lubricate the self-align bearing and the
prevent it from interfering with axle removal. cylinder-mount pin.
14. Remove the capscrews securing the axle supports 7. Install the drive shaft assemblies. Refer to Section
to the machine frame. 5.8.5, “Drive Shaft Installation.”
15. Remove the axles from the machine using the jack, 8. If reinstalling an axle previously removed from the
hoist or overhead crane and sling supporting the machine, position the driveshaft yoke on the axle
axle. DO NOT raise or otherwise disturb the machine according to the alignment marks made earlier. If
while removing the axle. Balance the axle and installing a new axle, note the position of the
prevent it from tipping, turning or falling while driveshaft yoke at the transmission. Align the
removing it from beneath the machine. Place the driveshaft yoke on the axle in the same plane as the
axle on a suitable support or holding stand. yoke on the transmission.
9. Install the wheel and tire assemblies. Refer to
b. Axle Installation
Section 5.9.2, “Installing Wheel and Tire Assembly
1. Before proceeding, ensure that the machine will onto Machine.”
remain in place during axle installation. Block the 10. Carefully remove the jack, hoist or overhead crane
front and rear of both tires on the axle that is already and sling supporting the axle.
installed on the machine.
11. Carefully raise the machine using a suitable jack or
2. If applicable, raise the machine using a suitable jack hoist. Remove the supports from beneath the frame
or hoist. Place suitable supports beneath the frame and lower the machine to the ground.
5-8 6036, 6042, 8042, 10042, 10054

12. Remove the blocks from the front and rear of both
tires on the other axle.
Note: ALWAYS use new o-rings when servicing the
machine.
13. Install new o-rings into the fittings. Lubricate the 4
o-rings with clean hydraulic oil.
14. Uncap and connect the steering and brake lines at
their axle fittings.
15. Check the hydraulic reservoir oil level.
16. Properly connect the battery. 4
17. Remove the Do Not Operate Tags from both the 5
18. Start the engine. Turn the steering wheel several
times lock to lock, operate the frame tilt function
several times in both directions and check the
MH3281
function of the brakes. Check for hydraulic leaks, and
tighten or repair as necessary. 5. Label and disconnect the wiring harness connectors
19. Front Axle: Install the front access panel. at both outrigger cylinder pressure switches (4).
Remove the wire ties securing the wiring harness to
the outrigger cylinders.
Note: The service brake circuit will need to be bled after 6. Tie a length of string to each pressure switch wiring
axle installation. Refer to Section 8.7.5, “Brake connector, and pull harness out through openings
Bleeding.” (5) at rear of outrigger housing.
5.6.6 Axle Replacement 7. Untie strings from wiring connectors and tape, or
(8042, 10042 & 10054) otherwise secure ends of strings to outrigger
housing. These strings will be used to pull harness
a. Outrigger Removal (10042 & 10054 only) through housing during installation.
On Models 10042 and 10054 equipped with outriggers, it

is necessary to remove the outrigger assembly before
removing the front axle.
position, engage the parking brake, straighten all
wheels and shut the engine OFF.
6036, 6042, 8042, 10042, 10054 5-9

Keep the assembly supported and balanced during

the installation procedure.
7
2. Place the same number and thickness of shims (8)
on the pivot pin, as recorded during removal.
3. Position the outrigger assembly onto the machine,
aligning the hole in the assembly on the axle pivot
pin and the mounting plate under the axle flanges.
4. Install the two mount plates (7) onto the top of the
axle and secure with the previously used hardware.
8 Note: ALWAYS use new o-rings when servicing the
machine.
9 6
5. Install new o-rings into the fittings. Lubricate the o-
rings with clean hydraulic oil.
hoses (6) to their appropriate locations.
7. Tie the strings left in the outrigger housing during
removal to each pressure switch wiring connector,
and pull the harness through the outrigger housing.
8. Connect the wiring connectors to the outrigger
cylinder pressure switches. Secure the harnesses to
MH6260
the cylinders with wire ties.
9. Check the hydraulic reservoir oil level.
8. Label, disconnect and cap the outrigger hydraulic
hoses (6). Cap all fittings to keep dirt and debris 10. Properly connect the battery.
from entering the hydraulic system. 11. Remove the Do Not Operate Tags from both the
9. Support the outrigger assembly using a suitable ignition key switch and the steering wheel.
jack, hoist or overhead crane. 12. Start the engine. Turn the steering wheel several
10. Remove the capscrews, hex nuts, flat washers and times lock to lock, operate the frame tilt function
mount plates (7). several times in both directions and check the
function of the brakes. Check for hydraulic leaks, and
Note: Record the number and thickness of shims to tighten or repair as necessary.
ensure correct installation.
11. Remove the outrigger assembly using a suitable c. Axle Removal
jack, hoist or overhead crane. Remove the shims (8) The front and rear axle assemblies differ in that the front
from the pivot pin. axle assembly is equipped with a parking brake
12. Move the outrigger assembly away from the machine mechanism and a limited-slip feature; the rear axle has
and carefully lower it to the ground. Block up or neither. The following steps outline a typical axle removal
support the assembly so that it does not move or fall. procedure, suitable for either the front or the rear axle
assembly.
13. Inspect the pivot bearing (9). Replace the bearing if
worn or damaged. Cleanliness is extremely important. Before attempting to
remove the axle, thoroughly clean the machine. Avoid
b. Outrigger Installation spraying water or cleaning solution on the stabilizer
solenoids and other electrical components. If using a
1. Using a suitable jack, hoist or overhead crane and steam cleaner, seal all openings before steam cleaning.
sling, remove the outrigger assembly from its
supports. Balance the assembly and prevent it from Note: Clear the work area of all debris, unnecessary
tipping, turning or falling while positioning it on the personnel, etc. Allow sufficient space to raise the
machine. DO NOT raise or otherwise disturb the machine and to remove the axle.
machine while installing the outrigger assembly.
5-10 6036, 6042, 8042, 10042, 10054

1. Park the machine on a firm, level surface, level the 12. Remove both wheel and tire assemblies from the
machine, fully retract the boom, lower the boom, axle that is being removed. (Refer to Section 5.9.1,
place the travel select lever in the (N) NEUTRAL “Removing Wheel and Tire Assembly from
position, engage the parking brake, straighten all Machine.”)
Note: The wheel and tire assemblies must be re-installed
2. Place a Do Not Operate Tag on both the ignition key later with the directional tread pattern “arrows” facing in
switch and steering wheel, stating that the machine the direction of forward travel.
13. Remove the drive shaft assembly. Refer to Section
3. Open the rear door. Allow the system fluids to cool. 5.8.3, “Drive Shaft Removal.”
5. Remove the fender assembly (if equipped).
6. Models 10042 and 10054, Front Axle Only: Remove
outrigger assembly. Refer to Section 5.6.6, a.
“Outrigger Removal (10042 & 10054 only).”
MAQ0960 3
1 2
7. If axle will be disassembled after removal, place a

suitable receptacle under axle drain plug (1).
4
Remove drain plug and allow axle oil to drain into
receptacle. Transfer used axle oil into a suitable 3 MAQ0980
covered container, and label container as “Used Oil.”

Dispose of used oil at an approved recycling facility.
8. Label, disconnect and cap the steering and brake 14. Remove the capscrew and locknut securing the
lines at the axle. Cap all fittings to prevent dirt and lower position cylinder-mount pin (2) to the cylinder.
debris from entering the hydraulic system. Wipe up Tap the cylinder mount pin out, and move the
any spilled oil. cylinder to prevent it from interfering with axle
9. Block the front and rear of both tires on the axle that removal.
is not being removed. Ensure that the machine will 15. Remove the capscrew and locknut securing the axle
remain in place during axle removal before pivot pin (3) to the frame.
proceeding.
Note: Record the number and location of shims (4) to
10. Raise the machine using a suitable jack or hoist. ensure correct installation.
Place suitable supports under both sides of the
frame and lower the machine onto the supports. 16. Remove the pivot pin and shims.
Ensure that the machine will remain in place during 17. Remove the axles from the machine using the jack,
axle removal. hoist or overhead crane and sling supporting the
11. Support the axle that is being removed with a suitable axle. DO NOT raise or otherwise disturb the machine
jack, hoist or overhead crane and sling. DO NOT while removing the axle. Balance the axle and
raise the axle or the machine. prevent it from tipping, turning or falling while
6036, 6042, 8042, 10042, 10054 5-11

removing it from beneath the machine. Place the 8. Apply multi-purpose grease through the self-tapping
axle on a suitable support or holding stand. lube fitting to lubricate the self-align bearing and the
cylinder-mount pin.
d. Axle Installation 9. Install the drive shaft assemblies. Refer to Section
1. Before proceeding, ensure that the machine will 5.8.5, “Drive Shaft Installation.”
remain in place during axle installation. Block the 10. If reinstalling an axle previously removed from the
front and rear of both tires on the axle that is already machine, position the driveshaft yoke on the axle
installed on the machine. according to the alignment marks made earlier. If
2. If applicable, raise the machine using a suitable jack installing a new axle, note the position of the
or hoist. Place suitable supports beneath the frame driveshaft yoke at the transmission. Align the
and lower the machine onto the supports, allowing driveshaft yoke on the axle in the same plane as the
enough room for axle installation. Ensure that the yoke on the transmission.
machine will remain in place during axle installation. 11. Install the wheel and tire assemblies. Refer to
3. Using a suitable jack, hoist or overhead crane and Section 5.9.2, “Installing Wheel and Tire Assembly
sling, remove the axle from its support or holding onto Machine.”
stand. Balance the axle and prevent it from tipping, 12. Carefully remove the jack, hoist or overhead crane
turning or falling while positioning it beneath the and sling supporting the axle.
machine. DO NOT raise or otherwise disturb the
13. Carefully raise the machine using a suitable jack or
machine while installing the axle. Keep the axle
hoist. Remove the supports from beneath the frame
supported and balanced on the jack, hoist or
and lower the machine to the ground.
overhead crane and sling throughout the installation
procedure. 14. Remove the blocks from the front and rear of both
tires on the other axle.
4. Position the axle under the frame, and align the pivot
pin bearings with the holes in the frame. Note: ALWAYS use new o-rings when servicing the
5. Coat the axle pivot pin (3) with a light film of clean machine.
engine or hydraulic oil; DO NOT use an anti-seize 15. Install new o-rings into the fittings. Lubricate the
compound. o-rings with clean hydraulic oil.
6. Install the axle pivot pin and shims (4). Add or 16. Uncap and connect the steering and brake lines at
remove shims until a maximum gap of 0.6 in their axle fittings.
(1.5 mm) is obtained. Balance the number and
17. Models 10042 and 10054, Front Axle Only: Install
thickness of shims equally of both sides. Secure the
outrigger assembly. Refer to Section 5.6.6, b.
pivot pin with one capscrew and a new locknut.
“Outrigger Installation.”
12 18. Check the hydraulic reservoir oil level.
11 1
5 10 2 19. Properly connect the battery.
9 3 20. Remove the Do Not Operate Tags from both the
8 4
21. Start the engine. Turn the steering wheel several
7 5
6 MT0822 times lock to lock, operate the frame tilt function
several times in both directions and check the
Note: If new frame level (front) or stabilizer (rear) function of the brakes. Check for hydraulic leaks, and
cylinder bearings (5) have been installed in the axles or tighten or repair as necessary.
machine frame, the fracture in the bearing race must be 22. Install the fender assembly (if equipped).
positioned at the 9 o’clock position as shown below.
7. Move the cylinder into position on the axle cylinder
anchor. Insert a cylinder-mount pin (2) through the Note: The service brake circuit will need to be bled after
cylinder and cylinder anchor. Secure the cylinder- axle installation. Refer to Section 8.7.5, “Brake
mount pin with one capscrew and new locknut. Bleeding.”
5-12 6036, 6042, 8042, 10042, 10054

5.7 AXLE ASSEMBLY AND DRIVE SHAFT TROUBLESHOOTING

1. Excessive axle noise while 1. Oil level too low. 1. Fill oil to correct level. Refer to
driving. Section 2.5, “Fluid
Specifications.”
2. Axle and/or wheel end housings 2. Drain axle and/or wheel end
filled with incorrect oil or oil level housings and fill to correct level
low. with Mobilfluid 424® ISO 46.
Refer to Section 2.5, “Fluid
Specifications.”
3. Incorrect alignment of ring and 3. Correct alignment by adding or

pinion gears. removing shims as needed.
4. Incorrect pinion (input) shaft 4. Correct bearing preload by

bearing preload. adding or removing shims as
needed.
5. Worn or damaged bearings. 5. Replace bearings as needed.
6. Worn or broken gear teeth. 6. Replace gears as needed.
7. Contamination in the axle. 7. Drain axle and/or wheel end

housings and fill to correct level
with Mobilfluid 424® ISO 46.
Refer to Section 2.5, “Fluid
Specifications.”
8. Axle housing damaged. 8. Replace damaged parts.
2. Intermittent noise when 1. Universal joint(s) worn or 1. Repair or replace universal

traveling. damaged. joints as needed.
2. Differential ring and/or pinion 2. Determine cause and repair as

gears damaged. needed.
3. Vibration or intermittent noise 1. Drive shaft universal joint 1. Tighten capscrews to correct
when traveling. assembly(ies) incorrectly torque.
tightened.
2. Drive shaft universal joint(s) 2. Repair or replace universal

worn or damaged. joints as needed.
3. Drive shaft(s) damaged/ 3. Replace drive shaft(s) as

unbalanced. needed.
6036, 6042, 8042, 10042, 10054 5-13


4. Oil leaking from axle 1. Drain and/or inspection plugs 1. Replace o-rings as needed and
(differential housing and/or loose and/or o-rings damaged tighten plugs to 96 lb-ft
axle housings). or missing. (130 Nm).
2. Hose fittings loose. 2. Tighten fittings.
3. Axle shaft seal damaged or 3. Replace seal and/or joint

missing and/or worn or coupling fork shaft (axle shaft).
damaged shaft sealing
surfaces.
4. Input shaft multi-seal ring 4. Replace multi-seal ring and/or

damaged or missing and/or input shaft. Adjust ring and
worn or damaged pinion (input) pinion alignment and bearing
shaft sealing surfaces. preload as described in the
Dana Repair Manuals.
5. Axle casing to brake housing 5. Replace o-rings and seals.

and/or brake housing to
differential assembly o-rings
and/or seals worn or damaged.
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 7. Replace housing(s) as needed.

housing(s) damaged.
5. Oil leaking from wheel end 1. Oil level plugs loose and/or 1. Replace o-rings as needed and
housing (planet carrier). o-rings damaged or missing. tighten plugs to 96 lb-ft
(130 Nm).
2. O-ring between hub and 2. Replace o-ring.

housing (planet carrier)
damaged or missing.
3. Shaft seal damaged or missing 3. Replace seal and/or fork joint

and/or worn or damaged shaft shaft.
sealing surfaces.
4. Housing capscrews loose. 4. Tighten housing capscrews to

41 lb-ft (55 Nm).
5. Housing (planet carrier) damaged. 5. Replace housing (planet carrier).
6. Oil leaking from steering 1. Hose fittings loose. 1. Tighten fittings.

cylinder.
2. Steering cylinder o-rings and/or 2. Replace o-rings and seals.
seals worn or damaged.
3. Piston rod seal worn or 3. Replace piston rod seal.

damaged.
4. Cylinder tube damaged. 4. Replace cylinder tube.
5-14 6036, 6042, 8042, 10042, 10054


7. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level with
Mobilfluid 424® ISO 46. Refer to
Section 2.5, “Fluid
Specifications.”
2. Axle and/or wheel end housings 2. Drain axle and fill to correct level
filled with incorrect oil or oil with Mobilfluid 424® ISO 46.
contaminated or oil level low. Refer toSection 2.5, “Fluid
Specifications.”
3. Dragging park brake. 3. Adjust park brake cable as

needed.
8. High steering effort required. 1. Steering (hydraulic) system not 1. Refer to Section 8.4, “Hydraulic
2. Excessive joint housing swivel 2. Correct bearing preload by

bearing preload. adding or removing shims as
needed.
3. Worn or damaged swivel 3. Replace swivel bearings as

bearings. needed.
9. Slow steering response. 1. Steering (hydraulic) system not 1. Refer to Section 8.4, “Hydraulic
2. Steering cylinder leaking 2. Repair or replace steering

internally. cylinder as needed.
10. Excessive noise when brakes 1. Brake discs worn. 1. Check brake discs for wear.
are engaged. Refer to Section 5.10.1, “Brake
Disc Inspection.”
2. Brake discs damaged. 2. Replace brake discs.
11. Brakes will not engage. 1. Brake (hydraulic) system not 1. Refer to Section 8.4, “Hydraulic
2. Brake piston o-rings and seals 2. Replace o-rings and seals.

damaged (leaking).
12. Brakes will not hold the 1. Brake discs worn. 1. Check brake discs for wear.
machine or braking power Refer to Section 5.10.1, “Brake
reduced. Disc Inspection.”
2. Brake (hydraulic) system not 2. Refer to Section 8.4, “Hydraulic

3. Brake piston o-rings and seals 3. Replace o-rings and seals.

damaged (leaking).
6036, 6042, 8042, 10042, 10054 5-15

5.8 DRIVE SHAFTS

TO TRANSMISSION
5.8.1 Drive Shaft Inspection and Service

Whenever servicing the machine, conduct a visual
inspection of the drive shafts and cross and bearing
assemblies (universal joints, or U-joints). A few moments
spent doing this can help prevent further problems and 1 2
down time later.
Inspect areas where the drive shaft flange yokes and slip
yokes mount to the drive shafts. Attempt to turn each
3
drive shaft in both directions. Look for excessive TO AXLE
MT0350
4
looseness, missing parts, cracks or other damage. Worn
or damaged drive shafts and cross and bearing 7. Remove the four bolts (1) and two straps (2)
assemblies may cause an excessive amount of vibration securing the bearing cross to the transmission
or noise. output shaft flange. Discard bolts.
Note: Any bolt removed from the drive shaft assembly 8. Remove the four bolts (3) and two straps (4)
MUST be replaced. Do Not re-torque. securing the bearing crosses to the axle. Discard
bolts.
5.8.2 Drive Shaft Maintenance 9. Remove the front drive shaft assembly.
Refer to Section 2.8, “Lubrication Schedules” for 10. Repeat the above procedure on the rear drive shaft.
information regarding the lubrication of the grease fittings
on the drive shafts. 5.8.4 Drive Shaft Cleaning and Drying
1. Disassemble and clean all parts using an approved
5.8.3 Drive Shaft Removal cleaning fluid. Allow to dry.
1. Park the machine on a firm, level surface, level the 2. Remove and burrs or rough spots from all machined
machine, fully retract the boom, lower the boom, surfaces. Re-clean and dry as required.
place the transmission control lever in (N) NEUTRAL,
5.8.5 Drive Shaft Installation
engage the park brake and shut the engine OFF.
1. Raise the drive shaft assembly into position. The
slip-yoke end of the drive shaft mounts toward the
axle. If reinstalling a drive shaft previously removed,
align the flange yokes according to the alignment
3. Open the engine cover. Allow the system fluids to marks made during removal.
cool.
Note: The yokes at both ends of the drive shaft must be
4. Properly disconnect the battery. in the same plane to help prevent excessive vibration.
5. Block the wheels.
2. Apply Loctite® 242TM to all mounting bolts.
6. The drive shaft assembly is a balanced assembly.
3. Install the two straps (2) and four new bolts (1)
Mark the yoke and axle, transmission and the shaft
securing the bearing crosses to the transmission.
and slip yoke so that these components can be
Torque bolts to 55-60 lb-ft (75-81 Nm).
returned to their original positions when reinstalled.
Yokes at both ends of the drive shaft must be in the 4. Install the two straps (4) and four new bolts (3)
same plane to help prevent excessive vibration. securing the bearing crosses to the axle. Torque
bolts to 55-60 lb-ft (75-81 Nm).
5. Repeat the above procedure on the rear drive shaft.
5-16 6036, 6042, 8042, 10042, 10054

5.9 WHEELS AND TIRES 5
WARNING
Mismatched tire sizes, ply ratings or mixing of tire
types (radial tires with bias-ply tires) may compromise
machine stability and may cause machine to tip over.
It is recommended that a replacement tire to be the same

size, ply and brand as originally installed. Refer to the
appropriate parts manual for ordering information. If not
using an approved replacement tire, It is recommended
MY4190
that replacement tires have the following characteristics:
• Equal or greater ply/load rating and size of original. The wheel and tire assemblies must be installed with the
directional tread pattern “arrows” (5) facing in the direc-
• Tire tread contact width equal or greater than tion of forward travel.
original.
• Wheel diameter, width and offset dimensions equal
5.9.1 Removing Wheel and Tire Assembly
to the original. from Machine
• Approved for the application by the tire manufacturer 1. Park the machine on a firm, level surface, fully
(including inflation pressure and maximum tire load). retract the boom, lower the boom, place the
The rims installed have been designed for stability the park brake and shut the engine OFF.
requirements which consist of track width, tire pressure
and load capacity. Size changes such as rim width, 2. Place an Do Not Operate Tag on both the ignition
center piece location, larger or smaller diameter, etc., key switch and steering wheel, stating that the
without written factory recommendations, may result in machine should not be operated.
unsafe condition regarding stability. 3. Loosen but DO NOT remove the lug nuts on the
Foam filled tires have a positive effect on the weight, wheel and tire assembly to be removed.
stability and handling characteristics of the machine, 4. Place a suitable jack under the axle pad closest to
especially under load. The use of hydrofill as a tire-fill the wheel being removed. Raise the machine and
substance is not recommended because of possible position a suitable support beneath the axle. Allow
environmental impact. sufficient room to lower the machine onto the
Large-bore valve stems are used to help expedite tire support and to remove the wheel and tire assembly.
inflation and deflation. An inner tube may be used if a tire 5. Lower the machine onto the support.
does not provide an airtight seal. Check tire inflation 6. Remove lug nuts and lug washers in an alternating
pressures when the tires are cold. When mounting a tire pattern.
on the wheel, the tire must be mounted on the wheel
respective of the directional tread pattern of the tire; this 7. Remove the wheel and tire assembly from the
produces a left or right tire and wheel assembly. machine.
6036, 6042, 8042, 10042, 10054 5-17

5.9.2 Installing Wheel and Tire Assembly 5.10 BRAKES

onto Machine
Note: The wheel and tire assemblies must be installed 5.10.1 Brake Disc Inspection
with the directional tread pattern “arrows” facing in the
A brake lining wear measurement on service brake
direction of forward travel.
(multi-disc brake) gives just limited information about the
overall condition of the multi-disk package–without
disassembly of the output.
TREAD “ARROWS” MUST
POINT FORWARD Check the brake discs for wear every 1,000 hours of
operation or yearly. Additionally, check brake discs if
braking behavior has changed in any of following ways:
• Brake noises
• Reduced braking power
• Changed deceleration
• Changed brake oil level
• Changed braking pressure
Wear measurement must be carried out on both output
sides of axle!
For more information on brake disc inspection, refer to
the appropriate axle repair manual.
INSTALL TIRES ONTO
WHEELS TO ROTATE IN 1. Block all four wheels to help prevent the machine
PROPER DIRECTION from moving.
MAQ0990
1. Position wheel onto studs on wheel end of axle.

2. Install wheel lug washers.
3. Start all nuts by hand to prevent cross threading. DO
NOT use a lubricant on threads or nuts.
3 5 MAQ0960
1 7 5
2. Place a suitable receptacle under axle drain plug (5).
10 9 Remove drain plug and allow axle oil to drain into
receptacle. Transfer used axle oil into a suitable
8 2 covered container, and label container as “Used Oil.”
6 4 Dispose of used oil at an approved recycling facility.
OY1220
4. Tighten lug nuts in an alternating pattern as

indicated in figure. Torque to 430–470 lb-ft
(583–637 Nm).
5. Remove machine from supports.
5-18 6036, 6042, 8042, 10042, 10054

5.11 TOWING A DISABLED MACHINE

Towing a disabled machine should only be attempted as
a last resort, after exhausting all other options. Make
every effort to repair the machine, and move it under its
own power. Towing the machine improperly can result in
damage to the machine drivetrain.
Note: In the event the machine is disabled and cannot
be moved under engine power, the situation must be
properly evaluated and dealt with on an individual basis.
Contact your local JLG distributor for specific instructions
for your particular situation.
If it is necessary to tow the machine a short distance to
avoid a potentially hazardous situation such as being in
an unsafe area on the worksite or on a roadway, prepare
the machine for towing as follows:
7 1. Remove the load from the machine.
2. Block all four wheels to help prevent the machine
6 MAQ1000
from moving after the parking brake is disabled.
3. Using a feeler gauge, check thickness of lined/inner 3. Remove the transmission covers.
disc (6). If thickness is less than or equal (≤) to 4. Position the towing vehicle in place. Attach any
3.75mm, replace the lined/inner discs. chains needed to secure the disabled machine.
Note: If discs are worn beyond their tolerance, discs 6036 & 6042
must be replaced on both sides of axle at the same time.
4. Repeat step 3 for other side of axle.
FRONT OF
5. Fill the axle with Mobilfluid 424® Tractor Hydraulic MACHINE
Fluid (ISO 46) through the axle fill hole until the oil
level is even with both axle level holes. Fill the axle
slowly, allow time for the oil to run across the
differential.
6. Reassemble the level plugs using new o-rings.
7. Install the axle fill plug into axle housing.
5 OA1231
6036, 6042, 8042, 10042, 10054 5-19

8042, 10042 & 10054
FRONT OF
MACHINE
5 6
OH1841
5. Attach a remote portable hydraulic pressurizing unit

to the parking brake gauge port (5) on the secondary
function manifold (6) mounted on the inside wall of
the frame on the left side next to the transmission.
6. Turn the key switch to the ON position, release the
park brake, and have an operator seated in the seat.
7. Pressurize the park brake with the pressurizing unit.
Close the pump needle valve on the pressurizing
unit.
CAUTION
DO NOT exceed 575 psi (40 bar) when pressurizing
the park brake. Applying too much pressure may
damage the brake seals.
8. Clear the area of all unnecessary personnel.

9. Remove the blocks from the wheels. Tow the
machine to a secure location.
10. Remove the hydraulic pressurizing unit.
Note: Without engine power, service brake power is
reduced. 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 6036, 6042, 8042, 10042, 10054

Section 6
Transmission
Contents

6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Transmission Specifications and Maintenance Information. . . . . . . . . . . . . . . . 6-3
6.4 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4.1 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4.2 Transmission Inspection and Internal Repair . . . . . . . . . . . . . . . . . . . . . . 6-5
6.4.3 Transmission Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.4.4 After Transmission Service or Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.5 Transmission Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6036, 6042, 8042, 10042, 10054 6-1

Transmission
6.1 TRANSMISSION ASSEMBLY

locations of the major assemblies of the transmission.
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
MAQ0740
6-2 6036, 6042, 8042, 10042, 10054

Transmission
cleaning solution onto or near transmission shift

WARNING solenoids and other electrical components.
DO NOT service the machine without following all 6.4.1 Transmission Removal
WARNING
6.2 TRANSMISSION SERIAL NUMBER NEVER lift a transmission alone; enlist the help of at
least one assistant or use a suitable hoist or overhead
crane and sling with the minimum lifting capacity of
1000 lb (454 kg).
machine, fully retract the boom, raise the boom,
place the transmission control lever in (N)
NEUTRAL, engage the park brake and shut the
engine OFF.
1 should not be operated.
3. Temporarily block up or support the boom.
OH2381
5. Drain the hydraulic oil reservoir. Refer to Section
Transmission serial number plate (1) is located on pump 8.5.1, “Hydraulic Oil Reservoir Draining.”
side (front) of transmission at bottom right toward 6. Properly disconnect the battery.
machine frame. Information on serial number plate is 7. Remove the transmission covers.
required in correspondence regarding transmission.
8. Thoroughly clean the transmission and surrounding
area, including all hoses and fittings, before
6.3 TRANSMISSION SPECIFICATIONS proceeding.
AND MAINTENANCE INFORMATION
Refer to Section 2, “General Information and
Specifications.” for transmission, oil specifications and
maintenance information.
Detailed transmission service instructions are provided in
the following publications:
• Service Manual - P/N 8990455
• Parts Manual - 6036 & 6042 P/N 31200731
- 8042,10042 & 10054 P/N 31200732
6.4 TRANSMISSION REPLACEMENT 1
Note: Contact your local JLG Service Department if OH2381

internal transmission repair is required during the
warranty period. 9. Place a suitable receptacle under transmission drain
plug (1). Remove transmission drain plug, and allow
Note: Cleanliness is of extreme importance. Before
transmission oil to drain into receptacle.
attempting to remove transmission, thoroughly clean
exterior of transmission to help prevent dirt from entering
during replacement process. Avoid spraying water or
6036, 6042, 8042, 10042, 10054 6-3

Transmission
10. Transfer the used transmission oil into a suitable, 16. Remove the capscrew (6) securing the lifting ring (7)
covered container, and label the container as “Used to the transmission housing. Once the lifting ring has
Oil.” Dispose of used oil at an approved recycling been removed, reinstall the capscrew into the hole.
facility. Clean and reinstall the transmission drain 17. Move the lifting ring to the holes (8) used to secure
plug. the black wire and clamp. Secure the lifting ring
11. Remove the engine-to- transmission and using the capscrews and tighten securely.
transmission-to-axle drive shafts. Refer to Section 18. Label, disconnect and cap the transmission oil
5.8.3, “Drive Shaft Removal.” cooler inlet and outlet hoses on the transmission.
12. Remove the hydraulic pump. Refer to Section 8.6.1, 19. Connect a lifting strap or chain to the lifting eye at
“Pump Replacement.” the top of the transmission and to a suitable hoist or
2 overhead crane. Operate the hoist or crane to
4
remove slack from the chain, but DO NOT raise the
transmission at this time.
20. Place blocks under the transmission to help support
3 it during removal.
1
MH3391
5
13. Label and disconnect the transmission temperature

9
switch connector (2) and shift solenoid wiring
harness connectors (3).
14. Remove the capscrew securing the black wire (4) to
the transmission housing, and disconnect the wire. MH6290
DO NOT reinstall the capscrew at this time.
21. Remove the capscrews and lockwashers securing
15. Remove the capscrew securing the clamp (5) and
the front transmission mount (9) to the transmission.
wiring harness to the transmission housing and
move the wiring harness safely out of the way. DO 22. Remove the two capscrews, hex locknuts and
NOT reinstall the capscrew at this time. rebound washers. Remove the front transmission
mount.
23. Remove the four capscrews and lockwashers
8 securing the rear transmission mount (1) to the
7
transmission.
24. Remove the two capscrews, hex locknuts and
rebound washers. Remove the rear transmission
mount.
25. Inspect the rubber mounts. Replace the mounts if
damaged.
26. Carefully remove the transmission from the machine.
Avoid causing damage to the transmission or
surrounding parts.
6 MH3401
6-4 6036, 6042, 8042, 10042, 10054

Transmission
27. Lift the transmission clear of the machine and lower

it onto suitable supports or secure it to a stand built
especially for the transmission or engine service.
3
Secure the transmission so that it will not move or 4
fall.
28. Remove any external transmission components as
required, including the transmission temperature
switch, and inlet and outlet cooler hose fittings.
Cover all transmission openings.
29. Remove the transmission oil filter and dispose of
properly. Clean the filter mounting surface. Cover or
cap the oil filter mount.
6.4.2 Transmission Inspection and Internal

MH3411
Repair
If replacing the entire transmission, transfer the Note: The lifting ring (3) must be repositioned to allow
transmission temperature switch to the replacement the covers to be installed.
transmission. The gear shift solenoids are included with a 7. Remove the two capscrews securing the lifting ring
new transmission. to the transmission housing. Save the capscrews for
later use.
6.4.3 Transmission Installation
8. Remove the capscrew and secure the lifting ring in
the storage position (4) on the transmission housing
WARNING as shown.
5
NEVER lift a transmission alone; enlist the help of at 7
least one assistant or use a suitable hoist or overhead
crane and sling with the minimum lifting capacity of
1000 lb (454 kg).
1. Install two rubber mounts and the rear transmission
mount (1) in the machine frame. Secure the mount 6
with the previously used hardware.
2. Use a hoist or overhead crane and sling attached to
the lifting eye at the top of the transmission. Raise
and position the transmission within the chassis.
3. Attach the transmission to the rear mounting bracket
with the previously used hardware. Torque to
148 lb-ft (200 Nm).
4. Install the two front rubber mounts and the front 6
transmission mounting bracket (9) on the MH3391
transmission with the previously used hardware.

9. Connect the transmission temperature switch
Torque to 148 lb-ft (200 Nm)
connector (5) and shift solenoid wiring harness
5. Attach the front mounting bracket to the frame with connectors (6).
the previously used hardware
10. Attach the black wire (7) to the transmission housing
6. Remove the hoist or overhead crane and sling. with a capscrew removed in step 7.
11. Secure the wiring harness to the transmission
housing using the clip and a capscrew removed in
step 7.
6036, 6042, 8042, 10042, 10054 6-5

Transmission

transmission oil cooler inlet and out hoses at the
transmission. 8
13. Install the hydraulic pump. Refer to Section 8.6.1,
“Pump Replacement.”
14. Install the engine-to-transmission and transmission-
to-axle drive shafts. Refer to Section 5.8.5, “Drive
Shaft Installation.”
15. Clean the transmission oil filter mounting surface.
16. Apply a thin film of clean Mobilfluid 424®
(ISO Grade 46) to the new transmission filter gasket.
Install the new filter and torque to 20-25 lb-ft MH6300
(27-34 Nm).
17. Transmission oil may be added through the dipstick 8. Reassemble all components and fill the transmission
tube. Remove the dipstick and add Mobilfluid 424® with clean, fresh Mobilfluid 424® (ISO Grade 46)
(ISO Grade 46). Check the oil level by taking through the dipstick tube opening (8). Check the
intermittent dipstick readings as outlined in the level by taking intermittent dipstick readings as
appropriate Operation & Safety Manual. DO NOT outlined in the appropriate Operation & Safety
overfill. Reinstall the dipstick when finished. Manual. DO NOT overfill. Reinstall the dipstick when
finished.
9. Run the engine for two minutes at idle to help prime the
19. Properly connect the battery. torque converter and the transmission oil lines.
20. Remove the Do Not Operate Tags from both the 10. Recheck the level of the fluid in the transmission with
ignition key switch and the steering wheel. the engine running at idle.
21. Close and secure the rear door. 11. Add Mobilfluid 424® (ISO Grade 46) as necessary to
bring the fluid level up until it reaches the FULL mark
6.4.4 After Transmission Service or on the dipstick. Recheck the oil level when it reaches
Replacement operating temperature 180-200° F (83-94° C).
In general: 12. Recheck all drain plugs, lines, connections, etc., for
1. Check the transmission oil level and add oil as leaks, and tighten where necessary.
required.
2. Install a new transmission filter.
3. Check the torque on the drive shaft yoke capscrews.
4. When an overhauled or repaired transmission is
installed, thoroughly clean the oil cooler lines to and
from the transmission.
5. Drain and flush the entire system.
6. Disconnect and clean all transmission cooler hoses.
When possible, remove transmission lines from the
machine for cleaning.
7. Thoroughly clean transmission filter screens and
cases, and replace transmission filter elements.
6-6 6036, 6042, 8042, 10042, 10054

Transmission
6.5 TRANSMISSION
TROUBLESHOOTING
This section provides an easy reference guide covering
the most common problems that may occur during
operation of the transmission.
Note: Contact the JLG Service Department if internal
transmission repair is required during the warranty
period.
The transmission should be checked, serviced and
repaired only by experienced service technicians who are
aware of all safety instructions and particular component
features.

1. Transmission will not engage 1. Oil level too high or low. 1. Fill transmission to correct level
or will not shift properly. with Mobilfluid 424® ISO
Grade 46. Refer to Section 2.5,
2. Transmission control lever not 2. Refer to Section 9.5, “Electrical

functioning properly and/or a System Schematics.”
fault in the wiring
harness.Transmission control
lever not functioning properly
and/or a fault in the wiring
harness.
3. Transmission valve body 3. Refer to Section 9.5, “Electrical

solenoids not functioning System Schematics.”
properly.
4. Pilot-operated shift valves not 4. Clean the valve spool and

operating properly. housing. Replace return spring
as needed.
5. Pump output pressure low. 5. Refer to Section 6.5,

“Transmission Troubleshooting,”
Problem 2. “Low or no pump
flow or pressure.”
6. Clutch piston o-rings damaged. 6. Replace o-rings.
7. Clutch discs worn or damaged. 7. Replace clutch discs.
8. Coupling shafts or gear teeth 8. Replace couplings.

damaged.
6036, 6042, 8042, 10042, 10054 6-7

Transmission

2. Low or no pump flow or 1. Low oil level. 1. Fill transmission to correct level
pressure. with Mobilfluid 424® ISO
2. Transmission filled with incorrect 2. Drain transmission and fill to

oil, or oil contaminated. correct level with Mobilfluid 424®
ISO Grade 46. Refer Section
2.5, “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.
3. Low clutch pressure. 1. Incorrect oil level. 1. Fill transmission to correct level
with Mobilfluid 424® ISO
2. Main pressure valve stuck open. 2. Clean the valve spool and
housing.
3. Broken or worn coupling shaft or 3. Replace coupling and/or o-rings.

piston o-rings.
4. Pressure reducing valve stuck 4. Clean the valve spool and

open. housing.
4. Lack of power. 1. Park or service brake dragging. 1. Refer to Section 8.4, “Hydraulic
Circuits.”
2. Low engine rpm causes 2. Adjust the engine rpm to

converter stall. specifications. Refer to
Transmission Service Manual.
3. Pump output pressure is low. 3. Refer to Section 6.5,

Problem 2. “Low or no pump
flow or pressure.”
4. Clutch discs worn or damaged. 4. Replace clutch discs.
5. Transmission overheating. 5. Refer to Section 6.5,

Problem 5. “Transmission
overheating (oil above 120° C
(248° F)).”
6-8 6036, 6042, 8042, 10042, 10054

Transmission

5. Transmission overheating 1. Low oil level. 1. Fill transmission to correct level
(oil above 120° C (248° F)). with Mobilfluid 424® ISO
2. Clogged radiator. 2. Remove debris from the

radiator.

oil, or oil contaminated. correct level with Mobilfluid 424®
ISO Grade 46. Refer to Section
4. Excessive “roading.” 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.
6. Grinding or “clunking” noise 1. Oil level too low. 1. Fill oil to correct level. Refer to
from transmission. Section 2.5, “Fluid
Specifications.”

oil. correct level with Mobilfluid 424®
ISO Grade 46. Refer to Section
3. Incorrect clutch engagement. 3. Refer to Section 9.10.3,

“Transmission Solenoid Valves.”
4. Internal damage. 4. Repair or replace parts as

needed.
5. Broken diaphragm (flex plate). 5. Replace diaphragm (flex plate).

Refer to Section 6.4.1,
“Transmission Removal.”
6. Loose diaphragm (flex plate) 6. Tighten capscrews.

mounting capscrews.
6036, 6042, 8042, 10042, 10054 6-9

Transmission

7. Oil leaking from transmission. 1. Oil leaking from vent (high oil 1. Remove drain plug and drain oil
level). as needed, until oil is at correct
level. Refer to Section 2.5,
“Fluid Specifications.” Replace
o-rings as needed and tighten
plugs to 96 lb-ft (130 Nm).
2. Drain plug loose and/or o-rings 2. Replace o-rings as needed and

damaged or missing. tighten plug to 26 lb-ft (35 Nm).
3. Hose fittings loose. 3. Tighten fittings.
4. Oil leaking at valve bodies 4. Replace gaskets and/or tighten

(possible valve body gaskets capscrews to 7 lb-ft (9,5 Nm).
damaged or missing and/or
mounting capscrews not tight).
5. Housing capscrews loose. 5. Tighten capscrews to 34 lb-ft

(46 Nm).
6. Oil leaking at pump (possible 6. Replace o-rings and/or tighten

pump-to-housing o-rings capscrews to 85 lb-ft (115 Nm).
missing or damaged, and/or
pump mounting capscrews not
tight).
7. Oil leaking at converter bell 7. Replace converter and/or input

(possible converter leak and/or shaft seal.
input shaft seal damage).
8. Oil leaking at output shaft 8. Replace output shaft seal.

(output shaft seal damaged).
9. Housing damaged. 9. Replace housing as needed.
6-10 6036, 6042, 8042, 10042, 10054

Section 7
Engine
Contents

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.2 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.4.1 Coolant System Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.4.2 Radiator/Oil Cooler and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.6.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.6.2 Fuel/Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.6.3 After Fuel System Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.7.1 Exhaust System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.7.2 Exhaust System Installation - LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.8 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.8.1 Air Cleaner Assembly Removal - ULS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.8.2 Air Cleaner Assembly Installation - ULS . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.8.3 Air Cleaner Assembly Removal - LS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.8.4 Air Cleaner Assembly Installation - LS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.9.1 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.9.2 Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.10 Isolation Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.10.1 Isolation Coupler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.10.2 Isolation Coupler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
6036, 6042, 8042, 10042, 10054 7-1

Engine
7.1 INTRODUCTION 7.3 SPECIFICATIONS AND

MAINTENANCE INFORMATION
7.1.1 Disclaimer and Scope
For engine, coolant and oil specifications, and
maintenance information, refer to Section 2, “General
WARNING Information and Specifications.”
DO NOT service the machine without following all Note: Detailed Cummins engine service instructions
safety precautions as outlined in Section 1, “Safety (covering disassembly, inspection, internal repair,
Practices,” of this manual. assembly, adjustment and troubleshooting) are provided
in appropriate Cummins engine service manual.
Note: Refer to Section 9.13, “Troubleshooting,” for error
WARNING codes and troubleshooting.
Engine fuel lines are pressurized. DO NOT attempt
repairs unless specific training has been completed.
These instructions are written for worldwide use. In
territories where legal requirements govern engine smoke
emission, noise, safety factors, etc., apply all instructions,
data and dimensions provided herein in such a way that
after maintenance, service and repair of the engine,
engine operation does not violate local regulations.
Note: These instructions cover only the routine
maintenance, removal, installation and troubleshooting
of engine. Refer to local Cummins Engine Distributor
and the applicable Cummins Engine Service Manual for
assistance with comprehensive engine diagnosis, repair
and component replacement. A gradual running-in
(break-in) of a new engine is not necessary. Full load
can be applied to a new engine as soon as engine is put
into service and the coolant temperature is at least
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.
7.1.2 Component Terminology

locations of the engine components. The following
illustration identifies the components that are referred to
throughout this section.
7.2 ENGINE SERIAL NUMBER

The serial number is stamped on a plate which is typically
located on engine rocker cover, but may be located on
the side of gear housing. Information contained in the
serial number is required in correspondence with the
engine manufacturer.
7-2 6036, 6042, 8042, 10042, 10054

Engine
IF EQUIPPED FOR ULS IF EQUIPPED FOR LS
TURBOCHARGER
TURBOCHARGER
THERMOSTAT
OIL FILTER
ALTERNATOR
OIL FILTER
ALTERNATOR
THERMOSTAT
FUEL FILTER
STARTER
FUEL INJECTOR PUMP
MAQ0480
STARTER
FUEL INJECTOR FUEL FILTER
PUMP
MAQ0490
6036, 6042, 8042, 10042, 10054 7-3

Engine
7.4 ENGINE COOLING SYSTEM IF EQUIPPED FOR ULS

1 6
7.4.1 Coolant System Pressure Cap

2
If equipped for ULS, the surge tank cap is designed to
use a 17 psi (120 kPa) cap.
If equipped for LS, the radiator cap is designed to use 4
13 psi (90 kPa) cap.
An incorrect or malfunctioning cap can result in the loss 5
of coolant and a hot-running engine.
7.4.2 Radiator/Oil Cooler and Replacement 4

3
Before considering radiator or oil cooler replacement
for other than obvious damage, conduct a cooling
system pressure test, check coolant specific gravity,
MAQ0500
coolant level, fan belt tension and dash panel
temperature indicator. 5. If equipped for ULS, slowly turn surge tank cap (1)
• If engine runs hot, check temperature of upper to first stop and allow any pressure to escape.
radiator hose. Remove surge tank cap.
• If hose is not hot, thermostat may be stuck in IF EQUIPPED FOR LS
closed position.
• If engine has overheated, performance may
2
suffer, indicating other damage including a leaking 1
cylinder head gasket, cracked cylinder head or
block, and/or other internal engine damage.
3
a. Radiator/Oil Cooler Removal
1. Park machine on a firm, level surface, level machine,
fully retract the boom, lower boom, place travel select
lever in the (N) NEUTRAL position, engage parking
brake, and shut engine OFF.
switch and steering wheel, stating that the machine 4
3. Open the side and rear engine doors. Allow the MAQ0470
system fluids to cool.

6. If equipped for LS, slowly turn radiator cap (1) to
4. Disconnect the battery positive (+) and negative (-) first stop and allow any pressure to escape. Remove
cables from the appropriate battery terminals. the radiator cap
Remove the battery or batteries.
7. Place a suitable container beneath radiator drain.
8. 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
coolant needs to be replaced. Tighten the radiator
drain petcock.
9. If equipped for ULS, label and disconnect all hoses
and tubes attached to radiator (2), charge air
cooler(3), oil cooler (4), and fuel cooler (5). Remove
surge tank(6).
7-4 6036, 6042, 8042, 10042, 10054

Engine
If equipped for LS, label and disconnect all hoses damage to both the injection pump and the injection
and tubes attached to radiator (2), charge air cooler nozzles. Use ASTM #2 diesel fuel with a minimum Cetane
(3) and oil cooler (4). rating of 40. #2 diesel fuel gives the best economy and
10. Working at rear of machine, remove capscrews and performance under most operating conditions. Fuels
lockwashers securing radiator assembly. with Cetane numbers higher than 40 may be needed in
high altitudes or extremely low ambient temperatures to
11. Remove radiator assembly through rear of machine. help prevent misfiring and excessive smoking.
b. Radiator/Oil Cooler Installation Inform the owner/operator of the machine to use #2

diesel fuel, unless ambient temperatures are below 32° F
1. If equipped for ULS, secure radiator (2), charge air (0° C). When temperatures are below 32° F (0° C), a
cooler (3), oil cooler (4), and fuel cooler (5) to blend of #1 diesel and #2 diesel fuels (known as
machine frame with previously used hardware. “winterized” #2 diesel) may be used.
Reinstall surge tank (6).
Note: #1 diesel fuel may be used, however, fuel
2. If equipped for LS, Secure radiator (2), charge air
economy will be reduced.
cooler (3) and oil cooler (4) to machine frame with
previously used hardware. If equipped for ULS, use ultra low-sulfur content fuel
3. Uncap and connect the all the previously labeled with a cloud point (temperature at which wax crystals
hoses and tubes to their appropriate locations. form in diesel fuel) at least 10° below lowest expected
fuel temperature. Viscosity of fuel must be kept above 1.3
4. Install the battery or batteries. Connect the battery centistrokes to provide adequate fuel system lubrication.
positive (+) and negative (-) cables to the
appropriate battery terminals. If equipped for LS, use low-sulfur content fuel with a
cloud point (temperature at which wax crystals form in
5. Fill the radiator completely with coolant and secure diesel fuel) at least 10° below lowest expected fuel
cap. Refer to Section 2.5, “Fluid Specifications,” for temperature. Viscosity of fuel must be kept above 1.3
proper capacities. centistrokes to provide adequate fuel system lubrication.
6. Run engine to operating temperature. Visually check
for leaks with engine running. Check coolant level in 7.6.2 Fuel/Hydraulic Oil Tank
overflow bottle and fill, or drain, as necessary.
Note: The fuel/hydraulic oil tank is part of a one piece unit
7. Close and secure side and rear engine doors. divided into a two compartment (tank) unit. It is located on
the right side of the machine, across from the operator cab. If
7.5 ENGINE ELECTRICAL SYSTEM it is determined that either the fuel of hydraulic oil tank must
be removed, both the fuel and hydraulic oil must be drained
The engine electrical system, including the starter, before tank removal. Always dispose of hydraulic oil or fuel
alternator and primary wiring, is described in Section 9, properly.
“Electrical System.”
a. Fuel/Hydraulic OIl Tank Removal
7.6 FUEL SYSTEM 1. Park the machine on a firm, level surface, level the
7.6.1 Diesel Fuel
position, engage the parking brake, and shut the
Fuel represents a major portion of machine operating engine OFF.
costs and therefore must be used efficiently. ALWAYS 2. Place a Do Not Operate Tag on both the ignition key
use a premium brand of high-quality, clean diesel fuel. switch and steering wheel, stating that the machine
Low cost, inferior fuel can lead to poor performance and should not be operated.
expensive engine repair.
Note: Use only diesel fuel designed for diesel engines.
Some heating fuels contain harmful chemicals that can
seriously affect engine efficiency and performance. Note: If replacing the tank, remove all internal and
external components from the old tank, and retain for
Note: Due to the precise tolerances of diesel injection
use on the replacement tank.
systems, keep the fuel clean, and free of dirt and water.
Dirt and water in the fuel system can cause severe
6036, 6042, 8042, 10042, 10054 7-5

Engine
Note: Have a dry chemical (Class B) fire extinguisher tank. Dispose of the old tank according to local
near the work area. regulations concerning hazardous materials disposal.
c. Cleaning and Drying

WARNING If contaminated fuel or foreign material is in the tank, the
NEVER drain or store fuel in an open container due to tank can usually be cleaned.
the possibility of explosion or fire. Discard the fuel in Note: If a leak is suspected in the fuel tank, contact your
an approved manner. local authorized Service Department.
5. Remove the fuel/hydraulic oil tank top cover. To clean the fuel tank:
6. Remove the two frame top covers from above the 1. Have a dry chemical (Class B) fire extinguisher near
frame. the work area.
9 2. Depending on which side of the tank is contaminated
(fuel or hydraulic oil), remove the fuel or oil tank
drain plug, and safely drain any fuel or hydraulic oil
into a suitable container. Dispose of fuel or hydraulic
oil properly.
3. Clean the fuel/hydraulic oil tank with a high pressure
washer, or flush the tank with hot water for five
minutes and drain the water. Dispose of
contaminated water properly.
4. For the fuel tank side, add a diesel fuel emulsifying
agent to the tank. Refer to manufacturer’s
instructions for the correct emulsifying agent-to-
water mixture ratio. Refill the tank with water, and
agitate mixture for 10 minutes. Drain the tank
8 completely. Dispose of contaminated water properly.
5. Refill the fuel tank with water until it overflows.
7 MAQ0330 Completely flush the tank with water. Empty the fuel
tank, and allow it to dry completely.
7. Remove fuel tank drain plug (7), and drain fuel into
an approved and suitable container. Dispose of fuel
d. Assembly
properly.
8. Drain the hydraulic oil tank (8). Refer to Section The fuel/hydraulic oil tank is a one piece-unit and cannot be
8.5.1, “Hydraulic Oil Reservoir Draining.” disassembled. The fuel level indicator and hydraulic filters
can be removed and reused on the new replacement tank.
9. Label, disconnect and cap the fuel and hydraulic
Dispose of the old tank according to local regulations
lines from the tank.
concerning hazardous materials disposal regulations.
10. Label and disconnect the electrical components from
the fuel/hydraulic oil tank. e. Inspection
11. Position and connect a suitable chain support to tank Note: If a leak is suspected in the fuel tank, contact your
lifting point (9) and take up slack in the chain. local authorized Service Department.
12. While supporting the tank, remove nuts and 1. Inspect the tank thoroughly for any cracks, slices,
lockwashers securing the tank to the machine frame. leaks or other damage.
Pull tank away from the tank carriage bolts, and
2. With tank removed from machine, plug all openings
remove tank.
except one elbow fitting. Install elbow fitting, and
apply approximately 1-1.5 psi (7-10 kPa) of air
b. Disassembly
pressure through elbow. Check reservoir for leaks by
The fuel/hydraulic oil tank is a one-piece unit and cannot applying a soap solution to the exterior and look for
be disassembled. The fuel level indicator and hydraulic bubbles to appear at cracked or damaged area.
filters can be removed and reused on the new replacement
7-6 6036, 6042, 8042, 10042, 10054

Engine
f. Fuel/Hydraulic Oil Tank Installation

1. Attach tank to a suitable lifting device at lift point.
2. Place tank carriage bolts into slotted holes in frame.
3. Position the tank and insert carriage bolts through
tank attachment holes. Install lockwashers and
finger tighten nuts onto carriage bolts. Slide the tank
and carriage bolts toward the front of machine, until
carriage bolts are bottomed out into the slotted
frame holes.
4. Connect the previously labeled electrical
components to the tank.
hoses to their appropriate locations.
6. Fill the tank according to specifications. Refer to
Section 2.5, “Fluid Specifications.”
7. Check tank for leaks.
8. Install the two frame top covers.
9. Install the fuel/hydraulic oil tank cover.
7.6.3 After Fuel System Service

1. Drain and flush the fuel tank if it was contaminated.
2. Vent air from the fuel system in accordance with the
instructions found in the appropriate Operator &
Safety Manual.
3. Fill the fuel tank with fresh, clean diesel fuel as
required.
6036, 6042, 8042, 10042, 10054 7-7

Engine
7.7 ENGINE EXHAUST SYSTEM

IF EQUIPPED FOR ULS
11
Rattles and noise vibrations in the exhaust system are
usually caused by misalignment or parts. When aligning
the system, leave all capscrews and nuts slightly loose
until all parts are properly aligned, then tighten all
fasteners working from the front of the system to the rear.
When replacing the muffler, also replace the tail pipe. 10
Before assembling components, use exhaust system

sealer at all slip joint connections.
13
When installing exhaust system components, allow
sufficient clearance between the components and other
pipes, hoses and wiring that could be adversely affected
by excessive heat.
10
7.7.1 Exhaust System Removal
12
machine, fully retract the boom, lower the boom, 10
14
MAQ0510
position, engage the parking brake, and shut the
engine OFF. IF EQUIPPED FOR LS

10
11
10
13
12
10
14
MAQ0520
5. Loosen three clamps (10) securing exhaust pipe to

muffler and engine. Remove exhaust pipe (11).
6. Loosen two bolts (13) securing muffler mounting
plate (12) to machine frame on right side of machine.
Do Not Remove bolts.
7. Remove two bolts (14) securing muffler mounting
plate on left side of machine.
8. Be sure to properly support muffler mounting plate
and muffler for removal.
9. Drop muffler mounting plate down on left side.
7-8 6036, 6042, 8042, 10042, 10054

Engine
10. Lift right side and slip bolts up and through slots on
the right side of frame.
11. Place mounting plate on level surface and replace
muffler, clamps and tailpipe. Note position of muffler
for re-installation purposes.
15
7.7.2 Exhaust System Installation - LS
Note: Install muffler in proper direction.
Note: Keep all clamps loosened until entire exhaust 16
system is in place. A VIEW FROM REAR OF MACHINE
MAQ1190
1. Install muffler and tailpipe on muffler mounting 5. Verify dimension (A) 1.94-2.06 in (49,2-52,3 mm)
plate (12) using proper clamps in proper position. between the end of the muffler (15) and the inside of
2. Lift muffler mounting plate up and slide mounting the left frame rail (16).
plate bolts (13) through slot in right side of frame.
3. Lift left side of muffler mounting plate up and 11
re-install mounting plate bolts (14).
4. Tighten all mounting plate bolts.
5. Install exhaust pipe (11) to muffler and engine.
6. Tighten all clamps (10).
C
9. Start engine and check for exhaust leaks at all
exhaust connections. Adjust or repair as needed.
B
7.7.3 Exhaust System Installation - ULS
Note: Install muffler in proper direction.
17
Note: Keep all clamps loosened until entire exhaust
system is in place.
1. Install muffler and tailpipe on muffler mounting
plate (12) using proper clamps in proper position.
2. Lift muffler mounting plate up and slide mounting
plate bolts (13) through slot in right side of frame.
3. Lift left side of muffler mounting plate up and MAQ1170
re-install mounting plate bolts (14). 6. Adjust the muffler intake tube to approximately (B)
4. Tighten all mounting plate bolts. 22.0°.
7. Tighten band clamp (17) enough to hold the muffler
in place.
8. Install exhaust pipe (11) to muffler and engine.
Tighten each clamp to secure the exhaust pipe in
place.
9. Measure distance (C) 8.75-9.5 in (222,2-241,3 mm)
on the flex pipe section of the exhaust pipe (11).
6036, 6042, 8042, 10042, 10054 7-9

Engine
The following steps may be required to achieve distance

(C) (Expanded web).
• Loosen the turbocharger clamp to allow rotation of
the top exhaust pipe (11). Do Not remove clamp.
• Pull up and out on exhaust pipe (11) to allow for a
straight line and expansion of the flex pipe.
• Tighten the turbocharger clamp while holding the
exhaust pipe (11) in place.
• If the flex pipe is in a “S” shape, loosen the band
clamp (17) securing the muffler.
• Rotate the muffler inlet tube forward until the flex
pipe becomes straight.
• It may be necessary to pull the muffler closer to the
frame until the flex pipe becomes straight.
10. Tighten the muffler band clamp and all remaining
clamps (10).
13. Start engine and check for exhaust leaks at all
exhaust connections. Adjust or repair as needed.
7-10 6036, 6042, 8042, 10042, 10054

Engine
7.8 AIR CLEANER ASSEMBLY 6. Remove air intake hose and pre-cleaner (16).
CAUTION
NEVER run the engine with only the inner safety
element installed.
Note: Refer to the appropriate Operation & Safety

17
Manual for your machine for the correct element change
procedure.
7.8.1 Air Cleaner Assembly Removal - ULS

18
position, engage the parking brake, and shut the 21
engine OFF. 20
19 MAQ0560
3. Open the rear door. Allow the system fluids to cool. 7. To complete removal it is necessary to disassemble
the air cleaner assembly.
8. Remove air cleaner cover and primary element (17).
9. Remove restriction indicator and remaining side
cover (18) from air filter body.
10. Remove three bolts securing air filter body to
weldment bracket (19).
11. Remove bolts securing weldment bracket to engine
16 (20) and tilt bracket forward to gain access to last
bolt (21). Remove last bolt.
12. Remove air cleaner body for replacement.
7.8.2 Air Cleaner Assembly

15 Installation - ULS
1. Reinstall components in reverse order of removal.
2. Attach air filter body to weldment body using all four
bolts (19, 21) removed earlier.
3. Secure weldment bracket to engine using bolts (20).
4. Reassemble restriction indicator and remaining side
cover (18) from air filter body.
MAQ0550
Note: Note orientation of pipe for reassembly. Pipe will

need to be aligned correctly for proper reassembly.
5. Loosen clamps securing exhaust pipe and air
cleaner hose and remove exhaust pipe and air
cleaner hose (15).
6036, 6042, 8042, 10042, 10054 7-11
Engine
7.8.3 Air Cleaner Assembly Removal - LS 7.9 ENGINE REPLACEMENT

1. Park machine on a firm, level surface, level machine,
fully retract boom, lower boom, place the travel select 7.9.1 Engine Removal
lever in the (N) NEUTRAL position, engage the
Note: The radiator and oil cooler must be removed from
parking brake, and shut the engine OFF.
the machine before engine removal. Refer to Section
2. Place a Do Not Operate Tag on both ignition key 7.4, “Engine Cooling System.” Several additional
switch and steering wheel, stating that the machine components must be removed before engine removal.
should not be operated. They will be addressed in the following procedures.
3. Open the rear door. Allow system fluids to cool. 1. Park the machine on a firm, level surface, level the
4. Properly disconnect the battery. machine, fully retract the boom, lower the boom,
22 position, engage the parking brake, and shut the
23 engine OFF.
24
5. Remove the rear door and engine side covers.
6. Drain and remove radiator assembly. Refer to
Section 7.4.2, “Radiator/Oil Cooler and
Replacement.”
25
MAQ0530
7. Label, disconnect and cap the heater hoses
attached to the engine (if equipped).
5. Loosen clamp securing air intake hose (22) and Note: The engine harness is routed and attached to the
remove hose. engine using hold-down clamps and plastic wire ties at
6. Loosen clamps securing air cleaner hose (23) to air various places on the engine. Before removing engine,
cleaner assembly and remove hose. ensure that the harness has been completely separated
(disconnected) from the engine. Move the harness clear
7. Remove capscrews and lockwashers (24) securing of the engine, and with the help of an observer, ensure
mounting band to air cleaner bracket (25). Remove that the engine clears the harness during removal.
air cleaner assembly.
8. Label and disconnect all electrical wire connections
7.8.4 Air Cleaner Assembly Installation - LS on the engine.
Note: Apply Loctite® 242TM threadlock to the capscrew 9. Label, disconnect and cap the fuel inlet line at the
threads before installation. fuel lift pump.
10. Label, disconnect and cap the fuel return line from
1. Secure air cleaner assembly to air cleaner bracket
the injector pump.
(25) with previously used hardware.
11. Remove the engine-to-transmission drive shaft.
2. Install the air cleaner assembly.
Refer to Section 5.8.3, “Drive Shaft Removal.”
3. Install air cleaner hose (23) to the air cleaner
12. Loosen the clamps on the sleeve reducer at the
assembly and secure with clamps.
engine and on the air suction pipe.
4. Install air intake hose (22) and secure with clamp.
13. Remove air intake hoses and pre-cleaner. It is not
5. Tighten all clamps. necessary to remove air cleaner assembly before
6. Properly connect the battery. engine is removed from frame.
7-12 6036, 6042, 8042, 10042, 10054
Engine
14. Remove the exhaust pipe and muffler system. Refer 2. Install the engine mounting brackets. Torque to
to Section 7.7.1, “Exhaust System Removal.” 93-100 lb-ft (126-135 Nm).
3. Place the engine on a flat, level surface.
4. Position a fork truck behind the engine, and drive
forward, placing the forks underneath the rear
engine mount and front right and left engine mount
brackets. Lift the engine and slowly drive it into the
back of the machine. Have an assistant ensure that
the engine clears all frame, hose and harness
components during installation. Position the engine
brackets over rear and front frame mounts.
5. Secure the rear engine mounts (2) to the frame
using the previously used hardware. Torque to 80-90
lb-ft (108-122 Nm).
6. Secure front (1) engine mount to frame using
previously used hardware. Torque to 80-90 lb-ft
(108-122 Nm).
7. Install exhaust pipe mount bracket.
2 8. Install the radiator overflow tube, overflow tank and
MAQ0540
1 hose support.
15. At the front right engine mount (1), remove the 9. Install the engine-to-transmission drive shaft. Refer
hardware securing the mount to the frame. to Section 5.8.5, “Drive Shaft Installation.”
16. Remove hardware securing rear engine mounts (2). 10. Uncap and connect the previously labeled fuel return
line to the injector pump.
17. Remove the exhaust pipe bracket.
11. Uncap and connect the previously labeled fuel inlet
18. Position a fork truck behind the machine, and drive line to the fuel lift pump.
forward, placing the forks underneath the rear
engine mount and front engine mount brackets. 12. Connect the previously labeled electrical wire
Slightly lift the engine, and slowly back engine out of connections on the engine.
the machine. Have an assistant ensure that the 13. Uncap and connect the previously labeled heater
engine clears all frame components during removal. hoses to the engine (if equipped).
19. Place engine on a flat, level surface. 14. Install the complete radiator assembly. Refer to
20. If replacing engine, attach a lifting chain to the front Section 7.4.2, “Radiator/Oil Cooler and
and rear engine lift brackets, and lift engine clear of Replacement.”
the ground. 15. Properly connect the battery.
21. Remove the three engine mounting brackets. 16. Remove the Do Not Operate Tags from both the
22. Remove air intake assembly. ignition key switch and the steering wheel.
17. Check that all hydraulic system, electrical system,
7.9.2 Engine Installation cooling system, fuel system and exhaust system
connections are correct and connected tightly.
Note: The engine harness is routed and attached at
various places on the engine using hold-down clamps Note: Have an assistant stand by with a Class B fire
and plastic wire ties. Before installing engine and with extinguisher.
the help of an assistant, ensure that the engine clears
18. Start the engine and run to normal operating
the harness during installation.
temperature then shut off the engine. While the
1. If replacing the engine, attach a lifting strap or chain engine is cooling, check for leaks.
to the front and rear engine lift brackets, and lift the 19. Allow the engine to cool. Check the radiator coolant
engine clear of the ground. level, and add coolant if needed. Replace the
radiator cap.
6036, 6042, 8042, 10042, 10054 7-13

Engine
20. Check for leaks from the engine, main hydraulic

pump and lines, transmission, hydraulic reservoir
and fuel tank. Check the levels of all fluids and 4
lubricants. Fill as required.
Note: During the full throttle check:
• DO NOT operate any hydraulic function. 3
• DO NOT steer or apply any pressure to the steering

wheel.
• Keep the transmission in (N) NEUTRAL.
21. Obtain and connect an appropriate engine analyzer
or tachometer. Check the engine rpm at full throttle. MH6360
22. Purge the hydraulic system of air by operating all

boom functions through their entire range of motion 7. Remove the capscrews and lockwashers securing
several times. Check the hydraulic oil level. the access cover plate (3).
23. Check for proper operation of all components. 8. Remove the capscrews securing the coupler (4) to
the flywheel.
24. Turn the engine OFF.
Note: The coupler is heavy and requires two people,
25. Install the side and rear engine covers.
one on each side, to remove.
7.10 ISOLATION COUPLER 9. Remove the coupler assembly.

10. At this time, use a suitable cleaner/solvent and
7.10.1 Isolation Coupler Removal thoroughly clean the mounting lip of the flywheel.
Wipe any debris from the inside of the bell housing.
1. Park the machine on a firm, level surface, level the Use the cleaner to clean the threaded holes around
machine, fully retract the boom, lower the boom, the flange of the bell housing.
place the transmission in (N) NEUTRAL, engage the
parking brake, and shut the engine OFF. 7.10.2 Isolation Coupler Installation
2. Place a Do Not Operate Tag on both the ignition key 1. Use cleaner to clean the backside of the coupler,
switch and steering wheel, stating that the machine where it comes in contact with the flywheel.
3. Open the rear door. Allow the system fluids to cool. Note: Apply Loctite® 242TM threadlock compound to all of
the capscrews used during assembly.
Note: The new coupler is heavy and requires two
Note: Rotating the fan belt by hand gives greater people, one on each side, to install.
access to removing the drive shaft mounting capscrews.
2. Place the new coupler into the indentation of the
5. Remove the capscrews and straps that secure the flywheel and use new hardware to secure the
drive shaft to the transmission yoke. coupler to the flywheel. DO NOT fully tighten until all
6. Remove the capscrews and lockwashers securing capscrews are in place.
the drive shaft to the coupling flange. 3. After all capscrews are in place, check to be sure the
Note: It may be necessary to loosen/remove the motor coupler is resting squarely in the indentation of the
mounts on either side of the engine to gain access to the flywheel. Torque all the capscrews to 37 lb-ft (48
bottom capscrews on the outer half of the coupler. Place Nm).
a jack under the bell housing (use a wood block to Note: Before assembling the drive shaft to the coupling;
support the engine) and carefully lift the engine until the be sure the access cover plate is placed on the engine-
bottom edge of the bell housing is at the top edge of the side of the frame member that mounts the rear axle to
frame member that mounts the rear axle to the frame. the frame.
Watch the fan-to-radiator clearance as your are lifting the
engine. If necessary, turn the fan slightly by hand to gain
additional clearance.
7-14 6036, 6042, 8042, 10042, 10054

Engine
4. Install the access cover plate over the drive shaft

and assemble the drive shaft flange to the coupler
using new hardware. Torque to 48 lb-ft (65 Nm).
5. If engine mounts were previously removed or
loosened, carefully lower the engine down onto the
front engine mounts. Reassemble the rebound
washer and secure in place with a new locknut.
Torque to 60 lb-ft (81 Nm). Repeat this procedure for
the engine mount on the other side.
6. Thoroughly clean the transmission yoke and secure
in place with new straps and hardware. Torque to
55–60 lb-ft (75–81 Nm).
7. After the drive shaft is in place, grease both u-joints
and the slip joint using multi-purpose grease.
6036, 6042, 8042, 10042, 10054 7-15

Engine
7-16 6036, 6042, 8042, 10042, 10054

Section 8
Hydraulic System
Contents

8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.3.1 Pressure Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.4.1 Hydraulic Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.4.2 Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
8.5 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.5.1 Hydraulic Oil Reservoir Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.5.2 Hydraulic Oil Reservoir Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.5.3 Hydraulic Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.5.4 Hydraulic Oil Reservoir Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
8.6 Hydraulic System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
8.6.1 Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
8.7 Valves and Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
8.7.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
8.7.2 Secondary Function Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
8.7.3 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
8.7.5 Brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
8.7.6 Power Steering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
8.7.7 Steer Select Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
8.7.8 Unloader Valve (6036 & 6042 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
8.7.9 Outrigger Valve (10042 & 10054 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
8.7.10 Extend Lockout Valve (10054 only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
8.8 Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
8.8.1 General Cylinder Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
8.8.2 Cylinder Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
8.8.3 Steering Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34
8.8.4 Cylinder Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
6036, 6042, 8042, 10042, 10054 8-1

Hydraulic System
8.1 HYDRAULIC COMPONENT

TERMINOLOGY
To understand the safety, operation and service
the operator/mechanic be familiar with the name and
location of the hydraulic components of the machine. The
following illustration identifies the components that are
referred to throughout this section.
6036 & 6042
LIFT/LOWER
CYLINDERS
COMPENSATION
CYLINDERS
ATTACHMENT
TILT
EXTEND/
CYLINDER
RETRACT
CYLINDER
UNLOADER
VALVE
HYDRAULIC FLUID
RESERVOIR
STEER SELECT
VALVE
MAIN
CONTROL
VALVE
FRAME LEVEL STABILIZER

CYLINDER CYLINDER
(6042 ONLY)
MAIN PUMP
STEERING
SERVICE CYLINDER
BRAKE (REAR)
SECOND- VALVE
ARY FUNC-
TION
STEERING
VALVE
STEERING
CYLINDER
(FRONT)
MA9251
8-2 6036, 6042, 8042, 10042, 10054

Hydraulic System
8042, 10042 & 10054
LIFT/LOWER
CYLINDERS
COMPENSATION
CYLINDERS
EXTEND/
RETRACT
ATTACHMENT
CYLINDER
TILT
CYLINDER
EXTEND LOCKOUT
VALVE (10054
MAIN PUMP
HYDRAULIC FLUID
RESERVOIR
STEER SELECT
VALVE
FRAME LEVEL STABILIZER

CYLINDER CYLINDER
SECOND-
ARY FUNC-
TION STEERING
CYLINDER
SERVICE (REAR)
BRAKE
STEERING VALVE
VALVE
MAIN OUTRIGGER
CONTROL VALVE (10042 &
VALVE 10054 ONLY)
OUTRIGGER STEERING
CYLINDERS (10042 & CYLINDER
10054 ONLY) (FRONT)
MH3441
6036, 6042, 8042, 10042, 10054 8-3

Hydraulic System
8.2 SAFETY INFORMATION 8.3 HYDRAULIC PRESSURE DIAGNOSIS

JLG Parts Department has a kit available to use for
WARNING hydraulic system maintenance and troubleshooting: the

JLG Pressure Test Kit. The kit is contained in a durable
polyethylene carrying case for demanding field service
DO NOT service the machine without following all conditions.
Practices,” of this manual. Hydraulic Pressure Test Kit
Petroleum-based hydraulic fluids are used in this The hydraulic pressure test kit is used to pressure test the
machine. Temperature of hydraulic fluid increases various hydraulic components in the hydraulic system.
during operation of various hydraulic functions. A heated The kit includes:
petroleum-based hydraulic fluid presents a fire hazard,
especially when an ignition source is present. Hydraulic • Gauges for testing high and low pressure circuits
fluid has a flash point that ranges from 300-600° F • Fittings, couplers and hoses
(150-318° C) and an auto-ignition temperature of
500-750° F (262-402° C).
Accordingly, periodically inspect all hydraulic system
components, hoses, tubes, lines, fittings, etc. Carefully
examine any deterioration and determine whether any
further use of the component would constitute a hazard.
If in doubt, replace the component.
Operate the hydraulic controls after the engine has
stopped to relieve trapped pressure.
Note: Residual pressure may remain in hydraulic
cylinders, hoses, valve bodies, components, etc. If the
hydraulic lines going to or coming from a component are
taut, slowly and cautiously relieve (“bleed off”) pressure.
Whenever you disconnect a hydraulic line, coupler, fitting
or other component, slowly and cautiously loosen part
involved. A hissing sound or slow seepage of hydraulic
fluid may occur in most cases. After hissing sound has
ceased, continue removing the part. Any escaping oil
should be directed into an appropriate container. Cap or MZ1460
otherwise block off the part to prevent further fluid seepage.
Hydraulic system maintenance will, at times, require that Contact JLG Parts Department Toll Free at
the engine be operated. Always follow safety precautions. 1-877-554-5438 or 717-485-6472 for ordering
A major cause of hydraulic component failure is information.
contamination. Keeping hydraulic fluid as clean as Approximat
possible will help avoid downtime and repairs. Sand, grit Part Price and
Description e
Number Availability
and other contaminants can damage finely machined Weight
surfaces within hydraulic components. If operating in an Dial Hydraulic Pressure
exceptionally dirty environment, change filters and 70000652 10 lbs. Consult Factory
Test Kit
inspect the fluid more often. When servicing the system, Digital Hydraulic Pressure
cap or plug hydraulic fittings, hoses and tube assemblies. 70000101 7 lbs. Consult Factory
Test Kit
Plug all cylinder ports, valves and hydraulic reservoir, and Digital Hydraulic Pressure
pump openings until installation occurs. Protect threads 70027911 7 lbs. Consult Factory
Test Kit
from contamination and damage.
Some hydraulic functions are actuated by interfacing with 8.3.1 Pressure Checks and Adjustments
electrical system components (switches, solenoids and
sensors). When the hydraulic system is not functioning When diagnosing trouble in the hydraulic system, use the
properly, check the electrical aspect of the malfunctioning hydraulic testing information in Section 8.4.1, “Hydraulic
circuit also. Pressures.”
In general, follow the steps below whenever conducting
pressure checks and performing adjustments:
8-4 6036, 6042, 8042, 10042, 10054

Hydraulic System
1. Park the machine on a firm, level surface. Engage Loose fittings, faulty o-rings or seals, trapped oil,
the park brake, place the travel select lever in (N) leaks, system opened for service, etc., can cause air
NEUTRAL, level the boom and turn the engine OFF. in the system. Determine what is causing air to enter
2. Test port is located at top right corner of main control the system and correct it. Bleed air from the system.
valve. Install a pressure gauge capable of measuring
at least 10% more pressure than that which circuit 8.4.1 Hydraulic Pressures
being checked operates under.
3. Start the engine. Operate machine functions several a. Checking Pressure
times to allow hydraulic oil to reach operating 1. Start the machine and warm the hydraulic system to
temperature. The hydraulic oil temperature should operating temperature.
be between 100-120°F (38-49° C). If a temperature
2. Shut off the machine and install a gauge of suitable
gauge or thermometer is unavailable, the hydraulic oil
pressure rating according to the following chart to
reservoir should be warm to the touch.
the appropriate test port.
4. Refer to Section 8.4.1, “Hydraulic Pressures,” for
testing procedures.
Test Gauge Fittings
5. Fully depress accelerator pedal if required. Place
Location
and hold joystick in position needed to operate the
particular machine function being checked. Continue 4000 psi gauge Unit equipped with
holding the joystick in position until pressure 2, 3, 4, 5
(280 bar gauge) fittings from factory.
readings are taken.
6. Check pressure gauge reading. It should read 1000 psi gauge Unit equipped with
6, 7, 8, 10
as specified in Pressure Readings column of the (70 bar gauge) fittings from factory.
charts found in Section 8.4.1, “Hydraulic Pressures.” Requires a male or
If the reading is not as specified, turn the engine 4000 psi gauge
9 female quick
OFF and check other components in the system. (280 bar gauge)
disconnect coupler.
Verify that all related hydraulic components and
electrical switches, sensors, solenoids, etc. are
operating correctly.
7. Adjust relief valve by turning adjustment screw.
Turning clockwise will increase pressure; turning
CAUTION
screw counterclockwise will decrease pressure. GAUGE DAMAGE may occur. Malfunctioning
8. Start engine and check pressure again. Turn engine hydraulic system circuits may have excessive
OFF. If there is pressure reading in gauge, bleed it pressure and can cause hydraulic pressure spikes.
off then disconnect or remove pressure gauge from Test circuit with the highest reading pressure gauge
the machine. first. If this gauge cannot record an accurate pressure
reading, use the next lower pressure gauge.
8.4 HYDRAULIC CIRCUITS
3. Start the machine, run the engine and follow the
This section covers the hydraulic circuits and includes procedures in Section 8.4.1, e. “Pressure
listings for all hydraulic function pressures, where and Specifications (8042, 10042 & 10054).”
how to check those pressures and a hydraulic schematic.
Electrical and hydraulic functions are often related. Verify b. Adjusting Hydraulic Pressure
that electrical components of the circuit are functioning 1. Shut the machine off. Remove the cap on the relief
properly whenever troubleshooting the hydraulic circuit. (if necessary).
Always check the following before beginning to 2. Start machine and loosen the jam nut on the relief.
troubleshoot a circuit that is not functioning correctly. Turn the relief clockwise to increase pressure or
1. Check hydraulic oil level in reservoir. Level should be counter-clockwise to decrease pressure. Set to the
in middle of sight glass with all cylinders retracted. correct pressure.
2. Check hoses, tubes, fittings and other hydraulic 3. Tighten jam nut and recheck pressure at full throttle.
components for leaks, bends, kinks, interference, etc. If reading is within specification, shut machine off,
3. Check for air in the hydraulic system. Erratic machine install safety cap and remove gauge from test port.
performance and/or spongy cylinder operation are 4. If the proper pressure cannot be set, use the
signs of air in the hydraulic system. accompanying hydraulic schematic and/or the
If air in the hydraulic system is suspected, you will electrical schematic to help troubleshoot and correct
hear air leakage when hydraulic fittings are loosened the problem.
and see air bubbles in the hydraulic fluid.
6036, 6042, 8042, 10042, 10054 8-5

Hydraulic System
c. Pressure Specifications (6036)
ATTACHMENT TILT
FRONT AXLE CYLINDER
FTR FTB
FRAME SWAY
CYLINDER
8
E R
FRONT STEERING
CYLINDER
BRAKE T MAIN CONTROL VALVE

VALVE P
LS C
7 1
T
SHUTTLE
VALVE PUMP
STEER
T P SELECT
RP B A VALVE
LT
POWER
STEERING HYDRAULIC
UNIT B RESERVOIR
OPERATOR'S CAB
E F
SECONDARY
FUNCTION
MANIFOLD
EXTEND/ P T
RETRACT
CYLINDER PS 5
PSG PBG
PP PPG PB
R E
4
6
LEFT RIGHT
LIFT/LOWER LIFT/LOWER
CYLINDER CYLINDER
2 A
R R
VG D
E E T
V
SFV 3
P LS LSG
LEFT R R RIGHT
SLAVE SLAVE
CYLINDER E E CYLINDER UNLOADER VALVE
REAR STEERING
CYLINDER
REAR AXLE
HYDRAULIC
OIL COOLER
MA6242
8-6 6036, 6042, 8042, 10042, 10054

Hydraulic System
Test Site Hydraulic Pump Flow Test

To check flow readings, a flow meter capable of measuring 60 gpm (3,8 liter/sec) and a load
1 valve capable of 6000 psi (413,4 bar) will be required. — 2000 psi (137,8 bar) load @ Engine
Speed of 2475–2525 rpm—Flow rate should be 28–32 GPM (1,8–2,0 liter/sec)
Test Valve Adj. Component Pressure

Pressure Test Procedures
Site Port Site Description Reading
Main System
With engine at idle, use the boom control lever to fully retract the
Unloader Relief
2 VG A boom. Hold over relief and check pressure. If pressure is
Valve 2900–3100 psi
incorrect, adjust or replace cartridge.
(200–214 bar)
Remove attachment if equipped. With the engine at full throttle,
Lift/Lower Relief
Unloader use the boom control lever to lower boom fully. Hold over
2 B 2900–3100 psi
Valve relief and check pressure. If pressure is incorrect, adjust or
(200–214 bar)
replace cartridge.
Standby
With engine at idle and no functions operated, check standby
Unloader Pressure
2 VG D pressure. If pressure is incorrect, adjust or replace the
Valve 250-300 psi
differential pressure sense cartridge on the unloader valve.
(17–21 bar)
Load Sense With engine at idle, load sense at 0 psi. With engine at
Unloader
3 LSG N/A 0-3000 psi FULL throttle, use boom control lever to fully retract boom. Hold
Valve
(0-207 bar) over relief. Pressure should be 2750–3000 psi (190–207 bar).
Secondary Steering Relief With engine at FULL throttle, turn the steering wheel all the way
4 PSG E Function 2400–2600 psi in one direction and hold while checking pressure. If pressure is
Manifold (165–179 bar) incorrect, adjust or replace the pressure-reducing cartridge.
With engine at idle, park brake released and no functions
operated, pressure should be 400 psi (28 bar) minimum. With
Park Brake engine at idle, park brake released and steering held over relief,
Secondary minimum pressure should be 550 psi (38 bar) maximum. If pressure is
5 PBG F Function 400 psi (28 bar) incorrect, adjust or replace the pressure reducing valve in the
Manifold maximum secondary function manifold. When adjusting the pressure
550 psi (38 bar) reducing valve, connect gauge to location 6. With engine at idle
and steering held over relief, adjust valve until gauge reads
500–550 psi (34–38 bar).
Brake Valve
With engine OFF, pump brake pedal twice. If pressure is
(Manual 400 psi (28 bar)
7 N/A incorrect, check for external leaks. If no leaks are found, refer
Brake minimum
to Section 8.7.5, “Brake Bleeding.”
Pressure)
Brake Valve
1000 psi With engine at idle, depress and hold brake pedal. DO NOT turn
(Service
7 N/A (69 bar) the steering wheel. Check pressure. If pressure is incorrect,
Brake
minimum refer to Section 8.7.5, “Brake Bleeding.”
Pressure)
With engine at low idle, move auxiliary control lever left or right.
Hold auxiliary control lever over relief and check pressure. If
Auxiliary 3000 psi
8 C pressure is incorrect, check unloader pressure per location 2.
Hydraulics (207 bar)
If location 2 is ok, check port reliefs on the aux section of main
control valve.
6036, 6042, 8042, 10042, 10054 8-7

Hydraulic System
d. Pressure Specifications (6042)
ATTACHMENT TILT FRAME SWAY

FRONT AXLE CYLINDER CYLINDER
FTR FTB
AUXILIARY
HYDRAULICS
Ø .040 Ø .047
E R
FRONT STEERING
CYLINDER
MAIN CONTROL VALVE
Ø .089
BRAKE
VALVE
T
P
Ø .089 LS Ø .029
SHUTTLE
UNLOADER VALVE
VALVE
Ø .089 SFV
LSG
4 LS
P
RP
LS T VG
LT EXTEND/ V
POWER
RETRACT
CYLINDER
B
STEERING D C A STEER
UNIT 2 SELECT
VALVE
OPERATOR'S CAB R E 3
B
T
T P A
P
PS
PBG PSG
PB PPG PP 1
6
SECONDARY
5
FUNCTION
MANIFOLD 7 LEFT RIGHT PUMP
CYLINDER R R CYLINDER
STABILIZER
CYLINDER E E
FTR V
9 G1
LEFT R R RIGHT
PT SLAVE SLAVE
CYLINDER
E E E CYLINDER
REAR STEERING
CYLINDER
REAR AXLE
HYDRAULIC
OIL COOLER
HYDRAULIC
RESERVOIR
MA9242
8-8 6036, 6042, 8042, 10042, 10054

Hydraulic System
Test
Hydraulic Pump Flow Test
Location
Speed of 2475–2525 rpm—Flow rate should be 34–40 GPM (2,1–2,5 liter/sec)
Test Valve Adj. Component Pressure

Site Port Site Description Reading
Main System
With engine at high idle, use the boom control lever to fully
Unloader Relief
2 VG A retract the boom. Hold over relief and check pressure. If
Valve 2900–3100 psi
pressure is incorrect, adjust or replace cartridge.
(200–214 bar)
With engine at high idle, move auxiliary control lever left or
right. Hold auxiliary control lever over relief and check
Auxiliary 2900–3100 psi
2 A pressure. If pressure is incorrect, check unloader pressure
Hydraulics (200–214 bar)
per location 2. If location 2 is ok, check port reliefs on the aux
section of the main control valve.
Note: DO NOT touch any functions while the pressure gauge
Standby
is connected. You will damage the pressure gauge. With
Unloader Pressure
3 VG B engine at idle and no functions operated, check standby
Valve 250–300 psi
pressure. If pressure is incorrect, adjust or replace the
(17–21 bar)
differential pressure sense cartridge on the unloader valve.
Load Sense With engine at idle, load sense is 0 psi. With engine at FULL
Unloader
4 LSG N/A 0–3000 psi throttle, use boom control lever to fully retract the boom. Hold
Valve
(0–207 bar) over relief. Pressure should be 2750–3000 psi (190–207 bar).
Secondary Steering Relief With engine at FULL throttle, turn steering wheel all way in
5 PSG C Function 2400–2600 psi one direction and hold while checking pressure. If pressure is
Manifold (165–179 bar) incorrect, adjust or replace the pressure-reducing cartridge.
With engine at idle, park brake released and no functions
Park Brake operated, pressure should be 400 psi (28 bar) minimum. With
minimum engine at idle, park brake released and steering held over
Secondary 400 psi (28 bar) relief, pressure should be 500–600 psi (34–41 bar)
6 PBG N/A Function
maximum maximum. After releasing steering wheel, pressure MUST
Manifold
500–600 psi NOT drop more than 50 psi in one minute. If pressure drop is
(34–41 bar) incorrect, refer to Section 8.7.3, “Service Brake Valve.” If
pressure is incorrect, adjust per test 7.
With engine at idle, park brake released and steering held
Secondary
500–600 psi over relief while checking pressure. If pressure is incorrect,
7 PBG D Function
(34–41 bar) adjust or replace the pressure reducing valve in the
Manifold
secondary function manifold.
Brake Valve 400 psi With engine OFF, pump brake pedal twice. If pressure is
8 N/A (Manual Brake (28 bar) incorrect, check for external leaks. If no leaks are found, refer
Pressure) minimum to Section 8.7.5, “Brake Bleeding.”
Brake Valve
1000 psi With engine at idle, depress and hold brake pedal. DO NOT
(Service
8 N/A (69 bar) turn steering wheel. Check pressure. If pressure is incorrect,
Brake
minimum refer to Section 8.7.5, “Brake Bleeding.”
Pressure)
Stabilizer 75–150 psi
9 G1 E With engine at idle, check the pressure on the cylinder.
Cylinder (5,2–10,3 bar)
6036, 6042, 8042, 10042, 10054 8-9

Hydraulic System
e. Pressure Specifications (8042, 10042 & 10054)
LEFT RIGHT
OUTRIGGER OUTRIGGER
CYLINDER CYLINDER
E R
R E
ATTACHMENT TILT
FRONT AXLE CYLINDER AUXILIARY
9 COUPLERS
FTR FTB
FRAME SWAY
CYLINDER
E R
FRONT STEERING
CYLINDER
2
BRAKE T MAIN CONTROL VALVE
VALVE P
LS
D
3 B
1
8 A
STEER
SHUTTLE T
SELECT
VALVE P VALVE
PUMP T P
RP B A
LT
POWER
STEERING
UNIT
C
HYDRAULIC
OPERATOR'S CAB
RESERVOIR
5 7 6
SECONDARY
FUNCTION
MANIFOLD
PBG B1 A2 B2
C A1
PSG G
T
PLT T
P
LS
P
PS PB
EXTEND/
RETRACT
R E CYLINDER OUTRIGGER
VALVE
(10042 & 10054 ONLY)
E F
LEFT RIGHT
CYLINDER CYLINDER
STABILIZER R R
CYLINDER
E E
FTR V
G
PT LEFT RIGHT
R R
10 SLAVE
CYLINDER E E
SLAVE
CYLINDER
REAR STEERING
CYLINDER
REAR AXLE
HYDRAULIC
OIL COOLER
MH6172
8-10 6036, 6042, 8042, 10042, 10054

Hydraulic System
Test
Hydraulic Pump Flow Test
Location
Speed of 2475–2525 rpm—Flow rate should be 48.9 GPM (3 liter/sec)
Test Adjust. Component Pressure

Location Location Description Reading
With all hydraulic functions in neutral position, park brake
Pump Standby 400–450 psi
2 A on, engine at high idle (2650 RPM), check pump standby
Pressure (28–31 bar)
pressure at main valve pressure tap (location 2)
Main Pump With park brake on, engine at high idle (2560 RPM) fully
3050–3150 psi
2 B Pressure retract boom hoist cylinder and hold while checking pump
(210–217 bar)
Check/Adjust maximum pressure at main valve pressure tap (location 2)
With park brake on, engine at high idle (2560 RPM) fully
Load Sense System Relief retract boom hoist cylinder and hold while checking load
3 C Relief Check/ 2900–3100 psi sense relief pressure tap (location C). If load sense relief
Adjust (200–214 bar) pressure cannot be achieved, refer to Section 8.6.1, d.
“Load Sense Relief Adjustment.”
With engine at idle, turn the steering wheel all the way in
Secondary Steering Relief
one direction. Hold over relief and check pressure. If
5 E (PR1) Function 2400–2600 psi
pressure is incorrect, adjust or replace the pressure
Manifold (165–179 bar)
reducing cartridge.
Park Brake
Secondary With engine at the idle and no hydraulic functions
Release
6 N/A Function operated, disengage the park brake, check pressure.
500–600 psi
Manifold This is not an adjustment.
(34–41 bar)
With engine at idle and park brake released, turn the
Park Brake
Secondary steering wheel all the way in one direction. Hold over relief
Pressure
7 F (PR2) Function and check pressure. If pressure is incorrect, adjust or
500–600 psi
Manifold replace the pressure reducing cartridge in the secondary
(34–41 bar)
function manifold.
Brake Valve 400 psi With engine OFF, pump brake pedal twice. If pressure is
8 N/A (Manual Brake (28 bar) incorrect, check for external leaks. If no leaks are found,
Pressure) minimum refer to Section 8.7.5, “Brake Bleeding.”
Brake Valve 1000 psi With engine at idle, depress and hold brake pedal. DO NOT
8 N/A (Service Brake (69 bar) turn steering wheel.Check pressure. If pressure is
Pressure) minimum incorrect, refer to Section 8.7.5, “Brake Bleeding.”
With engine at low idle, move auxiliary control lever left or
Auxiliary 3000 psi
9 D right. Hold control lever over relief and check pressure. If
Hydraulics (207 bar)
pressure is incorrect, check main relief per location 3.
Stabilizer 75–150 psi
10 N/A With the engine at idle, check the pressure of the cylinder.
Cylinder (5,2–10,3 bar)
6036, 6042, 8042, 10042, 10054 8-11

8-12
8.4.2
a. 6036
HOIST CYLINDER - 5.00 X 2.75 X 39.65
FRAME TILT CYL 4.50 X 2.25 X 8.69 SLAVE CYLINDERS - 3.75 X 1.50 X 11.40
FTB
3.93 BASE 1.97 ROD 4.4B STROKE

4000 4000
PSI PSI
FRONT
FTR L R
P T
4000 CRAB a b 4 STEERING SELECTOR
PSI L R STEER WHEEL VALVE
STEER MANIFOLD
A B
L R
REAR
P T
STEERING
FORK CYLINDER - VALVE
Hydraulic System
5.00 X 2.00 X 16.75
4000
PSI
PSG PP PPG PB PBG

Hydraulic Schematics
AUX FUNCTION PS
QUICK DISCONNECT
LOAD AT BOOM GOSENECK
PRESSURE SENSE OPTIONAL
TANK PORT OUT
B A B A B A B A B A
3250 3250 3250
3250
PSI
PSI PSI PSI
TANK
65
PSI LOAD .090 .090
SENSE DIA DIA
LOAD
SENSE
2500
PSI 550
OUT PSI
SHUTTLE
IN
P 650
PSI
14 6 14
GPM GPM GPM
MAX MAX MAX
EXTEND AUX HYD FRAME TILT FORK TILT

PRESSURE 3500 HOIST
PORT PSI
SECONDARY FUNCTION MANIFOLD
INLET TANK
MAIN CONTROL VALVE
250
PSI
T
2750
PSI FRONT
WHEEL
B2 .089 BRAKE
3
3.5 IN
LOW IDLE 1050 RPM P

15.9 GPM
HIGH IDLE 2750 RPM BYPASS
41.7 GPM TO TANK
RATED SPEED 2500 RPM
37.9 GPM .089
B1
25
PSI
REAR
60um WHEEL
L5 BRAKE
MAQ0570
10um
.073
10um
SERVICE BRAKE VALVE 1001091143
UNLESS OTHERWISE SPECIFIED, ALL

DIMENSIONS ARE IN INCHES.
6036, 6042, 8042, 10042, 10054

b. 6042
.040
G2 G3 FRAME TILT CYL 4.50 X 2.25 X 8.69 SLAVE CYLINDERS - 3.75 X 1.50 X 11.40
V FTR
3 .03 FTB
2A 3.93 BASE 1.97 ROD 4.4B STROKE

4000 4000 CYL2
PSI PSI
FRONT
CYL1 L
FTR R
2B
P T
4000 CRAB a b 4 STEERING SELECTOR
12A 4A 4B 12B STABILIZER STEER WHEEL
PSI L R VALVE
11 11 CYL STEER
.047 MANIFOLD
4.50x8.69x2.25 A B
100
1 PSI .06
6036, 6042, 8042, 10042, 10054

T
L R
P G1 REAR
P T
STEERING
FORK CYLINDER - VALVE
5.00 X 2.00 X 16.75
4000
PSI
AUX FUNCTION PSG PS PP PPG PB PBG

QUICK DISCONNECT
LOAD AT BOOM GOSENECK
PRESSURE SENSE OPTIONAL
TANK PORT OUT
B A B A B A B A B A
3250 3250 3250
3250
PSI
PSI PSI PSI
TANK
65
PSI LOAD .090
SENSE DIA
LOAD
SENSE
2500
PSI 550
OUT PSI
SHUTTLE
IN
P 650
.029 PSI
14 6 14
GPM GPM GPM
MAX MAX MAX
EXTEND AUX HYD FRAME TILT FORK TILT

PRESSURE 3500 HOIST
PORT PSI
SECONDARY FUNCTION MANIFOLD
INLET TANK MAIN CONTROL VALVE
.089
250
PSI
T
2750
PSI FRONT
WHEEL
.089 BRAKE
B2
3
3.5 IN
LOW IDLE 1050 RPM P

15.9 GPM
BYPASS
HIGH IDLE 2750 RPM TO TANK
41.7 GPM
RATED SPEED 2500 RPM
37.9 GPM .089
B1
25
PSI
REAR
MAQ0580
60um WHEEL
L5 BRAKE
10um
.073
10um
SERVICE BRAKE VALVE

Hydraulic System
UNLESS OTHERWISE SPECIFIED, ALL

DIMENSIONS ARE IN INCHES.
8-13
8-14
SLAVE CYLINDERS - 4.25 x 1.75 x 13.75
HOIST CYLINDER - 6.00 x 3.00 x 42.41 EXTEND CYLINDER - 5.00 x 3.00 x 131.25 G2 G3
V FTR
3 .03
2A
CYL2 3.93 BASE 1.97 ROD 4.48 STROKE
4000 4000
PSI PSI STABILIZER
FRONT
CYL
4.50x2.25x8.69 4000 L R
CYL1 IF NEEDED .040 PSI
2B
P T STEERING SELECTOR
4
CRAB VALVE
L R WHEEL
STEER MANIFOLD
FRAME TILT CYL 4.50x2.25x8.69 STEER a b
12A 4A 4B 12B
A B
11 11 FTB
100 FORK CYLINDER - L R

1 PSI 6.00 x 2.50 x 16.75
T .06 REAR
P T
Hydraulic System
.047
HOIST CYLINDER - 6.00 x 3.00 x 42.41 P G1 STEERING
c. 8042 (if equipped for ULS)
FTR VALVE
AUX FUNCTION
QUICK DISCONNECT
AT BOOM GOSENECK
4000 OPTIONAL
PSI
FEMALE MALE
DISCONNECT DISCONNECT ON
ON L.H.SIDE R.H.SIDE OF
OF BOOM BOOM PSG G PB PBG
B A B A B A B A B A
3250 3250
3250 3250
PSI PSI
3500 PSI PSI
PSI
TANK
3000
65 .090
PSI
PSI DIA
LOAD
SENSE 2500
SHUTTLE IN 550
PSI PSI
P 650
6 14 14 PSI
GPM GPM GPM
MAX MAX MAX
HOIST EXTEND FRAME TILT FORK TILT AUX C PLT
.0890 SECONDARY FUNCTION MANIFOLD

INLET
MAIN CONTROL VALVE
SHUTTLE VALVE
3100
PSI
LOW IDLE 18.3 GPM
HI IDLE 44.9 GPM
RATED 41.6 GPM 400
3 PSI
3.84 IN/REV STAND BY T
LOW IDLE-1100 RPM
HIGH IDLE-2700 RPM FRONT
RATED-2500 RPM WHEEL
BRAKE
B2
25
PSI
.089
P
60 um
10um
10 um .089
B1
195 F
HIGH HYD. OIL TEMP
REAR
WHEEL
L5 BRAKE
MAQ0590
.073
SERVICE BRAKE VALVE
6036, 6042, 8042, 10042, 10054

V FTR
3 .03
2A
4000 4000
PSI PSI STABILIZER
FRONT
CYL
4.50x2.25x8.69 4000 L R
CYL1 IF NEEDED .040 PSI
2B
4
CRAB VALVE
L R WHEEL
STEER MANIFOLD
12A 4A 4B 12B
A B
6036, 6042, 8042, 10042, 10054

11 11 FTB

1 PSI 6.00 x 2.50 x 16.75
T .06 REAR
P T
d. 8042 (if equipped for LS)
.047
FTR VALVE
AUX FUNCTION
QUICK DISCONNECT
AT BOOM GOSENECK
4000 OPTIONAL
PSI
FEMALE MALE
B A B A B A B A B A
3250 3250
3250 3250
PSI PSI
3500 PSI PSI
PSI
TANK
3000
65 .090
PSI
PSI DIA
LOAD
SENSE 2500
SHUTTLE IN 550
PSI PSI
P 650
6 14 14 PSI
GPM GPM GPM
MAX MAX MAX
.0890 SECONDARY FUNCTION MANIFOLD

INLET
MAIN CONTROL VALVE
125 PCI
3300
PSI
LOW IDLE 18.3 GPM
HI IDLE 44.9 GPM
RATED 41.6 GPM 575
3 PSI
LOW IDLE-1100 RPM
HIGH IDLE-2700 RPM FRONT
RATED-2500 RPM WHEEL
BRAKE
B2
25
PSI
.089
P
60~am
10um
10~am .089
B1
195 F
HIGH HYD. OIL TEMP
REAR
WHEEL
L5 BRAKE
MAQ0790
.073
Hydraulic System
SERVICE BRAKE VALVE
8-15
8-16
G2 G3
V FTR SLAVE CYLINDERS - 4.25 x 1.75 x 13.75
3 .03
HOIST CYLINDER - 6.00 x 3.00 x 42.41 EXTEND CYLINDER - 5.00 x 3.00 x 131.25 2A
CYL2
STABILIZER
CYL
4.50x2.25x8.69
3.93 BASE 1.97 ROD 4.48 STROKE
CYL1 IF NEEDED
4000 4000 .040
PSI PSI 2B FRONT
4000 L R
PSI
4A 4B 12B FRAME TILT CYL 4.50x2.25x8.69

12A
11 11 FTB STEERING SELECTOR
4 P T
CRAB VALVE
L R WHEEL
100 STEER MANIFOLD
STEER a b
1 PSI
T .06 A B
.047
P G1 FORK CYLINDER - L R
Hydraulic System
FTR 6.00 x 2.50 x 16.75 REAR

P T
BOOM LOCKOUT VALVE
e. 10042 (if equipped for ULS)
HOIST CYLINDER - 6.00 x 3.00 x 42.41 STEERING

VALVE
C1
AUX FUNCTION
QUICK DISCONNECT
AT BOOM GOSENECK
4000
PSI
T V1 FEMALE MALE
OF BOOM BOOM PSG G PBG
PB
B A B A B A B A B A
3250 3250
3250 3250
PSI PSI
3500 PSI PSI
PSI
LS TANK
T
OUTRIGGER
VALVE 3000
65 .090
PSI
PSI DIA
.156 LOAD
SHUTTLE IN SENSE 2500 550
PSI PSI
P 650
6 14 14 PSI
GPM GPM GPM
MAX MAX MAX
P SECONDARY FUNCTION MANIFOLD

INLET
LS .0890
B2 A2 A1 B1 MAIN CONTROL VALVE
E
E R
R
SHUTTLE VALVE
3100
PSI
LOW IDLE 18.3 GPM
HI IDLE 44.9 GPM
RATED 41.6 GPM 400
3 PSI
R.H. L.H.
LOW IDLE-1100 RPM FRONT
OUTRIGGER WHEEL
HIGH IDLE-2700 RPM BRAKE
CYLINDER
RATED-2500 RPM
5.00 X 3.00 X 13.31
B2
25
PSI
.089
P
60 um
10um
10 um .089
B1
195 F
HIGH HYD. OIL TEMP
REAR
WHEEL
L5 BRAKE
MAQ0600
SERVICE BRAKE VALVE .073
6036, 6042, 8042, 10042, 10054

f.
V FTR
3 .03
2A
4000 4000
PSI PSI STABILIZER
FRONT
CYL
4.50x2.25x8.69 4000 L R
CYL1 IF NEEDED PSI
.040
2B
6036, 6042, 8042, 10042, 10054

4
CRAB VALVE
L R WHEEL
STEER MANIFOLD
12A 4A 4B 12B
A B
11 11 FTB

1 PSI 6.00 x 2.50 x 16.75
.06 REAR
10042 (if equipped for LS)
T
P T
.047
FTR VALVE
AUX FUNCTION
QUICK DISCONNECT
AT BOOM GOSENECK
4000
PSI
FEMALE MALE
B A B A B A B A B A
3250 3250
3250 3250
PSI PSI
3500 PSI PSI
PSI
LS TANK
T
OUTRIGGER
VALVE 3000
65 .090
PSI
PSI DIA
.156 LOAD
SENSE 2500
SHUTTLE IN 550
PSI PSI
P 650
6 14 14 PSI
GPM GPM GPM
MAX MAX MAX

INLET
LS .0890
B2 A2 MAIN CONTROL VALVE
A1 B1
E
E R
R
125 PCI
3300
PSI
LOW IDLE 18.3 GPM
HI IDLE 44.9 GPM
RATED 41.6 GPM 575
3 PSI
R.H. 3.84 IN/REV STAND BY T
L.H.
LOW IDLE-1100 RPM
OUTRIGGER FRONT
HIGH IDLE-2700 RPM WHEEL
CYLINDER
RATED-2500 RPM BRAKE
5.00 X 3.00 X 13.31
B2
25
PSI
.089
P
60~am
10um
10~am .089
B1
195 F
HIGH HYD. OIL TEMP
REAR
WHEEL
L5 BRAKE
.073
MAQ0800
SERVICE BRAKE VALVE
Hydraulic System
8-17
8-18
G2 G3
3 .03
CYL2
STABILIZER
CYL
4.50x2.25x8.69
CYL1 IF NEEDED
4000 4000 .040
PSI PSI 2B FRONT
4000 L R
PSI

12A
4 P T
CRAB VALVE
L R WHEEL
100 STEER MANIFOLD
STEER a b
1 PSI
T .06 A B
.047
FTR 6.00 x 2.50 x 16.75 REAR
Hydraulic System
P T
BOOM LOCKOUT VALVE
g. 10054 (if equipped for ULS)
VALVE
C1
AUX FUNCTION
QUICK DISCONNECT
AT BOOM GOSENECK
4000
PSI
T V1 FEMALE MALE
PB
B A B A B A B A B A
3250 3250
3250 3250
PSI PSI
3500 PSI PSI
PSI
LS TANK
T
OUTRIGGER
VALVE 3000
65 .090
PSI
PSI DIA
.156 LOAD
PSI PSI
P 650
6 14 14 PSI
GPM GPM GPM
MAX MAX MAX

INLET
LS .0890
E
E R
R
SHUTTLE VALVE
3100
PSI
LOW IDLE 18.3 GPM
HI IDLE 44.9 GPM
RATED 41.6 GPM 400
3 PSI
R.H. L.H.
OUTRIGGER WHEEL
CYLINDER
RATED-2500 RPM
5.00 X 3.00 X 13.31
B2
25
PSI
.089
P
60 um
10um
10 um .089
B1
195 F
HIGH HYD. OIL TEMP
REAR
WHEEL
L5 BRAKE
MAQ0820
6036, 6042, 8042, 10042, 10054

G2 G3
3 .03
CYL2
STABILIZER
CYL
4.50x2.25x8.69
CYL1 IF NEEDED
4000 4000 .040
PSI PSI 2B FRONT
4000 L R
PSI

12A
4 P T
CRAB VALVE
L R WHEEL
6036, 6042, 8042, 10042, 10054

100 STEER MANIFOLD
STEER a b
1 PSI
T .06 A B
.047
FTR 6.00 x 2.50 x 16.75 REAR
P T
h. 10054 (if equipped for LS)
BOOM LOCKOUT VALVE

VALVE
C1
AUX FUNCTION
QUICK DISCONNECT
AT BOOM GOSENECK
4000
PSI
T V1 FEMALE MALE
PB
B A B A B A B A B A
3250 3250
3250 3250 PSI
PSI
3500 PSI PSI
PSI
LS TANK
T
OUTRIGGER
VALVE 3000
65 .090
PSI
PSI DIA
.156 LOAD
PSI PSI
P 650
6 14 14 PSI
GPM GPM GPM
MAX MAX MAX

INLET
LS .0890
E
E R
R
125 PSI
3300
PSI
LOW IDLE 18.3 GPM
HI IDLE 44.9 GPM
RATED 41.6 GPM 575
3 PSI
R.H. L.H.
OUTRIGGER WHEEL
CYLINDER
RATED-2500 RPM
5.00 X 3.00 X 13.31
B2
25
PSI
.089
P
60~am
10um
10~am .089
B1
195 F
HIGH HYD. OIL TEMP
REAR
WHEEL
L5 BRAKE
MAQ0810
Hydraulic System
8-19
Hydraulic System
8.5 HYDRAULIC RESERVOIR 5. Open the filler cap on the hydraulic oil reservoir.
Remove the drain plug on the side of the hydraulic
oil reservoir.
1
6. Transfer the used hydraulic oil into a suitable
covered container, and label as “Used Oil”. Dispose
2 of used oil at an approved recycling facility. Clean
and reinstall the drain plug.
7. Wipe up any hydraulic fluid spillage in, on, near and
around the machine and the work area.
8.5.2 Hydraulic Oil Reservoir Filling

1. Be sure the reservoir is clean and free of all debris.
2. Install a new hydraulic oil filter.
3. Fill the reservoir with Mobilfluid 424® (ISO Grade 46)
oil. Refer to Section 2.5, “Fluid Specifications.”
MH6180
Hydraulic reservoir (1) and fuel tank are one unit. They
are located on the right side of the frame under a cover. 8.5.3 Hydraulic Filter Replacement
Occasionally, fluid may seep, leak or be more forcefully 1. Be sure the reservoir is clean and free of all debris.
expelled from the filter head (2) when system pressure
exceeds the rating of the filter head or breather. If the 3
return filter becomes plugged, return hydraulic oil will
4
bypass the filter when pressure reaches 25 psi (1,7 bar)
and return to the reservoir unfiltered.
Carefully examine fluid seepage or leaks from the 5
hydraulic reservoir to determine the exact cause. Clean
the reservoir and note where any seepage occurs. 6
Leaks from a cracked or damaged reservoir require that
the reservoir be removed from the machine, flushed
completely with water and repaired by a certified welder
using approved techniques. If these conditions cannot be
met, the reservoir must be replaced in its entirety.
MAQ1160
8.5.1 Hydraulic Oil Reservoir Draining
2. Loosen and remove the four nuts (3) securing the
filter head assembly (4) to the hydraulic reservoir.
place the transmission control lever in 3. Remove the filter head assembly from the hydraulic
(N) NEUTRAL, engage the park brake and shut the reservoir allowing any excess hydraulic oil to drain
engine OFF. into the reservoir.
2. Place a Do Not Operate Tag on both the ignition key 4. Remove the hydraulic filter (5) from the filter head.
switch and the steering wheel, stating that the 5. Replace the hydraulic filter head gasket (6) if
machine should not be operated. necessary.
3. Open the rear door. Allow the system fluids to cool. 6. Install the new hydraulic filter to the filter head, lower
4. Properly disconnect the battery. the hydraulic filter head assembly into the hydraulic
reservoir.
8-20 6036, 6042, 8042, 10042, 10054

Hydraulic System
7. Install the four previously removed nuts securing the 9. Remove the bolts, lockwashers and washers
hydraulic filter assembly to the hydraulic reservoir. securing the pump to the transmission. Remove the
Torque the nuts to 75 lb-in (8.5 Nm). o-ring located between the transmission and the
8. Wipe up any hydraulic fluid spillage in, on, near and pump. Wipe up any hydraulic oil spillage.
around the machine and the work area. 10. Remove the hydraulic fittings from the pump to use
for later installation.
8.5.4 Hydraulic Oil Reservoir Replacement Note: Before removing any fittings from the pump, note
The hydraulic reservoir and the fuel tank are one unit and their orientation to ensure correct installation.
are removed together. Refer to Section 7.6.2, “Fuel/
Note: DO NOT disassemble the operating pump. The
Hydraulic Oil Tank,” for information on hydraulic
pump is pre-set from the manufacturer. Any adjustments
reservoir/fuel tank replacement.
or repairs performed by anyone other than an authorized
dealer could void the warranty.
8.6 HYDRAULIC SYSTEM PUMP
b. Pump Installation
For internal service instructions contact your local
authorized service distributor. 1. Install the fittings on the pump in the same
orientation as noted during removal.
8.6.1 Pump Replacement 2. Place the pump and a new, oiled o-ring into position
on the transmission. Align the pump shaft with the
a. Pump Removal internal transmission gear, so that the machined
1. Park the machine on a firm, level surface, level the teeth mesh together.
machine, fully retract the boom, raise the boom, place 3. Align the bolt holes with the pump mount holes.
the transmission control lever in (N) NEUTRAL, Secure the pump to the transmission with the
engage the park brake and shut the engine OFF. previously used hardware.
2. Place a Do Not Operate Tag on both the ignition key 4. Uncap and connect the previously labeled hydraulic
switch and the steering wheel, stating that the hoses to their appropriate locations.
5. Fill the hydraulic reservoir. Refer to Section 8.5.2,
3. Temporarily block up or support the raised boom. “Hydraulic Oil Reservoir Filling.”
4. Open the rear door. Allow the system fluids to cool. 6. Prime the pump by filling the case drain port with fresh,
5. Properly disconnect the battery. filtered hydraulic oil from a clean container before
installing the case drain connector and hose.
6. Drain the hydraulic reservoir. Refer to Section 8.5.1,
“Hydraulic Oil Reservoir Draining.” 7. Check all routing of hoses and tubing for sharp
bends or interference with any rotating members. All
tube and hose clamps must be tight.
3 ignition key switch and the steering wheel.
11. Start engine and run at approximately one-third to
one-half throttle for about one minute without moving
the machine or operating any hydraulic functions.
MH6490 12. Inspect for leaks and check all fluid levels. The
hydraulic reservoir oil level must be to the middle of
7. Thoroughly clean pump (3) and surrounding area, the sight gauge.
including all hoses and fittings before proceeding.
8. Label, disconnect and cap the hydraulic hoses c. Pump Test
attached to the pump. 1. Refer to Section 8.3.1, “Pressure Checks and
Adjustments.”
6036, 6042, 8042, 10042, 10054 8-21

Hydraulic System
d. Load Sense Relief Adjustment

EATON PUMP
REXROTH PUMP 6
6
4
4
5
7
MAQ1130
MAQ1090
1. With park brake on and engine at high idle

(2650 rpm), fully retract boom hoist cylinder and
SAUER PUMP hold. Check main pump maximum pressure tap (4).
6
Measurement range 3400–3500 psi (234,241 bar)
4
2. Adjust main pump maximum pressure (7) as
necessary. (load sense relief (6) may need to be
turned up two turns to achieve pressure first)
5 3. With park brake on and engine at high idle
hold. Check load sense relief pressure tap (5).
Measurement range 2950–3050 psi (203–210 bar).
4. Adjust main load sense relief (6) as necessary.
hold. Check pump maximum pressure at main valve
7
pressure tap (4). Measurement range 3050–3150
MAQ1120 psi (210–217 bar).
6. Adjust pump maximum pressure (7) as necessary.
hold. Check load sense relief pressure tap (5).
Measurement range 2950–3050 psi (203–210 bar).
8-22 6036, 6042, 8042, 10042, 10054

Hydraulic System
8.7 VALVES AND MANIFOLDS
8.7.1 Main Control Valve

The main control valve is mounted on the frame under the
lower transmission cover.
9
The main control valve assembly consists of individual
working sections with their own valve assemblies, each
providing a specific hydraulic function. 10
a. Main Control Valve Removal

machine, fully retract the boom, raise the boom, place
the transmission control lever in (N) NEUTRAL, 8
MA8482
machine should not be operated. 10. Record the distance (8) from the outer jam nut to the
3. Temporarily block up or support the raised boom. end of the ferrule on all cables, to ensure correct
4. Open the rear door. Allow the system fluids to cool. adjustment when reinstalling cables.
5. With the engine OFF, operate all the hydraulic Note: Record the location, and label all cables to ensure
functions to relieve trapped pressure. correct installation.
6. Remove the transmission covers. Thoroughly clean 11. Disconnect the control cables:
the main control valve and surrounding area, a. Remove the spring pin (9) and anchor pin. Save
including all hoses and fittings, before proceeding. the spring pin and anchor pin for installation.
7. Place a suitable container to catch hydraulic fluid b. Loosen the outer jam nut (10), and remove the
drainage beneath the frame. control cable from the bracket. Save the jam nut
for installation.
c. Route the cable clear of the main control valve.
d. Repeat steps for the remaining control cables.
12. Remove the bolts and nuts (9) securing the main
7 control valve to the frame.
13. Remove the main control valve from the frame.
b. Main Control Valve Disassembly

1. To disassemble the individual sections of the main
control valve, remove the nuts from one end of the
tie rods. Pull the tie rods out through the sections.
2. Disassemble each section assembly as required.
Some sections include a pre-adjusted relief valve that
regulates pressure in a specific circuit.
MH6190 Note: DO NOT adjust any of the relief valve assemblies.

Tampering with a relief valve will irrevocably alter
8. Label, disconnect and cap all the hydraulic hoses, pressure in the affected circuit, requiring recalibrating or a
tubes and wires at the main control valve (7). new relief valve.
around the machine and the work area.
6036, 6042, 8042, 10042, 10054 8-23

Hydraulic System
Disassemble each Valve Section Assemble the Main Control Valve.

1. Carefully separate the load sense outlet section from the 1. Place all three tie rods with the nuts through the end
next section. main control valve section.
2. Remove the o-rings from between the two sections. 2. Stand the end main control valve section on end.
3. Carefully separate each remaining sections, being 3. Install the proper o-rings and load sense shuttle on
careful not to lose the load sense shuttle ball. the inner face of the end main control valve section.
4. Remove both end caps from each end of the valve Align the next valve section over the three tie rods
sections then remove each control spool. and slide onto the end main control valve section.
5. Remove any check valves, compensator valves, 4. Using the proper o-rings and load sense shuttle,
anti-cavitation valves or shock valves from individual repeat step three for the remaining valve sections
valve section if equipped. and lastly the inlet end valve section.
6. Keep all parts being removed from individual valve
sections tagged and kept together.
c. Main Control Valve Parts Cleaning

Clean all components with a suitable cleaner, such as
triclorethylene, before continuing. Blow dry.
d. Main Control Valve Parts Inspection 2

Inspect all parts and internal passageways for wear,
damage, etc. If inner surfaces of any component DO NOT
display an ultra-smooth, polished finish, or are damaged 1
MH6200
in any way, replace the damaged part. Often, dirty
hydraulic fluid causes failure of internal seals, damage to 5. Install the three nuts on the tie rods. Torque the two
the polished surfaces within the component, and wear of bottom nuts (1) to 43-53 lb-ft (58-72 Nm). Torque the
and/or harm to other parts. top nut (2) to 66-82 lb-ft (89-111 Nm).
e. Main Control Valve Assembly
Note: ALWAYS replace seals, o-rings, gaskets, etc.,
with new parts to help ensure proper sealing and
operation. Lubricate seals and o-rings with clean
hydraulic oil.
Assemble each Valve Section

1. Reassemble any check valves, compensator valves,
anti-cavitation valves or shock valves from each
individual valve sections if equipped.
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.
8-24 6036, 6042, 8042, 10042, 10054

Hydraulic System
f. Main Control Valve Installation 7. Start engine and run at approximately one-third to
one-half throttle for about one minute without moving
1. Install the main control valve onto the frame, aligning
the machine or operating any hydraulic functions.
the bolts with the holes in the end sections of the
main control valve. Slide the main control valve into 8. Inspect for leaks and check the level of the hydraulic
position, and tighten the bolts. fluid in the reservoir. Shut the engine OFF.
2. Prime the main control valve by filling the inlet Note: Check for leaks and repair as required before
openings with fresh, filtered hydraulic oil from a continuing. Add hydraulic fluid to the reservoir as needed.
clean container, before attaching the hoses.
3. Use new oiled o-rings as required. Uncap and around the machine, work area and tools.
connect all previously labeled hoses, clamps, etc. to
the main control valve.
g. Main Control Valve Test

Conduct a pressure check of the hydraulic system in its
entirety. Adjust pressure(s) as required. Refer to Section
4 8.3.1, “Pressure Checks and Adjustments.”
8.7.2 Secondary Function Manifold

3
The secondary function manifold is a directional control
valve. Hydraulic oil from the pump flows into the
secondary function manifold where the pressure is
reduced before the oil is directed to the power steering
unit or the park brake.
5 The secondary function manifold is a machined block
with the ports for two pressure reducing valves, a
MA8482 pressure relief valve, two park brake solenoid valves (one
normally open and one normally closed), a check valve
4. Connect the control cables to the main control valve: and diagnostic test nipples. The secondary function
a. Slide the outer jam nut (3) over the end of the manifold is secured on the left side of the frame with two
control cable, and install the cable in the bracket carriage bolts and two hex flange nuts.
with one nut on either side of the bracket. DO Verify the correct operation of the solenoids before
NOT tighten the jam nuts at this time. considering replacement of the secondary function
b. Connect the end of the cable to the shaft from manifold. The manifold itself is not serviceable and must
the control valve. Secure with an anchor pin and be replaced if defective.
spring pin (4).
Note: DO NOT loosen, disassemble or attempt to adjust
c. Adjust the jam nuts until the distance (5) from the
outer jam nut to the end of the ferrule is the same any of pressure valves unless specifically instructed by
as recorded during removal. Tighten the jam manufacturer to do so. Tampering with a pressure valve
nuts. will irrevocably alter pressure in the affected circuits.
d. Repeat steps for remaining control cables.
5. Check routing of all hoses, wiring and tubing for
sharp bends or interference with any rotating
members, and install the tie wraps and/or the
protective conduit as required. Tighten all the tube
and hose clamps.
6. Fill the hydraulic fluid reservoir. Refer to Section
8.5.2, “Hydraulic Oil Reservoir Filling.”
6036, 6042, 8042, 10042, 10054 8-25

Hydraulic System
8.7.3 Service Brake Valve 2. Use new oiled o-rings as required. Uncap and
connect the previously labeled hoses to the service
a. Service Brake Valve Removal brake valve.
1. Park the machine on a firm, level surface, level the 3. Check the routing of all hoses, and tubing for sharp
machine, fully retract the boom, lower the boom, bends or interference with any rotating members,
place the transmission control lever in (N) NEUTRAL, and install tie wraps and/or protective conduit as
engage the park brake and shut the engine OFF. required. Tighten all tube and hose clamps.
2. Place a Do Not Operate Tag on both the ignition key 4. Properly connect the battery.
switch and the steering wheel, stating that the 5. Remove the Do Not Operate Tags from both the
machine should not be operated. ignition key switch and the steering wheel.
3. Open the rear door. Allow the system fluids to cool. 6. Start the engine and run at approximately one-third
4. Properly disconnect the battery. to one-half throttle for about one minute, without
moving the machine or operating any of the
5. Remove the lower and front dash panels. hydraulic functions.
7. Inspect the service brake valve and connections for
leaks, and check the level of the hydraulic fluid in the
1
reservoir. Shut the engine OFF.
Note: Check for leaks, and repair as required
before continuing. Add hydraulic fluid to the reservoir
as needed.
around the machine, work area and tools.
9. Install the lower and front dash panels.
8.7.5 Brake Bleeding

Carefully bleed the brake lines as soon as the brake valve
is installed in the machine. Air in the system will not allow
the brakes to apply properly. There are four brake
bleeder locations on the axles. Work with an assistant to
perform this procedure.
MH6210 1. Place the travel select lever in (N) NEUTRAL,
engage the park brake, and start the engine.
6. Label, disconnect and cap all hose attached to the
service brake valve (1). 2 6036 6042
7. Remove the four capscrews and four lockwashers

mounting the service brake valve to the steering
column support.
Note: DO NOT disassemble the service brake valve.
The service brake valve is not serviceable and must be
replaced in its entirety, if defective.
8.7.4 Service Brake Valve Installation

1. Install the service brake valve with the four
capscrews and four lockwashers onto the steering
column support.
with new parts to help ensure proper sealing and MAQ1100

hydraulic oil.
8-26 6036, 6042, 8042, 10042, 10054

Hydraulic System
8.7.7 Steer Select Valve

8042, 10042, 10054
2 4
MAQ1110
MH6190
2. Remove the plastic cap from the brake bleeder (2).

The machine can be used in the front-wheel, four-wheel
Attach one end of a length of transparent tubing over
the brake bleeder. Place the other end of this tubing or crab steering mode. The steer select valve (4) controls
in a suitable transparent container that is partially the direction of hydraulic fluid flow to the steering
filled with hydraulic oil. The end of the tubing must be cylinders mounted on each axle. The steer select valve is
below the oil level in the container. attached to a manifold mounted to a mounting plate
3. DO NOT open the brake bleeder without holding the inside the frame near the fuel tank.
tubing firmly on the bleeder. There is pressure at the Verify the correct operation of the steer select valve
brakes. Carefully open the bleeder with a wrench. solenoids before considering replacement of the valve.
Have the assistant depress the brake pedal. Close The housing of the steer select valve is not serviceable
the brake bleeder when air bubbles no longer appear and must be replaced if defective.
in the oil. Release the brake pedal. Remove the
tubing from the brake bleeder.
a. Steer Select Manifold and Valve Removal
4. Repeat Steps 2 and 3 for remaining brake bleeders.
5. Conduct a pressure and function check of service
brake. Refer to Section 8.4.1, “Hydraulic Pressures.”
the transmission control lever in (N) NEUTRAL,
8.7.6 Power Steering Valve
3 switch and the steering wheel, stating that the
3. Temporarily block up or support the raised boom.
6. Remove the transmission covers.
MZ0370
7. Label, disconnect and cap hydraulic hoses and
electrical plugs connected to steering select valve.
The power steering valve (3) is located at the base of the 8. Remove the bolts holding the steer select valve to
steering wheel shaft, concealed by the lower dash cover. the mounting plate on the frame.
The valve is not serviceable and must be replaced in its
9. Remove steer select manifold with attached steer
entirety if defective. For detailed information refer to
select valve from machine. Wipe up any hydraulic
Section 4.3.1, “Steering Column and Steering Valve.”
fluid spillage in, on, near and around the machine.
6036, 6042, 8042, 10042, 10054 8-27

Hydraulic System
b. Steer Select Manifold and Valve Disassembly, 7. Inspect for leaks and check the level of the hydraulic
Cleaning, Inspection and Assembly fluid in the reservoir. Shut the engine OFF.
1. Place the steer select assembly on a suitable Note: Check for leaks and repair as required before
work surface. continuing. Add hydraulic fluid to the reservoir as
2. Separate the steer select valve from the manifold by needed.
removing the four socket head capscrews. Discard 8. Wipe up any hydraulic fluid spillage in, on, near and
the four o-rings. around the machine, work area and tools.
3. Remove the solenoid valves and cartridges from the 9. Install the transmission covers.
steer select housing.
4. Clean all the components with a suitable cleaner
before inspection. d. Steering Test
5. Inspect the solenoid cartridges for proper operation. Refer to Section 8.4.1, “Hydraulic Pressures.”
Check by shifting the spool to ensure that it is
functioning properly. Check that the spring is intact. 1. Conduct a pressure check of the steering
Inspect the cartridge interior for contamination. hydraulic circuit.
6. Inspect internal passageways of the steer select 2. Check each steering mode for proper function.
manifold and valve for wear, damage, etc. If inner
surfaces of the manifold DO NOT display an ultra- 8.7.8 Unloader Valve (6036 & 6042 only)
smooth, polished finish, or components are
damaged in any way, replace the manifold or
appropriate part. Often, dirty hydraulic fluid causes
1
failure of internal seals and damage to the polished
surfaces within the secondary function manifold.
hydraulic oil.
7. Install the solenoid valves and cartridges in the steer
select housing.
8. Attach steer select valve to the manifold using four
new, oiled o-rings and four socket head capscrews.
c. Steer Select Valve and Manifold Installation

MA8391
1. Install the steer select valve to the mounting plate on
the frame using two capscrews. The unloader valve (1) creates system pressure and
2. Connect all the previously labeled hydraulic hoses, distributes the hydraulic fluid for various machine
fittings, solenoid wire terminal leads, etc., to the functions via its load sense, by to tank (via the oil cooler),
steer select valve. and primary and secondary valve ports. The unloader
valve is secured to the frame toward the front of the
3. Check the routing of all hoses, wiring and tubing for
machine near the main control valve.
sharp bends or interference with any rotating
members, and install tie wraps and/or protective
a. Unloader Valve Removal
conduit as required. Tighten all hose clamps.
4. Properly connect the battery. 1. Park the machine on a firm, level surface, level the
5. Remove the Do Not Operate Tags from both the the transmission control lever in (N) NEUTRAL,
ignition key switch and the steering wheel. engage the park brake and shut the engine OFF.
6. Start the engine and run at approximately 1/3-1/2 2. Place a Do Not Operate Tag on both the ignition key
throttle for about one minute without moving the switch and the steering wheel, stating that the
machine or operating any hydraulic functions. machine should not be operated.
8-28 6036, 6042, 8042, 10042, 10054

Hydraulic System
3. Temporarily block up or support the raised boom. solenoids before considering replacement of the valve.
a. Outrigger Valve Removal
6. Label, disconnect and cap hydraulic hoses attached
to the unloader valve. Cap all fittings to prevent dirt
the transmission control lever in (N) NEUTRAL,
and debris from entering the hydraulic system.
7. Remove the hardware securing the unloader valve to
the machine frame.
8. Remove the unloader valve. machine should not be operated.
3. Temporarily block up or support the raised boom.
b. Unloader Valve Disassembly
DO NOT loosen, disassemble or attempt to adjust any
cartridges unless specifically instructed by the 5. Properly disconnect the battery.
manufacturer. Tampering with the cartridges will 6. Remove the transmission covers.
irrevocably alter pressure in the affected circuits. 7. Label, disconnect and cap the hydraulic hoses and
the electrical plugs connected to the outrigger valve.
c. Unloader Valve Installation
8. Remove the two flange nuts and two carriage bolts
1. Place the unloader valve in its original orientation on securing the outrigger valve to the frame. Remove
machine frame and secure with previously used the outrigger valve from the machine.
hardware. Torque capscrews to 31 lb-ft (42 Nm).
2. Uncap and connect the previously labeled hydraulic around the machine, work area and tools.
hoses to their appropriate locations.
Note: ALWAYS replace seals, o-rings, gaskets, etc., b. Outrigger Valve Disassembly, Cleaning,
with new parts to help ensure proper sealing and Inspection and Assembly
operation. Lubricate seals and o-rings with clean 1. Place the outrigger valve assembly on a suitable
hydraulic oil. work surface.
3. Check routing of all hoses, wiring and tubing for
sharp bends or interference with rotating members.
4. Properly connect the battery. 3

6. Start the engine and run at approximately 1/3-1/2
throttle for about one minute without moving the
machine or operating any hydraulic functions.
2
7. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
Note: Check for leaks and repair as required before
continuing. Add hydraulic fluid to the reservoir as
needed.
around the machine, work area and tools. P
S
4
8.7.9 Outrigger Valve (10042 & 10054 only) T
The outrigger valve allows the left and right outriggers to

be raised or lowered depending on the position of the MH3881
outrigger switches located on the side console in the cab.

Verify the correct operation of the outrigger valve
6036, 6042, 8042, 10042, 10054 8-29
Hydraulic System
2. Remove the solenoid valve assemblies (2) from the 8. Inspect for leaks and check the level of the hydraulic
outrigger valve by removing the four capscrews (3). fluid in the reservoir. Shut the engine OFF.
Discard the four o-rings.
Note: Check for leaks and repair as required
3. Remove shuttle cartridges (4) from outrigger valve. before continuing. Add hydraulic fluid to the reservoir
4. Clean all components with a suitable cleaner as needed.
before inspection. 9. Wipe up any hydraulic fluid spillage in, on, near and
5. Inspect the solenoid cartridges for proper operation. around the machine, work area and tools.
Check by shifting the spool to ensure that it is 10. Install the transmission covers.
functioning properly. Check that the spring is intact.
Inspect the cartridge interior for contamination. 11. Close and secure the rear door.
6. Inspect internal passageways of the outrigger 8.7.10 Extend Lockout Valve (10054 only)
valve for wear, damage, etc. If inner surfaces of the
valve DO NOT display an ultra-smooth, polished
5
finish, or components are damaged in any way,
replace the valve or appropriate part. Often, dirty
hydraulic fluid causes failure of internal seals and
damage to the polished surfaces within the
secondary function manifold.
hydraulic oil.
7. Install the shuttle cartridges into the outrigger valve.
Torque to 35 lb-ft (48 Nm).
8. Attach the solenoid assemblies to the outrigger valve
using four new, oiled o-rings and the previously used
capscrews.
MH6190
c. Outrigger Valve Installation
Model 10054 has an extend lockout valve (5) which
1. Insert the previously used bolts through the bottom
prevents the boom from being extended beyond 42 feet
of the outrigger valve and loosely attach the flange
unless the outriggers are lowered onto firm terrain. Once
nuts to the carriage bolts.
the outriggers are lowered, pressure switches located on
2. Position the outrigger valve so that the heads of the each outrigger cylinder close and energize the solenoid
carriage bolts go through the slots in the frame. on the boom extend lockout valve. The boom can then be
Tighten the flange nuts. fully extended.
3. Connect all the previously labeled hydraulic hoses,
fittings, solenoid wire terminal leads, etc., to the a. Extend Lockout Valve Removal
outrigger valve. 1. Park the machine on a firm, level surface, level the
4. Check the routing of all hoses and wiring for sharp machine, fully retract the boom, raise the boom, place
bends or interference with any rotating members, the transmission control lever in (N) NEUTRAL,
and install tie wraps and/or protective conduit as engage the park brake and shut the engine OFF.
required. Tighten all hose clamps. 2. Place a Do Not Operate Tag on both the ignition key
5. Properly connect the battery. switch and the steering wheel, stating that the
6. Remove the Do Not Operate Tags from both the machine should not be operated.
ignition key switch and the steering wheel. 3. Temporarily block up or support the raised boom.
7. Start the engine and run at approximately 1/3-1/2 4. Open the rear door. Allow the system fluids to cool.
throttle for about one minute without moving the 5. Properly disconnect the battery.
8-30 6036, 6042, 8042, 10042, 10054

Hydraulic System
7. Label, disconnect and cap hydraulic hoses and 3. Connect all the previously labeled hydraulic hoses,
electrical plugs connected to extend lockout valve. fittings, solenoid wire terminal leads, etc., to the
8. Remove nut and bolt securing extend lockout valve outrigger valve.
to the frame. Remove the valve from the machine. 4. Check the routing of all hoses and wiring for sharp
9. Wipe up any hydraulic fluid spillage in, on, near and bends or interference with any rotating members,
around the machine, work area and tools. and install tie wraps and/or protective conduit as
required. Tighten all hose clamps.
b. Extend Lockout Valve Disassembly, Cleaning, 5. Properly connect the battery.
Inspection and Assembly 6. Remove the Do Not Operate Tags from both the
7
7. Start the engine and run at approximately 1/3-1/2
C1
throttle for about one minute without moving the
T
V1 8. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
6 Note: Check for leaks and repair as required before

continuing. Add hydraulic fluid to reservoir as needed.
MH3792
1. Secure the extend lockout valve assembly in a around the machine, work area and tools.
suitable bench vise if possible. Remove the solenoid 10. Install the transmission covers.
nut, coil and cartridge (6) from the valve. Remove
the pressure sense valve (7) from the valve. 11. Close and secure the rear door.
2. Clean all components with a suitable cleaner d. Extend Lockout Valve Test
before inspection.
Conduct a test of the extend lockout valve.
3. Inspect the solenoid cartridge for proper operation.
Check by shifting the spool to ensure that it is 1. Park the machine on a firm, level surface.
functioning properly. Check that the spring is intact. 2. With the boom fully retracted and lowered, lower
Inspect the cartridge interior for contamination. the outriggers.
4. Inspect internal passageways and the extend lockout 3. Extend the boom to 54 ft. The boom should extend
valve overall for wear, damage, etc. If inner surfaces fully and should not stop at 42 ft.
of the component DO NOT display an ultra-smooth,
polished finish, or are damaged in any way, replace 8.8 HYDRAULIC CYLINDERS
the extend lockout valve. Often, dirty hydraulic fluid
causes failure of internal seals and damage to the
polished surfaces within the valve. 8.8.1 General Cylinder Instructions
Note: ALWAYS replace seals, o-rings, gaskets, etc., a. Cylinder Removal
operation. Lubricate seals and o-rings with clean 1. Remove any attachment from the machine. Park the
hydraulic oil. machine on a firm level surface and fully retract the
boom. Allow sufficient work space around the
5. Install the solenoid valve. hydraulic cylinder being removed. Support the boom
6. Install the pressure sensing valve. Torque to 65 lb-ft if the lift/lower cylinder is being removed. Place the
(88 Nm). travel select lever in (N) NEUTRAL, engage the park
brake, shut the engine OFF and chock wheels.
c. Extend Lockout Valve Installation 2. Place a Do Not Operate Tag on both the ignition key
1. Place the extend lockout valve into position on the switch and the steering wheel, stating that the
mounting plate on the machine frame. machine should not be operated.
2. Install bolt and nut securing valve to frame. 3. Open the rear door. Allow the system fluids to cool.
6036, 6042, 8042, 10042, 10054 8-31

Hydraulic System
4. Label, disconnect and cap or plug hydraulic hoses in Note: Protect the finish of the rod at all times. Damage
relation to the cylinder. to the surface of the rod can cause seal failure.
5. Attach a suitable sling to an appropriate lifting device 5. Using a pin spanner wrench, unscrew the head
and to the cylinder. Make sure the device used can gland from the tube. A considerable amount of force
actually support the cylinder. will be needed to remove the head gland. Carefully
slide the head gland down along the rod toward the
6. Remove the lock bolt and/or any retaining clips rod eye, away from the cylinder barrel.
securing the cylinder pins. Remove the cylinder pins.
Note: When sliding the rod and piston assembly out of
7. Remove the cylinder. the barrel, prevent the threaded end of the barrel from
8. Wipe up any hydraulic fluid spillage in, on, near and damaging the piston. Keep the rod centered within the
around the machine, work area and tools. barrel to help prevent binding.
6. Carefully pull the rod assembly along with the head
b. Cylinder Disassembly gland out of the cylinder barrel.
1. Clean the cylinder with a suitable cleaner before 7. Fasten the rod eye in a soft-jawed vise, and place a
padded support under and near the threaded end of
disassembly. Remove all dirt, debris and grease
the rod to prevent any damage to the rod.
from the cylinder.
8. Remove the set screw from the piston head.
Note: It may be necessary to apply heat to break the
bond of the sealant between the piston and the rod
before the piston can be removed.
Some cylinder parts are sealed with a special organic
sealant and locking compound. Before attempting to
disassemble these parts, remove any accessible seals
from area of bonded parts. Wipe off any hydraulic oil, then
heat part(s) uniformly to break bond. A temperature of
300-400° F (149-204° C) will destroy bond. Avoid
overheating, or parts may become distorted or damaged.
Apply sufficient torque for removal while parts are still hot.
The sealant often leaves a white, powdery residue on
MH6520
threads and other parts, which must be removed by
2. Clamp the barrel end of the cylinder in a soft-jawed brushing with a soft brass wire brush prior to reassembly.
vise or other acceptable holding equipment if 9. Remove the piston head from the rod and carefully
possible. slide the head gland off the end of the rod.
10. Remove all seals, back-up rings and o-rings from
piston head and all seals, back-up rings and o-rings
WARNING from the head gland.
Significant pressure may be trapped inside the Note: The head gland bearing will need to be inspected
cylinder. Exercise caution when removing a to determine if replacement is necessary.
counterbalance valve or a pilot-operated check valve DO NOT attempt to salvage cylinder seals, sealing rings
from a cylinder. or o-rings. ALWAYS use a new, complete seal kit when
rebuilding hydraulic components. Consult the parts
Note: Avoid using excessive force when clamping the catalog for ordering information.
cylinder in a vise. Apply only enough force to hold the
cylinder securely. Excessive force can damage the c. Cylinder Cleaning Instructions
cylinder tube.
1. Discard all seals, back-up rings and o-rings. Replace
3. If applicable, remove the counterbalance valve from with new items from seal kit to ensure proper
the side of the cylinder barrel. cylinder function.
Note: DO NOT tamper with or attempt to adjust the 2. Clean all metal parts with an approved cleaning
counterbalance valve cartridge. If adjustment or solvent such as trichlorethylene. Carefully clean
replacement is necessary, replace the counterbalance cavities, grooves, threads, etc.
valve with a new part.
Note: If a white powdery residue is present on
4. Extend the rod as required to allow access to the threads or parts, it can be removed by using a soft
base of the cylinder.
8-32 6036, 6042, 8042, 10042, 10054

Hydraulic System
brass wire brush. Wipe clean with Loctite Cleaner 8. If applicable, install new counter balance valve into
prior to reassembly. block on the cylinder barrel.
d. Cylinder Inspection f. Cylinder Installation

1. Inspect internal surfaces and all parts for wear, 1. Grease the bushings at the ends of the hydraulic
damage, etc. If the inner surface of the cylinder cylinder. Using an appropriate sling, lift the cylinder
barrel does not display a smooth finish, or is scored into it’s mounting position.
or damaged in any way, replace the barrel. 2. Align cylinder bushing and install pin, lock bolt or
2. Remove light scratches on the piston, head gland, retaining clip.
rod or inner surface of the cylinder barrel with a 400- 3. Connect the hydraulic hoses in relation to the labels
600 grit emery cloth. Use the emery cloth in a rotary or markings made during removal.
motion to polish out and blend the scratch(es) into
the surrounding surface. 4. Before starting the machine, check fluid level of the
hydraulic fluid reservoir and if necessary fill to full
3. Check the piston rod assembly for run-out. If the rod mark with Mobilfluid 424® (ISO 46).
is bent, it must be replaced.
5. Start the machine and run at low idle for about one
e. Cylinder Assembly Instructions minute. Slowly activate hydraulic cylinder function in
both directions allowing the cylinder to fill with
1. Use the proper tools for specific installation tasks. hydraulic oil.
Clean tools are required for installation.
6. Inspect for leaks and check level of hydraulic fluid in
2. Install new seals, back-up rings and o-rings on the reservoir. Add hydraulic fluid if needed. Shut the
piston and new seals, back-up rings, o-rings and engine OFF.
bearing on the head gland.
Note: The extend/retract cylinder has a spacer that around the machine, work area and tools.
MUST be installed over the rod AFTER the head gland 8. Close and secure the rear door.
and 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.
Note: Protect the finish on the cylinder rod at all times.
Damage to the surface of the rod can cause seal failure.
4. Lubricate and slide the head gland over the cylinder
rod. Install the piston head on to the end of the
cylinder rod. Loctite® 243TM and install the set screw
in the piston head. Refer to Section 8.8.4, “Cylinder
Torque Specifications” for torque specifications for
the piston head and the set screw.
Note: Avoid using excess force when clamping the
cylinder barrel in a vise. Apply only enough force to hold
the cylinder barrel securely. Excessive force can
damage the cylinder barrel.
5. Place the cylinder barrel in a soft-jawed vise or other
acceptable holding devise.
Note: When sliding the rod and piston assembly into the
cylinder barrel, prevent the threaded end of the cylinder
barrel from damaging the piston head. Keep the cylinder
rod centered within the barrel to prevent binding.
6. Carefully insert the cylinder rod assembly into the
cylinder barrel.
7. Screw the head gland into the cylinder barrel and
tighten with a spanner wrench. Refer to Section
8.8.4, “Cylinder Torque Specifications” for torque
specifications for the head gland.
6036, 6042, 8042, 10042, 10054 8-33

Hydraulic System
8.8.2 Cylinder Pressure Checking

Attach 4000 psi (276 bar) gauge to test port on hydraulic
pump to check system pressure. For more information,
refer Section 8.3.1, “Pressure Checks and Adjustments.”
Note: If a hydraulic cylinder pressure is greater than
main control valve pressure, increase main control valve
pressure by adjusting the main relief. Generally, one half
turn clockwise will be adequate to check an individual
circuit. Activate circuit and if pressure is obtained turn
main relief counter clockwise one half turn. Re-check
main relief setting and adjust if necessary.
8.8.3 Steering Cylinders

The steer cylinder is attached to each axle center
housing.The steer cylinder assembly can be found in
Section 5.6, “Axle Assemblies.” The steer cylinder is
covered in the appropriate manufacturer’s axle literature.
STEERING CYLINDER
AXLE CENTER SECTION
8-34 6036, 6042, 8042, 10042, 10054

Hydraulic System
8.8.4 Cylinder Torque Specifications
a. Lift/Lower Cylinder
Model Nut Valve Locking Collar

6036, 6042 1750-2000 lb-ft 30-35 lb-ft 300-400 lb-ft
(2373-2712 Nm) (41-47 Nm) (407-542 Nm)
8042, 10042, 10054 1735-1885 lb-ft 30-35 lb-ft 300-400 lb-ft
(2352-2556 Nm) (41-47 Nm) (407-542 Nm)
b. Extend/Retract Cylinder
Model Head Piston Valve Set Screw

6036 300-400 lb-ft 300-400 lb-ft 45-50 lb-ft 12-13 lb-ft
(407-542 Nm) (407-542 Nm) (61-68 Nm) (18-19 Nm)
6042 300-400 lb-ft 330-390 lb-ft 40-50 lb-ft 10-26 lb-ft
(407-542 Nm) (447-529 Nm) (54-67 Nm) (13-35 Nm)
8042, 10042, 10054 300-400 lb-ft 390-460 lb-ft 150-160 lb-ft 9-11 lb-ft
(407-542 Nm) (529-624 Nm) (1203-217 Nm) (12-15 Nm)
c. Tilt Cylinder
Model Head Piston Locknut Locking Valve Set Screw

Collar
6036, 6042 300-400 lb-ft 200-300 lb-ft N/A N/A 30-35 lb-ft 30-35 lb-ft
(407-542 Nm) (271-407 Nm) (41-47 Nm) (41-48 Nm)
8042, 10042, N/A N/A 1735-1885 lb-ft 300-400 lb-ft 30-35 lb-ft N/A
10054 (2352-2556 Nm) (407-542 Nm) (41-47 Nm)
d. Level Cylinder
Head Locknut Valve

300-400 lb-ft (407-542 Nm) 1100-1250 lb-ft (1491-1695 Nm) 35-40 lb-ft (47-54 Nm)
e. Stabil-TRAK Cylinder
Model Locknut Check Valve Guide Set Screw Pressure Solenoid

Reducing/ Coil
PO Check
Valve
6042 1175-1400 lb-ft 20-25 lb-ft 300-350 lb-ft 3-4 lb-ft 35-40 lb-ft 25-30 lb-ft
(1593-1898 Nm) (27-34 Nm) (407-475 Nm) (4-5 Nm) (47-54 Nm) (34-41 Nm)
8042, 10042, N/A 20-25 lb-ft 300-350 lb-ft 3-4 lb-ft 35-40 lb-ft 25-30 lb-ft
10054 (27-34 Nm) (407-475 Nm) (4-5 Nm) (47-54 Nm) (34-41 Nm)
6036, 6042, 8042, 10042, 10054 8-35

Hydraulic System
f. Compensation Cylinder
Model Head Locknut Set Screw

6036 250-300 lb-ft (339-407 Nm) 675-750 lb-ft (915-1017 Nm) N/A
6042 300-350 lb-ft (407-475 Nm) 650-700 lb-ft (881-949 Nm) 3-4 lb-ft (4-5 Nm)
8042, 10042, 10054 300-400 lb-ft (407-542 Nm) 900-1050 lb-ft (1220-1424 Nm) N/A
g. Swing Carriage Cylinder (If Equipped)
Model Piston Head Set Screw Valves

6036, 6042 440-500 lb-ft 250-350 lb-ft 85-95 lb-ft 30-35 lb-ft
(597-678 Nm) (339-474 Nm) (115-129 Nm) (41-47 Nm)
8042, 10042, 10054 N/A 250-350 lb-ft 85-95 lb-ft 30-35 lb-ft
(339-474 Nm) (115-129 Nm) (41-47 Nm)
h. Side Tilt Carriage Cylinder (If Equipped)
Head Locknut Valve

300-400 lb-ft (407-542 Nm) 550-650 lb-ft (745-881 Nm) 30-35 lb-ft (41-47 Nm)
i. Outrigger Cylinder
Model Head Locknut Valves

10042, 10054 250-350 lb-ft (339-474 Nm) 1650-1800 lb-ft (2237-2440 Nm) 30-35 lb-ft (41-47 Nm)
8-36 6036, 6042, 8042, 10042, 10054

Section 9
Electrical System
Contents

9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.1.1 General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.4 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.4.1 Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.4.2 Cab Harness Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.5 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.5.1 Electrical Schematic (if equipped for ULS) . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.5.2 Electrical Schematic (if equipped for LS) . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
9.6 Engine start circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
9.6.1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
9.7 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
9.7.1 Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
9.8 Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
9.8.1 Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
9.8.2 Skylight Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
9.8.3 Windshield Washer Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
9.9 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
9.9.1 Cab Heater Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
9.10 Solenoids, Sensors and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
9.10.1 Coolant Level Switch (if equipped for ULS) . . . . . . . . . . . . . . . . . . . . . . . 9-21
9.10.2 Hydraulic Oil Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
9.10.3 Transmission Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
9.10.4 Transmission Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
9.10.5 Service Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
9.10.6 Boom Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
9.10.7 Boom Extend Interlock Sensor (10054 only). . . . . . . . . . . . . . . . . . . . . . . 9-26
9.10.8 Outrigger Pressure Switches (10054 Only). . . . . . . . . . . . . . . . . . . . . . . . 9-27
9.11 Display Monitor and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
9.11.1 Instrument Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
9.12 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
9.12.1 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
9.12.2 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
9.13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
9.13.1 Fault Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
9.13.2 Offboard Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
9.13.3 Engine Fault Codes Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
6036, 6042, 8042, 10042, 10054 9-1

Electrical System
9.1 ELECTRICAL COMPONENT

TERMINOLOGY
To understand the safety, operation, and service
the operator/mechanic be familiar with the name and
location of the electrical components of the machine. The
following illustration identifies the components that are
referred to throughout this section.
9.1.1 General Overview
COOLANT
TEMPERATURE SWITCH
DASH SWITCHES
ALTERNATOR
CAB HEATER
STARTER CONTROLS
IGNITION
TRANSMISSION SWITCH
TEMPERATURE
SENDER
INSTRUMEN
PARK BRAKE T PANEL
SWITCH
TRANSMISSION SERVICE
SOLENOID BRAKE
VALVES SWITCH
ACCELERATO
DIAGNOSTIC
R PEDAL
LOCATION
BOOM ANGLE
BOOM EXTEND SENSOR
INTERLOCK SENSOR (FOUR SECTION BOOM SHOWN)
(10054 ONLY)
MAQ0361
9-2 6036, 6042, 8042, 10042, 10054

Electrical System
9.2 SPECIFICATIONS 9.4 FUSES AND RELAYS

Electrical system specifications are listed in Section 2,
“General Information and Specifications.”
9.4.1 Engine Compartment
Starter relay (1), one 250 amp fuse (2) 200 amp relay (3)
9.3 SAFETY INFORMATION for cold start grid heater and starter lockout relay (4) (if
equipped) are located inside engine compartment in
protective case next to battery.
WARNING
DO NOT service the machine without following all
1
2
3
MAQ1010
6036, 6042, 8042, 10042, 10054 9-3

Electrical System
9.4.2 Cab Harness Fuses and Relays

6036, 6042, 8042 & 10042 10054
11 13
2 24 26
11 13 12 14
2
12 14 15
3 6 25 27
15 16
3 6
16 17
4 7 10 28
17 18
4 7 10
18 19 22
5 8 29
19 20 23
5 8
20
30
21
MAQ0350
21 MAQ0341
No. Volt/ Circuit No. Volt/ Circuit

Amp Amp
2 12 Volt Headlight Switch 23 7.5 Amp Outrigger
3 12 Volt Light Switch 24 12 Volt Park Brake Interlock
4 12 Volt Stabilizer Lock 25 12 Volt Boom Extend Lockout
5 12 Volt Boom Switch 26 12 Volt Stabil-TRAK Interlock
6 12 Volt Park Brake Disengage 27 12 Volt Stabil-TRAK Lock Up
7 12 Volt Neutral Start 28 12 Volt Boom Extend Interlock
8 12 Volt Back up 29 12 Volt Right Outrigger Lock
10 12 Volt Ignition 30 12 Volt Left Outrigger Lock
11 7.5 Amp Transmission
12 20 Amp Lights
13 15 Amp Horn/Heater
14 10 Amp Wiper (if equipped)
15 10 Amp Stabilizer
16 10 Amp Steer Select
17 7.5 Amp Optional Cab/ Outrigger (if equipped)
18 10 Amp Park Brake
19 7.5 Amp Optional
20 40 Amp Main
21 40 Amp Road/Worklights (if equipped)
22 7.5 Amp Outrigger
9-4 6036, 6042, 8042, 10042, 10054

Electrical System
9.5 ELECTRICAL SYSTEM SCHEMATICS

The following Ladder Diagrams may be used to further
investigate electrical circuits. If a resolution cannot be
found contact your local authorized service distributor
9.5.1 Electrical Schematic

THROTTLE SENSOR # 1
SN334
8 APS SUPPLY 1 ORG (18)
APS SIGNAL 1 VIO (18)
1
2
3
APS GROUND 1 YEL (18)
THROTTLE SENSOR # 2
P14
8 APS SUPPLY 2 RED (18)
APS GROUND 2 WHT (18)
C
B
A
APS SIGNAL 2 BLK (18)
HTR TAIL
8
8
1
HTR ORG (12)
S7

APS SUPPLY 2 RED (18)
APS SUPPLY 1 ORG (18)
HTR/HRN/CHARGE FUSE
1
CHG2 ORG (12)
CHG ORN (16)
ECM_BULK_23P
HARNESS, DASH/THROTTLE
S
J
P
G
Q
R
B
C
E
F
W
D
T
U
K
A
X
L
M
ECM_BULK_23P
MAQ0610
6036, 6042, 8042, 10042, 10054 9-5

9-6
9.5.1
LEFT OUTRIGGER VALVE

DOWN
OUTRIGGER MAIN PWR CAB GDN STUD
1
2
HV228
Electrical System
20 BLK (14)
60E YEL/GRN (16)

FUSE
2D BLK (16)
64 GRY/VIO (16)
60E YEL/GRN (16)

61 RED/GRY (16)
1
60A YEL/GRN (16)
2
62 VIO/WHT (16)
3
4
5
SWITCH
6
2B BLK (16)
7 HV226
RIGHT OUTRIGGER
60B YEL/GRN (16) 62 VIO/WHT (16)
8 1
2F BLK (16)
(DOWN)
SW216 2
RIGHT OUTRIGGER VALVE
SPL 60 SPL 2
63 BRN/YEL (16)
1 HV227
60C YEL/GRN (16) 2G BLK (16)
2 2
(UP)
64 GRY/VIO (16) 61 RED/GRY (16)

3 1
4
5
SWITCH
6
2A BLK (16)
7
LEFT OUTRIGGER
60D YEL/GRN (16)
8
SW217
Electrical Schematic (if equipped for ULS) (Continued)
2E BLK (16)
63 BRN/YEL (16)
1
2
HV229
HARNESS, WIRING, OUTRIGGERS
MAQ0620
LEFT OUTRIFFER VALVE
(UP)
6036, 6042, 8042, 10042, 10054

9-7 6036, 6042, 8042, 10042, 10054
MAQ0630
TO 41B IN CAB
TO 107B IN CAB
FUSEBLOCK PWR CAB GND STUD CAB HARNESS

TO 152B IN CAB
PARK BRAKE SWITCH
3 RED (14)
2 BLK (14)
7 TAN (16)
2J BLK (14)
3C RED (14)
45B DBL (16)
45B DBL (16)
52 DBL/RED (16)
35 BRN/GRN (16)
45A DBL/ORG (16)
51B BLU/WHT (16)
HARNESS, LOGIC
PARK BRAKE WIRING WITH OUTRIGGER HARNESS
SPL 3
SPL 2A
3A RED (14)
3B RED (14)
70B ORG/BLK (16)

RL254-87
70C ORG/BLK (16) 87
1
RL254-30
71 ORG/WHT (16) 30
1
RL254-87A
87a
1
2C1 BLK (16) 85
RELAY
RL254-85
2C2 BLK (16) 86
1
61 RED/GRY (16)
STAB INTERLOCK
1 RL254-86
2G BLK (16) 50B RED/WHT (16)
2 1
RIGHT UP
HV244
62 VIO/WHT (16)
1
2F BLK (16)
2
OUTRIGGER VALVES
HV245 RL255-87
45A DBL/ORG (16) 87
1
RIGHT DOWN
RL255-30
7 TAN (16) 30
1
RL255-87A
35 BRN/GRN (16) 87a
1
85
RELAY
RL255-85
2C1 BLK (16) 86
1
STAB LOCKUP
SPL 2B
RL255-86
70C ORG/BLK (16)
1
63 BRN/YEL (16)
1
2E BLK (16)
2
HV246
LEFT UP
64 GRY/VIO (16)
1 RL256-87
2D BLK (16) 65 DBL (16) 87
2 1
HV247 RL256-30
OUTRIGGER VALVES
66 BLK (20) 30
LEFT DOWN
1
71 ORG/WHT (16)
RL256-87A
71A ORG/WHT (16) 87a
1
85
RELAY
RL256-85
2A2 BLK (16) 86
1
RL256-86
23 ORG/GRN (16)
BOOM EXT INTERLOCK
1
50C RED/WHT (16)
A
57 GRY/ORG (16)
B
RIGHT
HV248
56 GRY/BLU (16)
OUTRIGGER CYL
A
57 GRY/ORG (16)
B
LEFT
HV249
RL257-87
87
1
RL257-30
68 RED/BLK (16) 30
1
RL257-87A
61 RED/GRY (16) 87a
1
51C BLU/WHT (18) 85
RELAY
A RL257-85
2K1 BLK (18) 2A2 BLK (16) 86
B 1
SFA
2A1 BLK (16)
HV250 RL257-86
71A ORG/WHT (16)
1
71B ORG/WHT (16)
RIGHT OUTRIGGER LOCKOUT
51D BLU/WHT (18)

SPL 51
A
2K2 BLK (18)
B
SEC. FUNC. VALVE

SFB
HV251
RL258-87
87
1
RL258-30
49 RED/BLU (16) 67 BRN/BLK (16) 30
A 1
23 ORG/GRN (16)
B RL258-87A
63 BRN/YEL (16) 87a
HV252 1
2A1 BLK (16) 85
RELAY
RL258-85
ENG. HARNESS
2A3 BLK (16) 86
58 GRN (18) 1
A
2H BLK (18) RL258-86
B 71B ORG/WHT (16)
1
HV253
LEFT OUTRIGGER LOCKOUT
BOOM EXT SOL.

66 BLK (20)
OUTRIGGER FUSE 2
OUTRIGGER FUSE 1
RL259-87
87
1
RL259-30
52 DBL/RED (16) 30
1
60A GRN (16)
RL259-87A
51A BLU/WHT (16) 87a
1
85
RELAY
56A GRY/BLU (16)
RL259-85
2B2 BLK (16) 86
SPL 60
1
RL259-86
70B ORG/BLK (16)
SPL 56 1
PARK BREAK INTERLOCK
70A ORG/BLK (16)
C
B
X269
RL260-87
55 ORN/RED (16) 87
1
RL260-30
66 ORG/GRY (16) 30
1
58 GRN (18)
RL260-87A
50C RED/WHT (16) 87a
1
50B RED/WHT (16) 85
RELAY
RL260-85
2B3 BLK (16) 86
1
2B2 BLK (16)
RL260-86
65 DBL (16)
BOOM EXT LOCKOUT
BLACK WIRE BLK (16)

WHITE WIRE WHT (16)
GREEN WIRE GRN (16)
BOOM EXTEND
70A ORG/BLK (16)
67 BRN/BLK (16)
2L2 BLK (16)

64 GRY/VIO (16)
2L1 BLK (16)

60B YEL/GRN (16)
68 RED/BLK (16)
60C YEL/GRN (16)
62 VIO/WHT (16)
60D YEL/GRN (16)
60E YEL/GRN (16)

1
8
7
6
5
4
3
2
4
3
2
1
8
7
6
5
X270
B
A
C
INSTR. PNL LT
SWITCH
SWITCH
LEFT OUTRIGGER
RIGHT OUTRIGGER
Electrical Schematic (if equipped for ULS) (Continued) 9.5.1
Electrical System
6036, 6042, 8042, 10042, 10054 9-8
ROAD LIGHT TAILS DIAGNOSTIC
5A 5A FUSE
1
1
27B RED (12)

MAQ0640
1 10A
CAB GND STUD DIAGNOSTIC
1
1
A
H
D
F
E
C
B
1
2
3
J
27F RED (12)

1
1
2
1
2
1
2
ROAD LIGHT HARN
LIGHTS FUSE
FUSE A
FUSE B
HEADLTS TAIL
CAN TERMINATION
HIGH BEAM
A
B
TURN SIGNAL
LB162
12C DBL (16)

6L GRN (18)
38H YEL (18)
154 BLU/WHT (16)
155 GRN/RED (16)

IGN BLU (18)
PWR RED (16)
CANH YEL (18)
CANL GRN (18)
2LL BLK (12)
IGN BLU (18)

GND BLK (16)
34A RED (16)
IGNA BLU (18)

2MM BLK (12)
EXT LIGHT FUSE

PWR RED (16)
PWR2 RED (16)
23 GRN (16)
HDLIGHTS PWR TAIL

34 RED/BLK (16)
21C RED (16)
MAIN FUSE 26B RED (10)

27 RED (10)
157 BRN (16) 35 BRN/WHT (16)
RL133-87
23 GRN (16) 87
1
RL133-30
157 BRN (16) 7 BRN (16) 27A RED (12) 30
1
RL133-87A
STABI-TRAK 87a
1
85
RL133-85
2KK BLK (18) 86
STAB FUSE 1
RL133-86
HEADLIGHT SWITCH
21C RED (16)

1
3B VIO (10)
1
S IGN
RL134-87
158 BLK (16) 12A DBL (12) 87
1 1
10054 OURIGGERS HORN
RL134-30
29 RED (12) 30
1
O
RL134-87A
87a
1
85
SPL 45 DIODE
O
RL134-85
45B DBL/ORG (16) SPL 45 45A DBL/ORG (16) 2DD BLK (18) 86
1
LIGHT SWITCH
45 DBL/ORG (16) TRANSMISSION FUSE

RL134-86
46 WHT/ORG (16) 12 BLU (18)
1
STR/STAB FUSE
FUSE BUSSBAR
3A VIO (10)
BRAKE PEDAL SW
SPL 20
O O
26 RED (10) SPL 26

1
RL132-87
1 WHT (10) 40A BRN/BLK (16) 87
1 1
RL132-30
48 VIO/BLK (16) 30
1
26A RED (10)
SPL 40
A RL132-87A
3C RED (10) 47 ORG/WHT (16) 87a
B 1
O O OO
IGNSW BLU (16) 85

STAB LK
C RL132-85
OPT 1 FUSE 2CC BLK (18) 86
D 1
IGNITION SW CONNECTORS
E RL132-86
114B BLU/ORN (16)
1
8 GRN/WHT (16) 114A BLU/ORN (16)
11A LGN (16)
1
11B LGN (16)
2
SPL 114
9 GRN/BLK (16)
3
4
5
O
6 RL135-87
SPL DIODE 112
2JJ BLK (18) 28 VIO/WHT (16) 87

7 1
11B LGN (16)
STEER MODE SW
8 RL135-30
39 RED/GRY (16) 30
1
RL135-87A
48 VIO/BLK (16) 87a
X330 1
85
1 RL135-85
38CH YEL (18) 2AA BLK (18) 86
2 1
BOOM SWITCH
6CL GRN (18)

3 RL135-86
2GG BLK (18) S CH 10 TAN (16)
4 1
17 GRY (18)
5
6
7
8 18 GRN (18)
151 YEL/GRN (16) S CL
9
GAUGE CLUSTER
154 BLU/WHT (16) 113C RED (16)
10 SPL 113 RL131-87
155 GRN/RED (16) 113B RED (16) 87
11 1
40B BRN/BLK (16) 153A GRY/WHT (16)
12 RL131-30
153 GRY/WHT (16) 30
13 1
HARNESS, CAB PWR DISTRIBUTION

14 RL131-87A
87a
1
107A BLU (18) 85
RL131-85
2EE BLK (18) 86
PARK BRAKE
1
41-B DBL/WHT (16)
RL131-86
42-A TAN (16) 107B BLU (18)
1 1
42-B TAN (16) INSTR FUSE
2
45A2 DBL/ORG (16)
3
152B BLK/WHT (16) 152A1 BLK/WHT (16)
4
SPL 111 DIODE
1 WHT (10)
5
111 RED (12)
6 RL139-87
PARK BRK SW
2HH BLK (18) 106 BLU/ORG (12) 87
7 1
42-B TAN (16)
8 RL139-30
111A RED (12) 30
1
SPL 111
RL139-87A
87a
1
114A BLU (16)
85
113A RED (16)
RL139-85
113A RED (16)

2FF BLK (18) 86
1
NEUTRAL START
113 RED (16)
INSTR PNL DIODE

1 RL139-86
104 YEL (16) 112A GRY (16)
2 1
102 PNK (16) SPL 112
3
112 GRY (16)
4
101 BRN (16)
5
105 GRN (16)
6
103 BLU (16)
7
SPL 20A
150 VIO (16)

8
TRANS CONN
153 GRY/WHT (16)
9
10 RL130-87
31 ORN/RED (16) 87
11 1
12 RL130-30
PARK BRAKE WIRING FOR MACHINES WITHOUT OUTRIGGER HARNESS

24A ORG/GRN (14) 30
1
RL130-87A
24 ORG/GRN (14) 87a
1
85
BACKUP
RL130-85
160 RED (12) 2BB BLK (18) 86
1 1
RL130-86
102B PNK (16)
1
ENG_BULK3_IF
HORN/HTR FUSE
PWR2 RED (16)
SPL 27
CAB FUSE
OPT FUSE
159B VIO (14)
SPL 12A
SPL 102
SPL 159 RL138-87
159A VIO (12) 159 VIO (12) 87
1
RL138-30
160 RED (12) 30
1
RL138-87A
87a
1
85
12AA DBL (12)
50 WHT/YEL (16)
152A2 BLK/WHT (16)
12B DBL (12)

IGNITION
RL138-85
51 WHT/RED (16)
2NN BLK (18) 86
1
RL138-86
1
3D VIO (18)
1
52 ORG (14)
41-A DBL/WHT (16)
15 LBL (18)
20A BLK (18)
10 TAN (16)
38 YEL (18)
28 VIO/WHT (16)
8 GRN/WHT (16)
101 BRN (16)

40 BRN/BLK (16)
104 YEL (16)

9 GRN/BLK (16)
35 BRN/WHT (16)
47 ORG/WHT (16)
34 RED/BLK (16)
20 BLK (12)
158 BLK (16)
150 VIO (16)

24A ORG/GRN (14)
6 GRN (18)
31 ORN/RED (16)
18 GRN (18)
151 YEL/GRN (16)

17 GRY (18)
102A PNK (16)

103 BLU (16)
106 BLU/ORG (12)
27D RED (12)

27C RED (12)
105 GRN (16)

32 GRY/WHT (16)
OUTRIGGER TAIL
LIGHT OPTION TAIL
10042 OUTRIGGERS TAIL

1
1
B5
B4
B3
B2
B1
A5
A4
A3
A2
A1
B5
B4
B3
B2
B1
A5
A4
A3
A2
A1
C5
C4
C3
C2
C1
C5
C4
C3
C2
C1
DIAGNOSTIC INDICATORS TAIL

ENG_BULK1_15F
ENG_BULK2_15M
WIPER TAIL
HEATER TAIL
Electrical Schematic (if equipped for ULS) (Continued) 9.5.1
Electrical System
9.5.1
SECONDARY GRID HTR BOOM SENSOR BOOM EXTEND GRID HTR RLY STARTER
STARTER RELAY
FUNCTION VALVE ENGINE BACK UP ALARM ENGINE X327
A
B
LOGIC CONN GENERIC 151 YEL (16)
1 HYD TEMP SW
LOGIC_2M
A
B
A
B
ENG_BULK3_IN
X325
BE_3F
X2 160 RED (12)
X4
AH330
1 T298
BOOM_3F
87a
30
86
85
HTR PWR RED (2)
87
30
86
85
A
B
A
B
1
APS GROUND 1 BLK (18)
2X BLK (16)
A T61
X321
EC302
1
1
1
1
2
APS SUPPLY 1 BLK (18)
EC303
1
1
1
1
A
B
C
A
B
C
B 1
1
1
1
STRT LOCK OUT

APS SIGNAL 1 BLK (18) 27D RED (12)
T299
C
RL288
RL288-1
RL288-2
SN113
SN112
RL109-85
RL109-87
RL109-30
RL109-86
D
EC291
EC291-B+
PWR BUSS
MAQ0650
EC291-B-
E
2F BLK (18)
2E BLK (18)
41B BLU (18)
41A BLU (18)

27C RED (12)
F 1
6036, 6042, 8042, 10042, 10054

160 RED (12)
STRT ORN (16)
49 RED (16)
G
23 ORN (16)
APS SUPPLY 2 RED (18) T328
H
STRT ORN (16)

161 RED (10)
APS GROUND 2 WHT (18) T58
J
BUSSBAR
OUTPUT RTN 1 BLK (18)
APS SIGNAL 2 BLK (18) 2Y BLK (16)
2T BLK (16)
2R BLK (16)
HTR PWR RED (2)
K 1
GRID HTR PWR RED (2)

STRT PWR RED (2/0)
L
STRT GND BLK (2/0)

M
OUTPUT RTN 2 BLK (18)

N
O
P T57
20E BLK (12)
ECM_BULK_23S
Q 1
20C BLK (12)
R
S X56
28B WHT (18)
T A
X1 2P BLK (18)
U B
12B-2F
V
W
S 41
T312
X
S 20A
2G BLK (16)
1 20D BLK (12) X55
18 GRN (16) 47B WHT (18)
TRANS TEMP SW1 A
TRANS GND
S 20B
T316 2N BLK (18)
X73 S 20D B
5 YEL (16)
S RTN
A1
17 GRY (16) 20B BLK (12)
A2 X54
20 BLK (12) 47A WHT (18)
A3 A
27C RED (12) 2M BLK (18)
A4 S 47 B
31 ORN (16)
A5
34 RED (16)
B1 X53
106 DBL (12) 28A WHT (18)
B2 A
150(S6) VIO (16) 2L BLK (18)
B3 B
STABILTRAK
151 YEL (16)

B4
27D RED (12)
B5
101(S5) BRN (16) S 20
ENG_BULK2_15F
C1 X52
102(S2) PNK (16) 40 BLK (18)
C2 A
103(S3) BLU (16) 2K BLK (18)
C3 B
104(S1) YEL (16)
C4
105(S4) GRN (16) 20D BLK (12)
LOCK_2F 12A-2F 4A-2F 4B-2F
C5
T319
ALT PWR RED (4)
X74 1
40 BLK (18)
A1 3
41 WHT (16) S 28 5 YEL (16)
A2 2
X324
47 ORN (16)
A3 1
20A BLK (12)
A4
158 WHT (16) ALT GND BLK (8)
ALTERNATOR
A5 1
18 GRN (16) T318
B1
24A BLK (16)
B2 T294
28 WHT (16) STRT PWR RED (2/0)
B3 1
35 BRN (16)
B4
38 YEL (16) ALT PWR RED (4)
B5 1
6 GRN (16) BAT POS
C1 T295
8 GRN (16)
C2
9 GRN (16) T296
C3
10 TAN (16) STRT GND BLK (2/0)
ENG_BULK1_15M
C4 S2 1 CHAS GND
16 BRN (16)
C5
AAT_SIGNAL BRN (18) ALT GND BLK (8)
4 4 1 BAT GND
104B(S1) YEL (16) VSENSOR_RTN_7 BLK (18)
1 3 3 T297
12OB(S2) YEL (18) S 104 S1 VSENSOR_7 BLU (18)
2 2 2 T351
103B(S3) BLU (18) MAF_SIGNAL ORG (18) BLOCK GND BLK (10)
3 1 1 1
2J BLK (18) S 102
UPPER
7 X346 MASS AIR FLOW X347
X300
105B(S5) GRN (18)
4
Electrical Schematic (if equipped for ULS) (Continued)
101B(S5) BRN (18) S 103 RETURN BLK (18)

5 2 2
150B(S6) GRN (18) SIGNAL ORG (18)
6 1 1
LOWER
2H BLK (18)
7 X348 WATER IN FUEL X349
X301
150A(S6) GRN (16) S 101
A
105A(S4) GRN (16)
B HARN P/N 1001130927
104A YEL (16) S 105
C
VP2
D
S 150
S GND
E
2D BLK (16)
F T350
CASE GND BLK (10)
D304 1 ECM CASE GROUND
S 117 FC314
S SUPPLY
103A BLU (16) ECM BATT RED (12)

A 1
BLOCK GND BLK (10)
30A
B 101A BRN (16) 2

102 PNK (16)
C T278
ATO FUSE
ECM BATT RED (12)

D 1 BATT +
ECM GND 5 BLK (12)
VP1
E
OEM SEN RTN BLK (18)

COOLANT LVL ORG (18)
SENSOR SUPP2 ORG (18)
2DD BLK (16)
F
D305
T352
T284
1
1
B
C
A
HV313 GND
8 GRN (16)
A ENG BLOCK
COOLANT LVL ORG (18)
SENSOR SUPP ORG (18)
BPM RED (18)

BPS RED (18)
GHR BLK (18)
16 BRN (16)
ECM PWR 3 RED (18)
ECM PWR 4 RED (18)
OUTPUT RTN BLK (18)
STRT LOCK ORG (18)
CNH YEL (18)
CNL GRN (18)
APS GROUND 1 BLK (18)
APS SUPPLY 1 BLK (18)
OEM SEN RTN BLK (18)
2C BLK (16)
34 RED (16)
CNH1 YEL (18)

CNL1 GRN (18)
ECM GND 1 BLK (18)
ECM GND 2 BLK (18)
ECM GND 3 BLK (18)
ECM GND 4 BLK (18)
STM_2F
9 GRN (16)
X329
1
2
3
4
5
6
7
8
9
X44
A
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
COOLANT LEVEL
B
C
A
2B BLK (16)
B
HV111 (P4) ECM 60 PIN CONN (P2)
STM_2M
STEER MODE VALVE

17 GRY (16) J1939
1
FUEL SENDER T87 HARNESS, ENGINE/CHASSIS
2A BLK (16)
1
T88
Electrical System
9-9
9-10
9.5.2
ECM_BULK_23P
A
B
C 8
D
E
F
G
H
J
K
Electrical System
L
8
(if equipped for LS)
M
Electrical Schematic
N
O
P
ECM_BULK_23P
Q
R
S
T
U
8
8
V
W S7
CHG ORN (16)
X


P14
B
C
CHG2 ORG (12)

3
2
1
SN334
HRT ORG (12)

1
1
HTR TAIL HTR/HRN/CHARGE FUSE
THROTTLE SENSOR # 2 THROTTLE SENSOR # 1
MAQ0660
HARNESS, DASH/THROTTLE
6036, 6042, 8042, 10042, 10054

9.5.2
LEFT OUTRIGGER VALVE

DOWN
OUTRIGGER MAIN PWR CAB GDN STUD
6036, 6042, 8042, 10042, 10054

1
2
HV228
20 BLK (14)
60E YEL/GRN (16)

FUSE
2D BLK (16)
64 GRY/VIO (16)
60E YEL/GRN (16)

61 RED/GRY (16)
1
60A YEL/GRN (16)
2
62 VIO/WHT (16)
3
4
5
SWITCH
6
2B BLK (16)
7 HV226
RIGHT OUTRIGGER
60B YEL/GRN (16) 62 VIO/WHT (16)
8 1
2F BLK (16)
(DOWN)
SW216 2
SPL 60 SPL 2
63 BRN/YEL (16)
1 HV227
60C YEL/GRN (16) 2G BLK (16)
2 2
(UP)
64 GRY/VIO (16) 61 RED/GRY (16)

3 1
4
5
SWITCH
6
2A BLK (16)
7
LEFT OUTRIGGER
60D YEL/GRN (16)
Electrical Schematic (if equipped for LS) (Continued)
8
SW217
2E BLK (16)
63 BRN/YEL (16)
1
2
HV229
HARNESS, WIRING, OUTRIGGERS
MAQ0670
LEFT OUTRIFFER VALVE
(UP)
Electrical System
9-11
6036, 6042, 8042, 10042, 10054 9-12
MAQ0680
FUSEBLOCK PWR CAB GND STUD CAB HARNESS
TO 41B IN CAB
TO 152B IN CAB
TO 107B IN CAB
PARK BRAKE SWITCH
3 RED (14)
2 BLK (14)
7 TAN (16)
2J BLK (14)
3C RED (14)
45B DBL (16)
45B DBL (16)
52 DBL/RED (16)
35 BRN/GRN (16)
45A DBL/ORG (16)
51B BLU/WHT (16)
HARNESS, LOGIC
SPL 3
SPL 2A
PARK BRAKE WIRING FOR MACHINES WITH OUTRIGGER HARNESS
3A RED (14)
3B RED (14)
70B ORG/BLK (16)

RL254-87
70C ORG/BLK (16) 87
1
RL254-30
71 ORG/WHT (16) 30
1
RL254-87A
87a
1
2C1 BLK (16) 85
RELAY
RL254-85
2C2 BLK (16) 86
1
61 RED/GRY (16)
STAB INTERLOCK
1 RL254-86
2G BLK (16) 50B RED/WHT (16)
2 1
RIGHT UP
HV244
62 VIO/WHT (16)
1
2F BLK (16)
2
OUTRIGGER VALVES
HV245 RL255-87
45A DBL/ORG (16) 87
1
RIGHT DOWN
RL255-30
7 TAN (16) 30
1
RL255-87A
35 BRN/GRN (16) 87a
1
85
RELAY
RL255-85
2C1 BLK (16) 86
1
STAB LOCKUP
SPL 2B
RL255-86
70C ORG/BLK (16)
1
63 BRN/YEL (16)
1
2E BLK (16)
2
HV246
LEFT UP
64 GRY/VIO (16)
1 RL256-87
2D BLK (16) 65 DBL (16) 87
2 1
HV247 RL256-30
OUTRIGGER VALVES
66 BLK (20) 30
LEFT DOWN
1
71 ORG/WHT (16)
RL256-87A
71A ORG/WHT (16) 87a
1
85
RELAY
RL256-85
2A2 BLK (16) 86
1
RL256-86
23 ORG/GRN (16)
BOOM EXT INTERLOCK
1
50C RED/WHT (16)
A
57 GRY/ORG (16)
B
RIGHT
HV248
56 GRY/BLU (16)
OUTRIGGER CYL
A
57 GRY/ORG (16)
B
LEFT
HV249
RL257-87
87
1
RL257-30
68 RED/BLK (16) 30
1
RL257-87A
61 RED/GRY (16) 87a
1
51C BLU/WHT (18) 85
RELAY
A RL257-85
2K1 BLK (18) 2A2 BLK (16) 86
B 1
SFA
HV250 2A1 BLK (16)
RL257-86
71A ORG/WHT (16)
1
71B ORG/WHT (16)
RIGHT OUTRIGGER LOCKOUT
51D BLU/WHT (18)

SPL 51
A
2K2 BLK (18)
B
SEC. FUNC. VALVE

SFB
HV251
RL258-87
87
1
RL258-30
49 RED/BLU (16) 67 BRN/BLK (16) 30
A 1
23 ORG/GRN (16)
B RL258-87A
HV252 63 BRN/YEL (16) 87a
1
2A1 BLK (16) 85
RELAY
RL258-85
ENG. HARNESS
2A3 BLK (16) 86
58 GRN (18) 1
A
2H BLK (18) RL258-86
B 71B ORG/WHT (16)
1
HV253
LEFT OUTRIGGER LOCKOUT
BOOM EXT SOL.

66 BLK (20)
OUTRIGGER FUSE 2
OUTRIGGER FUSE 1
RL259-87
87
1
RL259-30
52 DBL/RED (16) 30
1
60A GRN (16)
RL259-87A
51A BLU/WHT (16) 87a
1
85
RELAY
56A GRY/BLU (16)
RL259-85
2B2 BLK (16) 86
SPL 60
1
RL259-86
70B ORG/BLK (16)
1
SPL 56
PARK BREAK INTERLOCK
70A ORG/BLK (16)
C
B
X269
RL260-87
55 ORN/RED (16) 87
1
RL260-30
66 ORG/GRY (16) 30
1
58 GRN (18)
RL260-87A
50C RED/WHT (16) 87a
1
50B RED/WHT (16) 85
RELAY
RL260-85
2B3 BLK (16) 86
1
2B2 BLK (16)
RL260-86
65 DBL (16)
BOOM EXT LOCKOUT
BLACK WIRE BLK (16)

WHITE WIRE WHT (16)
GREEN WIRE GRN (16)
BOOM EXTEND
70A ORG/BLK (16)
2L2 BLK (16)

67 BRN/BLK (16)
2L1 BLK (16)

64 GRY/VIO (16)
68 RED/BLK (16)
60B YEL/GRN (16)
60C YEL/GRN (16)
62 VIO/WHT (16)
60D YEL/GRN (16)
60E YEL/GRN (16)

8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
X270
B
A
C
INSTR. PNL LT
SWITCH
SWITCH
LEFT OUTRIGGER
RIGHT OUTRIGGER
Electrical Schematic (if equipped for LS) (Continued) 9.5.2
Electrical System
9-13 6036, 6042, 8042, 10042, 10054
ROAD LIGHT TAILS DIAGNOSTIC
5A 5A FUSE
1
1
27B RED (12)

1 10A
CAB GND STUD DIAGNOSTIC
1
1
A
H
D
F
E
C
B
1
2
3
J
27F RED (12)

1
1
2
1
2
1
2
ROAD LIGHT HARN
LIGHTS FUSE
FUSE A
FUSE B
HEADLTS TAIL
CAN TERMINATION
HIGH BEAM
A
B
TURN SIGNAL
LB162
12C DBL (16)

6L GRN (18)
38H YEL (18)
154 BLU/WHT (16)
155 GRN/RED (16)

IGN BLU (18)
GND BLK (16)
PWR RED (16)
CANH YEL (18)
CANL GRN (18)
2LL BLK (12)
IGN BLU (18)

34A RED (16)
IGNA BLU (18)

2MM BLK (12)
EXT LIGHT FUSE

PWR RED (16)
PWR2 RED (16)
23 GRN (16)
HDLIGHTS PWR TAIL

34 RED/BLK (16)
21C RED (16)
MAIN FUSE 26B RED (10)

27 RED (10)
157 BRN (16) 35 BRN/WHT (16)
RL133-87
23 GRN (16) 87
1
RL133-30
157 BRN (16) 7 BRN (16) 27A RED (12) 30
1
RL133-87A
STABI-TRAK 87a
1
85
RL133-85
2KK BLK (18) 86
STAB FUSE 1
RL133-86
HEADLIGHT SWITCH
21C RED (16)

1
3B VIO (10)
1
S IGN
RL134-87
158 BLK (16) 12A DBL (12) 87
1 1
10054 OURIGGERS HORN
RL134-30
29 RED (12) 30
1
O
RL134-87A
GND BLK (16) 87a
1
85
SPL 45 DIODE
O
RL134-85
45B DBL/ORG (16) SPL 45 45A DBL/ORG (16) 2DD BLK (18) 86
1
LIGHT SWITCH
45 DBL/ORG (16) TRANSMISSION FUSE

RL134-86
46 WHT/ORG (16) 12 BLU (18)
1
STR/STAB FUSE
FUSE BUSSBAR
3A VIO (10)
BRAKE PEDAL SW
SPL 20
O O
26 RED (10) SPL 26

1
RL132-87
1 WHT (10) 40A BRN/BLK (16) 87
1 1
RL132-30
48 VIO/BLK (16) 30
1
26A RED (10)
SPL 40
A RL132-87A
3C VIO (10) 47 ORG/WHT (16) 87a
B 1
O O OO
IGNSW BLU (16) 85

STAB LK
C RL132-85
OPT 1 FUSE 2CC BLK (18) 86
D 1
IGNITION SW CONNECTORS
E RL132-86
114B BLU/ORN (16)
1
8 GRN/WHT (16) 114A BLU/ORN (16)
11A LGN (16)
1
11B LGN (16)
2
SPL 114
9 GRN/BLK (16)
3
4
5
O
6 RL135-87
SPL DIODE 112
2JJ BLK (18) 28 VIO/WHT (16) 87

7 1
11B LGN (16)
STEER MODE SW
8 RL135-30
39 RED/GRY (16) 30
1
RL135-87A
48 VIO/BLK (16) 87a
X330 1
85
1 RL135-85
38CH YEL (18) 2AA BLK (18) 86
2 1
BOOM SWITCH
6CL GRN (18)

3 RL135-86
2GG BLK (18) S CH 10 TAN (16)
4 1
17 GRY (18)
5
6
7
8 18 GRN (18)
151 YEL/GRN (16) S CL
9
154 BLU/WHT (16) 113C RED (16)
10 SPL 113 RL131-87
155 GRN/RED (16) 113B RED (16) 87
11 1
40B BRN/BLK (16) 153A GRY/WHT (16)
12 RL131-30
153 GRY/WHT (16) 30
13 1
HARNESS, CAB/PWR DISTRIBUTION

14 RL131-87A
87a
1
107A BLU (18) 85
RL131-85
2EE BLK (18) 86
PARK BRAKE
1
41-B DBL/WHT (16)
RL131-86
42-A TAN (16) 107B BLU (18)
1 1
42-B TAN (16) INSTR FUSE
2
45A2 DBL/ORG (16)
3
152B BLK/WHT (16) 152A1 BLK/WHT (16)
4
SPL 111 DIODE
1 WHT (10)
5
111 RED (12)
6 RL139-87
PARK BRK SW
2HH BLK (18) 106 BLU/ORG (12) 87
7 1
42-B TAN (16)
8 RL139-30
111A RED (12) 30
1
SPL 111
RL139-87A
87a
1
114A BLU (16)
85
113A RED (16)
RL139-85
113A RED (16)

2FF BLK (18) 86
1
NEUTRAL START
113 RED (16)
INSTR PNL DIODE

1 RL139-86
104 YEL (16) 112A GRY (16)
2 1
102 PNK (16) SPL 112
3
112 GRY (16)
4
101 BRN (16)
5
105 GRN (16)
6
103 BLU (16)
7
SPL 20A
150 VIO (16)

8
TRANS CONN
153 GRY/WHT (16)
9
10 RL130-87
31 ORN/RED (16) 87
11 1
PARK BRAKE WIRING FOR MACHINES WITHOUT OUTRIGGER HARNESS

12 RL130-30
24A ORG/GRN (14) 30
1
24 ORG/GRN (14)
RL130-87A
87a
1
85
BACKUP
RL130-85
160 RED (12) 2BB BLK (18) 86
1 1
RL130-86
102B PNK (16)
1
ENG_BULK3_IF
HORN/HTR FUSE
PWR2 RED (16)
SPL 27
CAB FUSE
OPT FUSE
159B VIO (14)
SPL 12A
SPL 102
SPL 159 RL138-87
159A VIO (12) 159 VIO (12) 87
1
RL138-30
160 RED (12) 30
1
RL138-87A
87a
1
85
12AA DBL (12)
50 WHT/YEL (16)
152A2 BLK/WHT (16)
12B DBL (12)

IGNITION
RL138-85
51 WHT/RED (16)
2NN BLK (18) 86
1
RL138-86
1
3D VIO (18)
1
52 ORG (12)
41-A DBL/WHT (16)
15 LBL (18)
20A BLK (18)
10 TAN (16)
38 YEL (18)
8 GRN/WHT (16)
28 VIO/WHT (16)
101 BRN (16)

40 BRN/BLK (16)
104 YEL (16)

9 GRN/BLK (16)
35 BRN/WHT (16)
47 ORG/WHT (16)
34 RED/BLK (16)
20 BLK (12)
158 BLK (16)
150 VIO (16)

24A ORG/GRN (14)
6 GRN (18)
31 ORN/RED (16)
18 GRN (18)
151 YEL/GRN (16)

17 GRY (18)
102A PNK (16)

103 BLU (16)
106 BLU/ORG (12)
27D RED (12)

27C RED (12)
105 GRN (16)

32 GRY/WHT (16)
OUTRIGGER TAIL
LIGHT OPTION TAIL
10042 OUTRIGGERS TAIL

1
1
B5
B4
B3
B2
B1
A5
A4
A3
A2
A1
B5
B4
B3
B2
B1
A5
A4
A3
A2
A1
C5
C4
C3
C2
C1
C5
C4
C3
C2
C1
DIAGNOSTIC INDICATORS TAIL

MAQ0690
ENG_BULK1_15F
ENG_BULK2_15M
WIPER TAIL
HEATER TAIL
Electrical Schematic (if equipped for LS) (Continued) 9.5.2
Electrical System
9-14
9.5.2
SECONDARY GRID HTR BOOM SENSOR BOOM EXTEND GRID HTR RLY STARTER
STARTER RELAY
FUNCTION VALVE ENGINE BACK UP ALARM ENGINE X327
A
B
LOGIC CONN GENERIC 151 YEL (16)
1 HYD TEMP SW
LOGIC_2M
A
B
A
B
ENG_BULK3_IN
X325
BE_3F
160 RED (12)
X4
AH330
1 T298
BOOM_3F
HTR PWR RED (2)
87
30
86
85
A
B
A
B
X2 1
APS GND 1 BLK (18)
2X BLK (16)
A T61
EC302
1
1
1
1
2
ASP SUPP 1 BLK (18)
EC303
1
1
1
1
A
B
C
A
B
C
B 1
1
1
1
APS SIG 1 BLK (18) 27D RED (12)
PWR BUSS
T299
C
RL288
RL288-1
RL288-2
SN113
SN112
RL109-85
RL109-87
RL109-30
RL109-86
D
EC291
EC291-B+
EC291-B-
E
2F BLK (18)
2E BLK (18)
41B BLU (18)
41A BLU (18)

27C RED (12)
F 1
160 RED (12)
49 RED (16)
G
23 ORN (16)
T328
APS SUPP 2 RED (18)
PWR BUSS
161 RED (10)

APS GND 2 WHT (18) T58
J
BUSSBAR
APS SIG 2 BLK (18) 2Y BLK (16)
2T BLK (16)
2R BLK (16)
HTR PWR RED (2)
K 1 BAT GND
Electrical System

STRT PWR RED (2/0)
L
STRT GND BLK (2/0)
OUTPUT RTN BLK (18)

M
N
O
P T57
20E BLK (12)
ECM_BULK_23S
Q 1
20C BLK (12)
R
S X56
28B WHT (18)
T A
2P BLK (18)
X1U B
12B-2F
V
W
S 41
T312 CHG ORN (16)
X
S 20A
2G BLK (16)
1 20D BLK (12) X55
18 GRN (16) 47B WHT (18)
1 A
S 20B
T316 2N BLK (18)
X73 S 20D B
5 YEL (16)
A1
17 GRY (16) 20B BLK (12)
A2 X54
20 BLK (12) 47A WHT (18)
A3 A
27C RED (12) 2M BLK (18)
A4 S 47 B
31 ORN (16)
A5
34 RED (16)
B1 X53
106 BLU (16) 28A WHT (18)
B2 A
150(S6) VIO (16) 2L BLK (18)
B3 B
STABILTRAK
151 YEL (16)

B4
27D RED (12)
B5
101(S5) BRN (16) S 20
ENG_BULK2_15F
C1 X52
102(S2) PNK (16) 40 BLK (18)
C2 A
103(S3) BLU (16) 2K BLK (18)
C3 B
104(S1) YEL (16)
C4
105(S4) GRN (16) 20D BLK (12)
LOCK_2F 12A-2F 4A-2F 4B-2F
C5
T319
ALT PWR RED (4)
X74 1
40 BLK (18)
A1 3
41 WHT (16) S 28 CHG ORN (16)
A2 2
X324
47 ORN (16) 5 YEL (16)

A3 1
20A BLK (12)
A4
158 WHT (16) ALT GND BLK (8)
ALTERNATOR
A5 1
18 GRN (16) T318
B1
24A BLK (16)
B2
28 WHT (16)
B3
35 BRN (16)
B4
38 YEL (16)
B5
6 GRN (16)
8
8
8
C1 T294
8 GRN (16) STRT PWR RED (2/0)
C2 1 BAT PWR
9 GRN (16)
C3
10 TAN (16) ALT PWR RED (4)
ENG_BULK1_15M
C4 S2 1 BAT PWR
C5 150A T295
104B(S1) YEL (16)

1
12OB(S2) YEL (18) S 104 S1 T296
2
103B(S3) BLU (18) STRT GND BLK (2/0)
3 1 CHASSIS GND
2J BLK (18) S 102
UPPER
7
X300 ALT GND BLK (8)
1 BAT GND
Electrical Schematic (if equipped for LS) (Continued)
105B(S5) GRN (18)

4 T297
101B(S5) BRN (18) S 103 CASE GND BLK (10)
5 1 ECM CASE GROUND
150B(S6) GRN (18) BLOCK GND BLK (10)
6 T349 1 BAT GND
LOWER
2H BLK (18)
7 T351
X301
150A(S6) GRN (16) S 101
A X344
105A(S4) GRN (16) WATER IN FUEL ORG (18)
B 1 1
104A YEL (16) S 105 WATER IN FUEL RTN BLK (18)
C 2 2
VP2
D X343
S 150
S GND
E
2D BLK (16)
F
D304
ECM GND 5 BLK (12)
S 117 FC314
CASE GND BLK (10)
BLOCK GND BLK (10)
103A BLU (16) ECM BATT RED (12)

A 1
##A
B 101A BRN (16) 2

30A
102 PNK (16)

C T278
ATO FUSE
ECM BATT RED (12)

D 1 BATT +
VP1
T350
E
T284
1
1
2DD BLK (16)

F
D305 BLOCK GND
ECM GND 1 BLK (16)

ECM GND 2 BLK (16)
ECM PWR 1 RED (16)
ECM PWR 2 RED (16)
HV313
OUTPUT RTN BLK (18)
8 GRN (16)
A
APS SUPP 2 RED (18)
APS GND 1 BLK (18)
GHR BLK (18)
34 RED (16)
APS GND 2 WHT (18)
CNH YEL (18)

CNL GRN (18)
ASP SUPP 1 BLK (18)
APS SIG 1 BLK (18)
APS SIG 2 BLK (18)
2C BLK (16)
CNH1 YEL (18)

CNL1 GRN (18)
B
STM_2F
9 GRN (16)
X329
1
2
3
4
5
6
7
8
9
X44
X342
A
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
1
2
3
4
B
MAQ0700
A
2B BLK (16)
B
HV111 (P4) ECM 60 PIN CONN (P2)
STEER MODE VALVE

17 GRY (16) J1939
1
T87
2A BLK (16) HARNESS, ENGINE/CHASSIS
1
T88
FUEL SENDER STM_2M
6036, 6042, 8042, 10042, 10054

Electrical System
9.6 ENGINE START CIRCUIT 1. The main fuse may be blown, requiring replacement.
Check for the cause of the blown fuse.
9.6.1 Starter 2. There may be a defect in the ignition key switch,
ignition wiring or starter solenoid.
IF EQUIPPED FOR ULS 3. Check battery condition. Clean the battery posts and
the connectors at each end of the battery cables.
4. Check for broken wiring and damaged insulation on
the wiring. Replace all broken or damaged wiring.
5. Check all connections at the starter solenoid, key
switch and wiring harness plugs. Clean and tighten
all connections.
6. If the starter still does not operate after these checks
have been performed, check the starting circuit.
b. Starter Circuit Checks

1. Check wires and connections for looseness,
corrosion, damage, etc.
2. If a “whirring” noise is heard but engine does not turn
over, starter is spinning but not engaging flywheel.
Starter drive or solenoid that pushes drive forward to
engage flywheel may be defective. Missing or
damaged teeth on flywheel can also prevent starter
1
from cranking engine.
3. If starter only “clicks” it may indicate that battery is
discharged, or that there is a loose or corroded
battery cable connection. Check battery state of
IF EQUIPPED FOR LS
charge and battery condition first, then check cables
and cable connections.
4. For additional information on the starting circuit, refer
to Section 9.5, “Electrical System Schematics.”
c. Starter Removal
Remove the starter only if it fails. To remove the starter:
2. Open the rear and side engine covers. Allow the
4. Remove wires from solenoid stud. Remove positive
1
(+) battery cable from starter. Label and disconnect
MAQ0710
wire from starter solenoid housing stud. Record how
The starter (1) is located on the left side of the engine. wires are installed to ensure correct installation later.
5. Loosen, but DO NOT remove, fasteners securing
a. Testing the Starter on the Engine starter to flywheel housing. Support starter securely,
If the starter does not engage when the ignition key as it is relatively heavy and will fall if not supported.
switch is turned, check the following:
6036, 6042, 8042, 10042, 10054 9-15

Electrical System
6. Support starter and remove fasteners securing 9.7 CHARGING CIRCUIT

starter to engine. Remove negative (-) ground cable
from its starter mounting bolt. IF EQUIPPED FOR ULS
7. Remove the starter from the machine. 2
d. Starter Installation
1. Position starter in its mounting on flywheel housing.
Position ground cable over correct starter mounting
bolt. Secure starter with previously used hardware.
2. Connect positive (+) battery cable to upper solenoid
stud. Install wires to upper solenoid stud, and secure
with lock washer and nut.
3. Connect the wire to the solenoid mounting stud.
2
6. Close and secure the rear and side engine covers.
IF EQUIPPED FOR LS
MAQ0720
Before using a battery charger, an attempt can be made

to recharge the battery by jump-starting the machine
(Refer to the appropriate Operation & Safety Manual).
Allow the engine to run, which will enable the
alternator (2) to charge the battery.
If the engine alternator charging warning indicator
illuminates, perform the following checks:
1. Check all battery cable connections at the battery,
and verify that they are clean and tight.
2. Check the external alternator wiring and
connections, and verify that they are in good
condition.
3. Check the fan belt condition and tension.
9-16 6036, 6042, 8042, 10042, 10054

Electrical System
4. Run the engine and check the alternator for noise. A alignment. (Refer to the appropriate Operation &
loose drive pulley, loose mounting hardware, worn or Safety Manual.)
dirty internal alternator bearings, a defective stator 4. Connect the previously labeled wire leads to the
or defective diodes can cause noise. Replace a worn alternator.
or defective alternator.
9.7.1 Alternator 6. Remove the Do Not Operate Tags from both the
a. Alternator Removal 7. Close and secure the rear and side engine covers.
2. Open the rear and side engine covers. Allow the
4. Install a drive ratchet into the square hole in the
serpentine belt tensioner bracket.
5. While lifting the automatic belt tensioner away from
the belt, remove the fan serpentine belt.
Note: Record how the alternator is installed to ensure
correct installation later.
6. Label and disconnect the wire leads attached to the
alternator.
7. Remove the lower mounting capscrew securing the
alternator to the lower mounting hole on the engine.
8. While supporting the alternator with one hand,
remove the upper (longer) mounting hardware from
the upper alternator mount. Remove the alternator
from the machine.
b. Alternator Installation
1. Position the alternator and align with the upper
alternator mount on the engine bracket. Insert the
upper (longer) mounting hardware through the
alternator mount. Thread the longer capscrew into
the alternator front mount. DO NOT tighten
completely at this time.
2. Align the lower alternator mount hole with the lower
mounting bracket on the engine, and insert the lower
mounting capscrew. Tighten the lower capscrew and
upper capscrew securely.
3. Place a drive ratchet into the square hole on the
serpentine belt tensioner bracket. Apply pressure
against the tensioner bracket and route the
serpentine belt onto the alternator and engine
pulleys. Release and check the tensioner pulley to
verify that it is pivoting freely in order to provide the
proper tension on the belt. Check for proper belt
6036, 6042, 8042, 10042, 10054 9-17

Electrical System
9.8 WINDOW WIPER/WASHER 12. Remove the metal hex jam nut and metal washer
WINDSHIELD WIPER MOTOR from the motor shaft.
13. Remove the motor mounting bolts, panto adapter
and gasket from the motor shaft.
9.8.1 Windshield Wiper Motor
Note: Retain all hardware removed from the wiper
a. Removal assembly for possible reuse on the replacement motor
Note: It may be necessary to remove several hydraulic housing.
hoses from behind the dash in order to remove and 14. Remove the motor from the inside of the cab.
install the wiper motor housing. (Refer to Section 4.3.1,
“Steering Column and Steering Valve.”) b. Disassembly
1. Park the machine on a firm, level surface, level the DO NOT disassemble the motor. The motor is not
machine, fully retract the boom, lower the boom, serviceable. Replace motor if found to be defective.
(N) NEUTRAL, engage the park brake and shut the c. Inspection and Replacement
engine OFF.
Inspect the motor terminals for continuity. Replace motor
2. Place a Do Not Operate Tag on both the ignition key if continuity is not found.
machine should not be operated. d. Installation and Testing
3. Open the rear door. Allow the system fluids to cool. 1. Install all required hardware to the motor assembly.
4. Properly disconnect the battery. Align spacer and wiper motor bracket, and apply
5. Remove the right side instrument panel. masking tape in order to hold the two components
together during installation.
6. Remove the lower access panel below the
instrument panel. 2. Align motor with the mounting holes and insert motor
through cab.
7. Disconnect the right side defroster hose from the
dash panel hose connector. 3. Have an assistant insert gasket, panto adapter onto
the motor shaft. Insert bolts through front cab holes
3 and thread into motor housing. Tighten bolts.
4. Install metal washer and metal hex jam nut. Tighten
metal hex jam nut. Install rubber cap and knurled
driver onto the motor shaft.
Note: Align the wiper blade arm with the hex jam nut.
4
Tighten shaft to ensure wiper stroke covers window
area, and it does not swipe past the glass area.
5. Install wiper blade arm at 90° from the motor shaft
flat.
6. Connect the cab harness connectors to windshield
MA8431 wiper motor connectors.
8. Disconnect the cab harness connectors from the
wiper motor (3). 8. Remove the Do Not Operate Tags from both the
9. From the outside and front of the cab, remove the
windshield wiper blade arm (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.
9-18 6036, 6042, 8042, 10042, 10054

Electrical System
9. Turn ignition key switch to the RUN position, and 8. Unclip the plastic motor cover (6) and remove.
operate windshield wiper in both LOW and HIGH 9. From the top of the cab, remove the nut from the
speeds to ensure proper operation and that correct wiper motor shaft.
wiper travel is achieved.
10. From inside the cab, pull the wiper motor down and
10. If previously removed, install hydraulic hoses under away from the roof.
the dash. (Refer to Section 4.3.1, “Steering Column
and Steering Valve.”) 11. Label and disconnect the cab harness connectors
from the wiper motor.
11. Install the previously removed dash panels.
12. Close and secure the rear door. b. Disassembly
DO NOT disassemble the motor. The motor is not
9.8.2 Skylight Wiper Motor serviceable. Replace motor if found to be defective.
a. Removal
c. Inspection and Replacement
Inspect the motor terminals for continuity. Replace motor
if continuity is not found.
d. Installation and Testing
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key 1. Hold wiper motor up toward cab top and install the
switch and the steering wheel, stating that the cab harness connectors.
machine should not be operated. 2. With the help of an assistant, insert the wiper motor
3. Open the rare door. Allow the system fluids to cool. through the roof hole and have the assistant thread
the nut onto the wiper motor shaft. Ensure that the
4. Properly disconnect the battery. motor housing is facing the front of the cab.
3. Install the wiper arm onto the wiper motor shaft.
4. Install the screws through the plastic motor cover
and into the top locknut plate and tighten.
5. Connect washer hose to top hose fitting.
5 7. Remove the Do Not Operate Tags from both the
8. Turn the ignition key to the RUN position and turn
skylight wiper switch to the ON position. Ensure
wiper stays on the window through a full stroke. Turn
6 the skylight wiper switch to the OFF position.
9. Engage the washer switch and ensure washer fluid
is sprayed on the skylight window. Turn the ignition
key switch to the OFF position.
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.
6036, 6042, 8042, 10042, 10054 9-19

Electrical System
9.8.3 Windshield Washer Reservoir c. Installation and Testing

1. Connect windshield washer hoses to reservoir.
2. Connect the cab wiring harness connectors to the
reservoir connectors.
3. Install the reservoir tank onto the welded studs.
7 4. Install the lock washers and nuts and secure.
5. Fill the washer fluid reservoir with washer fluid.
8. Turn the ignition key switch to the RUN position and
press the washer switch. Verify that fluid is sprayed
on both the windshield and rear glass.
MA8351
The windshield washer motor and reservoir (7) is a unit
and cannot be serviced separately. 9.9 CAB HEATER AND FAN
a. Removal
9.9.1 Cab Heater Controls
1. Park the machine on a firm, level surface, level the Note: If the suspect component is found to be within the
machine, fully retract the boom, lower the boom, heater box, the heater box must be removed as a
place the transmission control lever in complete unit and replaced.
engine OFF. a. Cab Heater Controls Removal
5. Remove the nuts and the lock washers from the
washer mounting bolts.
6. Pull the washer reservoir out and away from the
mounting bracket.
7. Rotate the washer reservoir, label and remove the MAQ0780
cab harness connectors from the washer reservoir
connectors. 1. Park machine on a firm, level surface, level machine,
8. Remove the windshield washer hose from the fully retract boom, lower boom, place transmission
reservoir. control lever in (N) NEUTRAL, engage the park
brake and shut the engine OFF.
b. Disassembly 2. Place a Do Not Operate Tag on both ignition key
switch and steering wheel, stating that machine
DO NOT disassemble the pump. The pump is not
serviceable. Replace pump if found to be defective.
5. Remove the setscrew from the variable speed fan
control knob or temperature control knob.
6. Remove the right side control panel screws.
9-20 6036, 6042, 8042, 10042, 10054

Electrical System
7. Remove the screws and backing locknuts from the 9.10 SOLENOIDS, SENSORS AND
cab heater and fan control panel. SENDERS
8. Pull the control panel out from the dash panel, and if
removing variable speed fan control, remove the cab
9.10.1 Coolant Level Switch
harness connector.
9. If removing the temperature control knob, disconnect
the cable connector and remove control knob. a. Coolant Level Switch Removal
10. Remove the locknut from the suspect control shaft. 1. Park machine on a firm, level surface, level machine,
11. Remove the control panel from the panel. fully retract boom, raise the boom, place
b. Disassembly the park brake and shut the engine OFF.
DO NOT disassemble the cab heater and fan controls. 2. Place a Do Not Operate Tag on both ignition key
The controls are not serviceable. Replace controls if switch and steering wheel, stating that machine
found to be defective. should not be operated.
c. Installation and Testing 4. Temporarily block up or support the boom.
1. Check that the variable speed fan control is in the 5. Properly disconnect the battery.
OFF position.
2. If installing the temperature control, attach the
control cable to the back of the control.
3. Insert the control shaft through the panel, ensuring
that the knob is in the VERTICAL position.
4. Install the locknut on the shaft and tighten.
5. Connect the cab harness connector to the variable
speed fan control.
6. Install the screws and backing locknuts securing the
control panel to the dash panel.
7. Install the setscrew securing the knob to the control.
8
8. Install the right side control panel.
11. Turn the ignition key to the ON position and check MAQ0730
the fan speeds. If further repair is needed, refer to

Section 9.5, “Electrical System Schematics.” 6. Label and disconnect the wiring connector from the
Coolant Level Switch (8).
12. Start the machine and allow engine to warm to
operating temperature. Check heat control at 7. Unthread switch from deaeration tank.
different levels.
b. Coolant Level Switch Disassembly
DO NOT disassemble the Coolant Level Switch. Replace
a defective switch with a new part.
c. Coolant Level Switch Installation

1. Thread switch into engine. Tighten securely.
2. Connect previously labeled wiring connector
to switch.
6036, 6042, 8042, 10042, 10054 9-21

Electrical System

5. Start engine. Allow it to reach operating temperature
and observe the operator instrument cluster for
warning indication. If switch is not defective, problem
could be elsewhere; possibly in a shorted wire,
improper running engine, improper or low coolant,
obstructed or faulty radiator, coolant pump, loose fan
belt, defective instrument cluster, etc.
9.10.2 Hydraulic Oil Temperature Switch

The hydraulic oil temperature switch (9) is threaded into
a fitting at the lower inside wall of the hydraulic oil tank.
a. Hydraulic Oil Temperature Switch Removal

engine OFF.
9
3. Open the rear door. Allow the system fluids to cool. MA7671

c. Hydraulic Oil Temperature Switch Installation
5. Drain oil from the hydraulic tank reservoir into a
clean container for reuse. 1. Thread the switch into its fitting on the hydraulic
6. Label and disconnect the temperature switch wiring reservoir. Tighten securely.
connector from the harness connector. 2. Fill hydraulic oil reservoir with hydraulic oil.
7. Unthread the switch from the hydraulic reservoir. 3. Connect the switch wiring connector to the harness
connector.
b. Disassembly 4. Properly connect the battery.
DO NOT disassemble the switch. The switch is not 5. Remove the Do Not Operate Tags from both the
serviceable. Replace switch if found to be defective. ignition key switch and the steering wheel.
6. Start the engine, check for hydraulic fluid leaking at
the hydraulic oil temperature switch and allow the
hydraulic fluid to reach operating temperature. Cycle
the boom several times and check whether the
hydraulic oil temperature warning indicator
illuminates on the operator display panel.
9-22 6036, 6042, 8042, 10042, 10054

Electrical System
9.10.3 Transmission Solenoid Valves 5. Open the rear door. Allow the system fluids to cool.
7. Unplug the transmission temperature sender
11
connector from the wiring harness connector.
8. The sender is threaded into the transmission
housing. Remove the sender.
b. Transmission Temperature Sender Inspection and

Replacement
10
Inspect the sender and the wiring harness connector
terminals for continuity. Replace a defective or faulty
sender with a new part.
MH6380
c. Transmission Temperature Sender Installation and

Note: If the transmission is not shifting properly, the
Testing
transmission shift control switch (travel select lever),
wiring harness or transmission shift solenoids (10) 1. Thread the transmission temperature sender into the
should be checked in order to determine which transmission housing snugly, then connect the sender
component is defective. Specific information to connector to the wiring harness connector.
determine which travel position and corresponding 2. Properly connect the battery.
component is not responding can be found in the
detailed transmission service instructions (covering 3. Remove the Do Not Operate Tags from both the
repair, disassembly, reassembly and adjustment ignition key switch and the steering wheel.
information) are provided in the 4. Check for proper fluid level.
ZF 4 WG-98 TC Repair Manual P/N 5871 135 002 5. Start the engine, allow it to reach operating
(JLG P/N 8990455). and can be obtained by calling your temperature and observe the operator display
local Authorized Service Department. cluster for warning indication. If the sender is not
The transmission should be checked, serviced and defective, the problem could be elsewhere; possibly
repaired only by experienced service technicians who are in a shorted wire, damaged transmission, improper
aware of all safety instructions and particular component or low fluid, etc.
features. 6. Install the transmission covers.
Note: Contact your local authorized Service Department 7. Close and secure the rear door.
if internal transmission repair is required during the
warranty period.
9.10.4 Transmission Temperature Sender
a. Transmission Temperature Sender Removal

The transmission temperature sender (11) is threaded
into the top of the transmission housing.
machine, fully retract the boom, raise the boom,
engine OFF.
4. Temporarily block up or support the boom.
6036, 6042, 8042, 10042, 10054 9-23

Electrical System
9.10.5 Service Brake Switch b. Service Brake Switch Installation

1. Ensure that there is only one thread showing above
the locknut on the shaft of the switch body.
12 2. Insert switch body through the top of the service
brake switch bracket.
13
3. Thread the switch dust cover onto the switch body
until finger tight against the service brake switch
bracket.
4. Use a wrench and fully tighten the locknut against
the service brake switch bracket. There should now
be approximately two or three threads showing
above the locknut.
5. Thread the bottom lip of the switch plunger through
the hole in the bottom of the dust cover.
6. Connect the cab harness electrical connectors to the
service brake switch connectors.
MH6210 8. Remove the Do Not Operate Tags from both the
The service brake switch (12) works in conjunction with
9. Adjust the brake switch. Refer to Section 9.10.5, c.
the Stabil-TRAK system. With the boom above 40°, the
“Service Brake Switch Adjustment.”
transmission shifter in either forward or reverse, and the
service brake depressed, the Stabil-TRAK system
c. Service Brake Switch Adjustment
engages. If the Service Brake Switch is suspect in the
proper operation of the Stabil-TRAK system, refer to Note: The service brake switch adjustment will require
Section 10.7, “Stabil-TRAK™ System Test.”. two people. Enlist the help of an assistant before
attempting to follow the adjustment procedure.
a. Service Brake Switch Removal
1. Remove the lower access panel.
1. Park the machine on a firm, level surface, level the 2. Loosen locknut securing the switch body to the
machine, fully retract the boom, lower the boom, service brake switch bracket.
(N) NEUTRAL, engage the park brake and shut the 3. Connect a 1000 psi (69 bar) pressure gauge to the
engine OFF. test port on the service brake valve.
WARNING
NEVER attempt to adjust the service brake switch
without an assistant. Anytime the engine is running
4. Properly disconnect the battery. and the parking brake is disengaged, there must be
5. Label and disconnect the electrical connectors an operator located in the cab and the two front tires
attached to the service brake switch. must be blocked.
6. Loosen locknut and remove switch dust cover (13). 4. Block both front tires.
Remove switch body.
5. Start the engine and run at low idle.
6. Position the boom above 40°, release the park brake
and place the transmission control lever in forward
4th gear.
7. Slowly depress and hold the brake pedal to maintain
150 ±50 psi (10,3 ±3,4 bar) brake pressure.
9-24 6036, 6042, 8042, 10042, 10054

Electrical System
8. Using the switch dust cover and the locknut in 2. Place a Do Not Operate Tag on both the ignition key
combination, position the brake switch so the Stabil- switch and the steering wheel, stating that the
TRAK dash light comes ON at the 150 ±50 psi machine should not be operated.
(10,3 ±3,4 bar) brake pressure. 3. Open the rear door. Allow the system fluids to cool.
9. Repeat steps 6 through 8 until the Stabil-TRAK dash 4. Properly disconnect the battery.
light comes ON at 150 ±50 psi (10,3 ±3,4 bar) brake
pressure. 5. Unplug the engine boom angle sensor connector
from the wiring harness connector.
10. After the required pressure is achieved, use a
wrench and fully tighten the locknut against the 6. Loosen and remove the sensor locknut.
service brake switch bracket. 7. Remove the sensor from the outside of boom frame.
In order to test the switch for proper operation, the boom
must be raised above the 40° position, the parking brake b. Disassembly
switch must be in the OFF position and the machine must DO NOT disassemble the sensor. The sensor is not
be in a forward or reverse gear mode. Proper operation serviceable. Replace the sensor if found to be defective.
of the switch will activate the Stabil-TRAK dash panel
indicator. If the Stabil-TRAK indicator does not activate c. Boom Angle Sensor Installation
when all conditions are met, the boom angle sensor must
be adjusted. Refer to Section 9.10.6, c. “Boom Angle 1. Install boom angle sensor through outside of boom
Sensor Installation.” frame.
11. Shut off the engine. 2. Install locknut onto sensor.
12. Remove the blocks from the front tires.

15
13. Remove the pressure gauge.
14. Install the lower access panel.
9.10.6 Boom Angle Sensor
MH6310
14 3. Measure the clearance between the sensor and

frame, and adjust sensor distance (15) to 0.120”
(3,05 mm) and tighten locknut.
MAQ0240
The boom angle sensor (14) is located at the rear of, and
on the right side of the machine. When the boom is lifted
above 40°, the boom sensor sends a signal to the Stabil-
TRAK indicator on the instrument cluster.
a. Boom Angle Sensor Removal

engine OFF.
6036, 6042, 8042, 10042, 10054 9-25

Electrical System
9.10.7 Boom Extend Interlock Sensor 7. Loosen the inside locknut (17) on the sensor (18).
(10054 only) 8. Slide the sensor out of the bracket and remove.
The boom extend interlock sensor is located on the left
side of the machine, on the outer boom frame and just b. Boom Extend Interlock Sensor Installation
behind the cab. The boom extend interlock sensor 1. Partially install inside locknut (17) onto the sensor
prohibits the last boom section from extending unless (18).
both outriggers are down and pressure is applied to the
ground surface. 2. Make sure that there are four to six threads,
approximately 0.975 in (24,7mm) and
a. Boom Extend Interlock Sensor Removal 1.0 in (25,4mm)(19), between the outside locknut
(20) and the end of the sensor.
3. Make sure that the wire harness is between the
bracket and the sensor, and slide the sensor into the
bracket.
engine OFF. 4. Connect the boom extend interlock sensor
connector (16) to the boom extend harness
connector.
machine should not be operated. 5. Replace wire ties as necessary.
3. Open the rear door. Allow the system fluids to cool. 6. Properly connect the battery.
4. Properly disconnect the battery. 7. Remove the Do Not Operate Tags from both the
5. Make note of wire tie locations and clip wire ties
where necessary. 8. Close and secure the rear door.
17
20
18 19
16
MH6121
6. Disconnect the boom interlock sensor electrical

connector (16).
9-26 6036, 6042, 8042, 10042, 10054

Electrical System
9.10.8 Outrigger Pressure Switches 9.11 DISPLAY MONITOR AND GAUGES

(10054 Only)
a. Removal 9.11.1 Instrument Cluster
1. Park the vehicle on a firm, level surface. Level the a. Instrument Cluster Removal
vehicle, ground the attachment, place the travel select
lever in the (N) NEUTRAL position, place the neutral
lock lever in the (N) NEUTRAL LOCK position and
engage the parking brake switch.
2. Raise both outriggers fully, and shut the engine OFF. engine OFF.
3. Open the rear door. Allow the system fluids to cool. 2. Place a Do Not Operate Tag on both the ignition key
4. Properly disconnect the battery. switch and the steering wheel, stating that the
switch and the steering wheel, stating that the 3. Open the rear door. Allow the system fluids to cool.
machine should not be operated. 4. Properly disconnect the battery.
5. Remove the right access panel.
4
1
3
MAQ0260
6. Unscrew the locking ring from below the instrument

2 cluster (4). Pull the instrument cluster up and away
from the cut-out, and unplug the harness connector.
b. Instrument Cluster Bulb Removal

1. Remove the instrument cluster from the cab. Refer
to Section 9.11.1, a. “Instrument Cluster Removal.”
MAQ0250
2. Remove the instrument cluster rear cover plate.
6. Disconnect the pressure switch wiring connector (1)
3. Rotate the bulb assembly 1/4 turn counterclockwise
from the harness connector (2).
and remove bulb.
7. Remove the outrigger pressure switch (3) from the
outrigger cylinder. c. Instrument Cluster Installation and Testing
8. Wipe up any spilled hydraulic oil. 1. Connect the harness connector to the instrument
cluster terminal.
b. Installation
2. Place the instrument cluster into the cut-out, and
1. Install the pressure switch (3), and torque to 25-38 install the plastic retaining ring and secure.
lb-ft (34-41 Nm).
3. Install the right access panel.
2. Connect the pressure switch wiring connector (1) to
the harness connector (2).
6. Turn the ignition to the RUN position. All lights must
illuminate for 3 seconds.
6036, 6042, 8042, 10042, 10054 9-27

Electrical System
9.12 DASH SWITCHES c. Inspection and Replacement

To determine the proper operation of the ignition key
Note: For information on the front windshield wiper, rear
switch, test the terminals on the back of the switch for
window wiper and washer systems, refer to Section 9.8,
continuity with an ohmmeter.
“Window Wiper/Washer Windshield Wiper Motor.”
Test the ignition key switch for continuity, by checking
9.12.1 Ignition Key Switch from the ignition (BLUE) wire to each of the following
wires in each corresponding switch position. Continuity
a. Ignition Switch Removal (X) should be present as indicated in the following chart:

Switch Position
place the transmission control lever in Test from BLUE wire to: OFF RUN START
WHT Wire, Pin B on 3 Pin X
engine OFF.
Connector
2. Place a Do Not Operate Tag on the steering wheel,
stating that the machine should not be operated.
Test the ignition key switch for continuity, by checking
3. Open the rear door. Allow the system fluids to cool. from the ignition (RED) wire to each of the following wires
4. Properly disconnect the battery. in each switch position. Continuity (X) should be present
as indicated in the following chart:
Switch Position
Test from RED wire to: OFF RUN START
PUR Wire, Pin B on 5 Pin X X
Connector
RED/BLK Wire, Pin C on 5 X X
Pin Connector
5
If all terminals do not show proper continuity, replace the

ignition switch.
6
d. Ignition Switch Installation
1. Connect the ignition key switch to the previously
MAQ0270 labeled connectors.
5. Remove the lower access panel (5). 2. The ignition switch has a drain hole located on the
shaft, between the backing nut and the face of the
6. From under the dash, remove the hex nut securing
ignition switch cylinder, behind the dash panel. Align
the ignition key switch (6) to the dash.
the ignition switch so that when it is in the OFF
7. Label and disconnect the ignition switch connectors position, the key slot is positioned vertically (straight up
and remove the switch from the machine. and down) and the indicator mark for the drain hole,
is pointing down. Install the nut securing the ignition
b. Disassembly switch to the dash. DO NOT overtighten.
DO NOT disassemble the ignition switch. Replace a 3. Install the lower access panel.
defective switch with a new part. 4. Properly connect the battery.
Note: If further information is needed, refer to Section
9.5, “Electrical System Schematics.”
9-28 6036, 6042, 8042, 10042, 10054

Electrical System
9.12.2 Dash Switches c. Inspection and Replacement

Inspect the switch terminals for continuity and shorting in
a. Switch Removal
both the engaged and disengaged positions. Replace a
1. Park the machine on a firm, level surface, level the defective or faulty switch with a new switch.
place the transmission control lever in d. Switch Installation
1. Connect the switch to the cab harness connector.
engine OFF.
2. Position the switch over the rectangular switch bezel
and snap into position.
machine should not be operated. 3. Properly connect the battery.
3. Open the rear door. Allow the system fluids to cool. 4. Remove the Do Not Operate Tags from both the
7 5. Start the machine and check the replaced switch for
proper function.
8
MAQ0770
5. Carefully pry the switch and wiring (7) out of the

mounting plate (8).
6. Label and disconnect the wiring from the switch.
Remove the switch.
b. Disassembly
DO NOT disassemble the dash switch. Replace a
defective switch with a new part.
6036, 6042, 8042, 10042, 10054 9-29

Electrical System
9.13 TROUBLESHOOTING
9.13.1 Fault Detection

Faults are detected while key switch is in RUN position,
during operation of machine itself. If a fault becomes
active (currently detected) at this time, a fault is logged in
memory and a snapshot of engine parameters is logged.
In addition, certain faults may illuminate warning lamp
(amber) or stop lamp (red) depending upon severity of
the active fault. Fault codes will display in the instrument
cluster display (9).
For more information, contact your local authorized
Cummins service distributor.
Note: Refer to Engine Fault Code Chart for a full list of
fault codes.
11 10
MAQ0750
9.13.2 Offboard Diagnostics

INSITETM, is the Windows®-based PC service/
programming/diagnostic tool for the Cummins engine. It
is used to help troubleshoot and repair the engine with
extended fault diagnostics and processing power.
INSITETM allows the user to view active and inactive
faults and clear the inactive faults. It provides a monitor
function that allows the service technician to monitor
measured parameters, actuator status and some
calculated values. 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.
9-30 6036, 6042, 8042, 10042, 10054

Electrical System
9.13.3 Engine Fault Codes Chart
Fault SPN FMI Area

LAMP Diagnostic Description
Code Code Code Description
EGR Valve Position Circuit—Voltage Below Normal, or
2272 27 4 Amber Not Available
Shorted to Low Source
Wheel-based Vehicle Speed Sensor Circuit—Data Erratic, Intermittent, or

241 84 2 Amber
Vehicle Speed Incorrect
Wheel-based Vehicle Speed Sensor Circuit tampering has been detected—

242 84 10 Amber
Vehicle Speed Abnormal Rate of Change
Accelerator Accelerator Pedal or Lever Position Sensor Circuit—Voltage

131 91 3 Red
Pedal Position Above Normal, or Shorted to High Source
Accelerator Accelerator Pedal or Lever Position Sensor Circuit—Voltage

132 91 4 Red
Pedal Position Below Normal, or Shorted to Low Source
Accelerator Accelerator Pedal or Lever Position Sensor Circuit—Abnormal

147 91 1 Red
Pedal Position Frequency, Pulse Width, or Period
Accelerator Accelerator Pedal or Lever Position Sensor Circuit—Abnormal

148 91 0 Red
Pedal Position Frequency, Pulse Width, or Period
Accelerator Accelerator Pedal or Lever Position Sensor 1 and 2—Data

1242 91 2 Red
Pedal Position Erratic, Intermittent, or Incorrect
SAE J1939 Multiplexed Accelerator Pedal or Lever Sensor

3326 91 9 Red
System—Abnormal update rate
Auxiliary Constrained Operation Curve Validation Switch—

528 93 2 Amber Switch - Data
Data Erratic, Intermittent, or Incorrect
Fuel Filter Differential Pressure—Data Valid But Above Normal

2372 95 16
Operating Range—Moderately Severe Level
Amber/ Water in Fuel Water in Fuel Indicator High - Data Valid but Above Normal
418 97 15
Blinking Indicator Operational Range – Least Severe Level
Water in Fuel Water in Fuel Sensor Circuit - Voltage Above Normal, or

428 97 3 Amber
Indicator Shorted to High Source
Water in Fuel Water in Fuel Sensor Circuit - Voltage Below Normal, or

429 97 4 Amber
Indicator Shorted to Low Source
Water in Fuel Water in Fuel Indicator—Data Valid but Above Normal

1852 97 16 Amber
Indicator Operational Range—Moderately Severe Level
Engine Oil Oil Pressure Sensor Circuit—Voltage Above Normal, or

135 100 3 Amber
Pressure Shorted to High Source
6036, 6042, 8042, 10042, 10054 9-31

Electrical System
Fault SPN FMI Area

Engine Oil Oil Pressure Sensor Circuit—Voltage Below Normal, or
141 100 4 Amber
Pressure Shorted to Low Source
Engine Oil Oil Pressure Low—Data Valid but Below Normal Operational
143 100 18 Amber
Pressure Range—Moderately Severe Level
Engine Oil Oil Pressure Low – Data Valid but Below Normal Operational
415 100 1 Red
Pressure Range - Most Severe Level
Engine Oil Oil Pressure Sensor Circuit - Data Erratic, Intermittent, or

435 100 2 Amber
Pressure Incorrect
Crankcase Pressure—Data Valid But Above Normal Operating

Range—Moderately Severe Level
Crankcase Pressure—Data Valid But Above Normal Operating

556 101 0 Red Not Available
Range—Moderately Severe Level
Crankcase Pressure Circuit—Voltage Above Normal, or

Shorted to High Source
Crankcase Pressure Circuit—Below Normal, or Shorted to

Low Source
1942 101 2 Amber Not Available Crankcase Pressure—Data Erratic, Intermittent or Incorrect
Amber/ Crankcase Pressure—Data Valid But Above Normal Operating

1974 101 15 Not Available
Blinking Range—Least Severe Level
Boost Intake Manifold Pressure Sensor Circuit—Voltage Above

122 102 3 Amber
Pressure Normal, or Shorted to High Source
Boost Intake Manifold Pressure Sensor Circuit—Voltage Below

123 102 4 Amber
Pressure Normal, or Shorted to Low Source
Boost Intake Manifold Pressure Sensor Circuit—Data Erratic,

2973 102 2 Amber
Pressure Intermittent, or Incorrect
Turbocharger Turbocharger #1 Speed High - Data Valid but Above Normal

595 103 16 Amber
1 Speed Operational Range—Moderately Severe Level
Turbocharger Turbocharger #1 Speed Low—Data Valid but Below Normal

687 103 18 Amber
1 Speed Operational Range—Moderately Severe Level
Turbocharger 1 Speed—Data Valid But Above Normal

2288 103 15 None Not Available
Operating Range—Least Severe Level
9-32 6036, 6042, 8042, 10042, 10054

Electrical System
Fault SPN FMI Area

Intake
Intake Manifold Air Temperature Sensor Circuit—Voltage
153 105 3 Amber Manifold #1
Above Normal, or Shorted to High Source
Temp
Intake
Intake Manifold Air Temperature Sensor Circuit—Voltage
154 105 4 Amber Manifold #1
Below Normal, or Shorted to Low Source
Temp
Intake
Intake Manifold Air Temperature High—Data Valid but Above
155 105 0 Red Manifold #1
Normal Operational Range—Most Severe Level
Temp
Intake Intake Manifold 1Temperature—Data Valid but Above Normal
488 105 16 Amber
Manifold Operational Range—Moderately Severe Level
Barometric Barometric Pressure Sensor Circuit —Voltage Above Normal,

221 108 3 Amber
Pressure or Shorted to High Source
Barometric Barometric Pressure Sensor Circuit—Voltage Below Normal,

222 108 4 Amber
Pressure or Shorted to Low Source
Barometric Barometric Pressure Sensor Circuit—Data Erratic, Intermittent,

295 108 2 Amber
Pressure or Incorrect
Engine
Coolant Temperature Sensor Circuit—Voltage Above Normal,
144 110 3 Amber Coolant
or Shorted to High Source
Temperature
Engine
Coolant Temperature Sensor Circuit—Voltage Below Normal,
or Shorted to Low Source
Temperature
Engine
Coolant Temperature High—Data Valid but Above Normal
Operational Range—Moderately Severe Level
Temperature
Engine
Coolant Temperature Low—Data Valid but Above Normal
151 110 0 Red Coolant
Operational Range—Most Severe Level
Temperature
2646 110 31 Amber Not Available Engine Coolant Temperature—Condition Exists
Coolant Level Sensor Circuit—Voltage Above Normal, or

195 111 3 Amber Coolant Level
Coolant Level Sensor Circuit—Voltage Below Normal, or

Coolant Level—Data Valid but Below Normal Operational

Range —Moderately Severe Level
Coolant Level Low—Data Valid but Below Normal Operational

235 111 1 Red Coolant Level
Range—Most Severe Level
6036, 6042, 8042, 10042, 10054 9-33

Electrical System
Fault SPN FMI Area

422 111 2 Amber Coolant Level Coolant Level - Data Erratic, Intermittent, or Incorrect
Amber/ Coolant Level—Data Valid But Below Normal Operating

2448 111 17 Coolant Level
Blinking Range - Least Severe Level
Injector Fuel Pressure High—Data Valid but Above Normal
449 157 0 Red Metering Rail Operational
1 Pressure Range—Moderately Severe Level
Injector
Injector Metering Rail #1 Pressure Sensor Circuit—Voltage
451 157 3 Amber Metering Rail
Above Normal, or Shorted to High Source
1 Pressure
Injector
Injector Metering Rail #1 Pressure Sensor Circuit—Voltage
1 Pressure
Injector
Injector Metering Rail #1 Pressure High—Data Valid but Above
Normal Operational Range—Moderately Severe Level
1 Pressure
Injector
Injector Metering Rail #1 Pressure Low—Data Valid but Below
1 Pressure
Injector Injector Metering Rail 1 Pressure—Data Valid but Above
1911 157 0 Amber
Metering Rail Normal Operational Range—Most Severe Level
Injector
Injector Metering Rail 1 Pressure—Data Valid but Below
Normal Operational Range—Most Severe Level
1 Pressure
Electrical
Battery #1 Voltage Low—Data Valid but Below Normal
441 168 18 Amber Potential
(Voltage)
Electrical
Battery #1 Voltage High—Data Valid but Above Normal
442 168 16 Amber Potential
(Voltage)
Engine Speed High - Data Valid but Above Normal Operational
234 190 0 Red Engine Speed
Range—Most Severe Level
Primary Engine Speed Sensor Error—Data Erratic,

689 190 2 Amber Engine Speed
Intermittent, or Incorrect
Engine Speed /Position Sensor #1—Data Erratic, Intermittent,

2321 190 2 None Engine Speed
or Incorrect
Engine Crankshaft Speed/Position—Data Valid But Above

2468 190 0
Normal Operating Range—Moderately Severe Level
Transmission
Transmission Output Shaft Speed - Data Valid but Above
349 191 16 Amber Output Shaft
Normal Operational Range - Moderately Severe Level
Speed
9-34 6036, 6042, 8042, 10042, 10054

Electrical System
Fault SPN FMI Area

Transmission
Transmission Output Shaft Speed—Data Valid but Below
489 191 18 Amber Output Shaft
Speed
3328 191 9 Amber Transmission Output Shaft Speed—Abnormal update rate
Exhaust Gas
Recirculation Exhaust Gas Recirculation (EGR) Temperature Sensor
2375 412 3 Amber
(EGR) Circuit— Voltage Above Normal, or Shorted to High Source
Temperature
Exhaust Gas
Recirculation Exhaust Gas Recirculation (EGR) Temperature Sensor
2376 412 4 Amber
(EGR) Circuit— Voltage Below Normal, or Shorted to Low Source
Temperature
Engine Intake
Exhaust Gas Recirculation (EGR) Temperature—Data Valid
2961 412 15 None Valve Actuator
But Above Normal Operating Range—Least Severe Level
#12
Auxiliary
292 441 14 Red Auxiliary Temperature Sensor Input 1—Special Instructions
Temperature 1
OEM Auxiliary Temperature Sensor Input # 1 Circuit—Voltage

293 441 3 Amber
Temperature Above Normal, or Shorted to High Source
OEM Auxiliary Temperature Sensor Input # 1 Circuit—Voltage

294 441 4 Amber
Temperature Below Normal, or Shorted to Low Source
Accelerator Accelerator Pedal or
431 558 2 Amber Pedal Low Idle Lever Idle Validation Circuit - Data Erratic, Intermittent, or
Switch Incorrect
Accelerator
Accelerator Pedal or Lever Idle Validation Circuit - Out of
432 558 13 Red Pedal Low Idle
Calibration
Switch
System
OEM Intermediate (PTO) Speed switch Validation—Data
523 611 2 Amber Diagnostic
Erratic, Intermittent, or Incorrect
code # 1
System
Sensor Supply 4 Circuit—Voltage Below Normal, or Shorted to
Low Source
code # 1
System Engine Speed/Position Sensor Circuit lost both of two signals
115 612 2 Red Diagnostic from the magnetic pickup sensor—Data Erratic, Intermittent,
Code # 2 or incorrect
Red Stop Red Stop Lamp Driver Circuit—Voltage Below Normal, or
244 623 4 Amber
Lamp Shorted to Low Source
351 627 12 Amber Controller #1 Injector Power Supply - Bad Intelligent Device or Component
6036, 6042, 8042, 10042, 10054 9-35

Electrical System
Fault SPN FMI Area

Power Lost With Ignition On—Data Erratic, Intermittent,
1117 627 2 None Power Supply
or Incorrect
Engine Control Module Warning internal hardware failure - Bad

343 629 12 Amber Controller #1
Intelligent Device or Component
Fuel Control
2311 633 31 Amber Fueling Actuator #1 Circuit Error—Condition Exists
Valve #1
SAE J1939 SAE J1939 Multiplexing PGN Timeout Error—Abnormal

285 639 9 Amber
Datalink Update Rate
SAE J1939 SAE J1939 Multiplexing Configuration Error—Out of

286 639 13 Amber
Datalink Calibration
Engine
External Auxiliary Commanded Dual Output Shutdown—
599 640 14 Red
Protection Special Instructions
Input
External External Speed Input (Multiple Unit Synchronization)—Data
237 644 2 Amber
Speed Input Erratic, Intermittent, or Incorrect
Fan Clutch
Fan Control Circuit—Voltage Below Normal, or Shorted to Low
245 647 4 Amber Output Device
Source
Driver
Fan Clutch
Fan Control Circuit—Voltage Above Normal, or Shorted to
2377 647 3 Amber Output Device
High Source
Driver
Injector Injector Solenoid Cylinder #1 Circuit – Current Below Normal,
322 651 5 Amber
Cylinder #01 or Open Circuit

331 652 5 Amber

324 653 5 Amber

332 654 5 Amber
Starter
Solenoid Starter Relay Driver Circuit—Voltage Above Normal, or
584 677 3 Amber
Lockout Relay Shorted to High Source
Driver Circuit
Circuit— Auxiliary Input/Output 2 Circuit—Voltage Above Normal, or
527 702 3 Amber
Voltage Shorted to High Source
Circuit— Auxiliary Input/Output 3 Circuit—Voltage Above Normal, or

529 703 3 Amber
Voltage Shorted to High Source
9-36 6036, 6042, 8042, 10042, 10054

Electrical System
Fault SPN FMI Area

Auxiliary Equipment Sensor Input 3 Engine Protection
2195 703 14
Critical— Special Instructions
Engine Speed/Position #2 Mechanical Misalignment Between
Engine Speed
731 723 7 Amber Camshaft and Crankshaft Sensors—Mechanical System
Sensor #2
Not Responding Properly or Out of Adjustment
Engine Speed Engine Speed Sensor (Camshaft) Error—Data Erratic,
778 723 2 Amber
Sensor #2 Intermittent, or Incorrect
Engine Speed Engine Speed /Position Sensor #2—Data Erratic, Intermittent,

2322 723 2 None
Sensor #2 or Incorrect
Inlet Air
Intake Air Heater #1 Circuit—Voltage Above Normal, or
2555 729 3 Amber Heater Driver
#1
Inlet Air
Intake Air Heater #1 Circuit—Voltage Below Normal, or
2556 729 4 Amber Heater Driver
#1
Remote Remote Accelerator Pedal or Lever Position Sensor Circuit—
133 974 3 Red
Accelerator Voltage Above Normal, or Shorted to High Source
Remote Remote Accelerator Pedal or Lever Position Sensor Circuit—

134 974 4 Red
Accelerator Voltage Below Normal, or Shorted to Low Source
Remote SAE J1939 Multiplexing Remote Accelerator Pedal or Lever

288 974 19 Red
Accelerator Data Error—Received Network Data In Error
Sensor Circuit ECM Internal Temperature Sensor Circuit—Voltage Above

697 1136 3 Amber
- Voltage Normal, or Shorted to High Source
Sensor
ECM Internal Temperature Sensor Circuit—Voltage Below
698 1136 4 Amber Circuit—
Normal, or Shorted to Low Source
Voltage
Turbocharger
#1Compressor Turbocharger 1 Compressor Inlet Temperature Circuit—
691 1172 3 Amber
Inlet Voltage Above Normal, or Shorted to High Source
Temperature
Engine Turbocharger Wastegate Actuator 1 Position—Data
3925 1188 2 Amber
erratic, intermittent or incorrect
Exhaust Gas Exhaust Gas Pressure Sensor Circuit—Voltage Above

2373 1209 3 Amber
Pressure Normal, or Shorted to High Source
Exhaust Gas Exhaust Gas Pressure Sensor Circuit—Voltage Below Normal,

2374 1209 4 Amber
Pressure or Shorted to Low Source
2554 1209 2 Amber Not Available Exhaust Gas Pressure—Data Erratic, Intermittent or Incorrect
6036, 6042, 8042, 10042, 10054 9-37

Electrical System
Fault SPN FMI Area

Fuel Pump
High Fuel Pressure Solenoid Valve Circuit—Voltage Below
271 1347 4 Amber Pressurizing
Normal, or Shorted to Low Source
Assembly #1
Fuel Pump
High Fuel Pressure Solenoid Valve Circuit—Voltage Above
272 1347 3 Amber Pressurizing
Normal, or Shorted to High Source
Assembly #1
Multiple Unit Synchronization Switch Circuit—Data Erratic,
497 1377 2 Amber Switch Circuit
Intermittent, or Incorrect
Engine Oil
Amber/
649 1378 31 Change Change Lubricating Oil and Filter—Condition Exists
Blinking
Interval
Auxiliary
296 1388 14 Red Auxiliary Pressure Sensor Input 1—Special Instructions
Pressure
3186 1623 9 Amber Tachograph Output Shaft Speed—Abnormal update rate
Tachograph Output Shaft Speed—Received Network Data In

3213 1623 2 Amber
Error
3737 1675 11 NA Engine Starter Mode Overcrank Protection—Condition Exists
Accelerator Accelerator Pedal or Lever Position Sensor 2 Circuit—Voltage

1239 2623 3 Amber
Pedal Position Above Normal, or Shorted to High Source
Accelerator Pedal or Lever Position Sensor 2 Circuit—Voltage

1896 2791 13 Amber Not Available EGR Valve Controller—Out of Calibration
EGR Valve Control Circuit—Current below normal or open

circuit
EGR Valve Control Circuit—Current above normal or

2353 2791 6
grounded circuit
EGR Valve Control Circuit—Mechanical system not

responding or out of adjustment
2765 2797 13 None Not Available Engine Injector Bank 1 Barcodes—Out of Calibration
5 Volts DC Sensor Supply Voltage #1 Circuit – Voltage Below Normal, or

352 3509 4 Amber
Supply Shorted to Low Source
9-38 6036, 6042, 8042, 10042, 10054

Electrical System
Fault SPN FMI Area

5 Volts DC Sensor Supply Voltage #1 Circuit – Voltage Above Normal, or
386 3509 3 Amber
Supply Shorted to High Source
5 Volts DC Sensor Supply Voltage #2 Circuit—Voltage Below Normal, or

187 3510 4 Amber
Supply Shorted to Low Source
5 Volts DC Sensor Supply Voltage #2 Circuit—Voltage Above Normal, or

227 3510 3 Amber
Supply Shorted to High Source
System
Sensor Supply Voltage #3 Circuit—Voltage Below Normal, or
code # 1
System
Sensor Supply Voltage #3 Circuit—Voltage Above Normal, or
code #2
Sensor Supply 4 Circuit—Voltage above normal, or shorted to
2185 3512 3
high source
Sensor Supply 5—Voltage Above Normal, or Shorted to

High Source
Sensor Supply 5—Voltage Below Normal, or Shorted to

Low Source
Sensor Supply 6 Circuit—Voltage above normal, or shorted to

high source
Sensor Supply 6 Circuit—Voltage below normal, or shorted to

low source
ECU Power Output Supply Voltage 1—Data Valid But Below

Normal Operating Range—Moderately Severe Level
ECU Power Output Supply Voltage 1—Voltage Above Normal,

or Shorted to High Source
ECU Power Output Supply Voltage 1—Voltage Below Normal,

or Shorted to Low Source
Engine Air Shutoff Circuit—Voltage above normal, or shorted

3139 3667 3 Amber
to high source
Engine Air Shutoff Circuit—Voltage below normal, or shorted

3141 3667 4 Amber
to low source
3918 5421 13 Amber Engine Turbocharger Wastegate Actuator—Out of Calibration
6036, 6042, 8042, 10042, 10054 9-39

Electrical System
Fault SPN FMI Area

Engine Turbocharger Wastegate Actuator—Mechanical
3921 5421 7 Amber
system not responding or out of adjustment
Engine Turbocharger Wastegate Actuator—Current below

3922 5421 5 Amber
normal or open circuit
Engine Turbocharger Wastegate Actuator—Current above

3923 5421 6 Amber
normal or grounded circuit
Engine Turbocharger Wastegate Actuator—Root Cause

3927 5421 11 Amber
Not Known
3928 5421 11 Amber Engine Turbocharger Wastegate Actuator—Condition Exists
High Pressure Common Rail Fuel Pressure Relief Valve—

3727 5571 7 NA
Mechanical system not responding or out of adjustment
952 #### 31 Amber Not Available Reserved for temporary use—Condition Exists
953 #### 31 Amber Not Available Reserved for temporary use—Condition Exists
3222 #### 12 Amber Glow Plug Module—Bad intelligent device or component
Engine Crankcase Ventilation Hose Disconnected—

3377 #### 31 Amber Not Available
Condition Exists
3924 #### 11 Amber Utility Reverse kW Fault—Condition Exists
9-40 6036, 6042, 8042, 10042, 10054

Section 10
Stabil-TRAK™ System and Boom Interlock System
Contents

10.1 Stabil-TRAK™ System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
10.2 Boom Extend Interlock System Component Terminology (10054 Only) . . . . . . 10-4
10.3 Stabil-TRAK™ Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
10.4 Stabil-TRAK™ Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
10.4.1 Understanding Stabil-TRAK™ System . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
10.4.2 Stabil-TRAK™ Solenoid Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
10.4.3 Logic Wiring Harness (10054 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
10.4.4 Relay Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
10.4.5 Outrigger Pressure Switches (10054 Only). . . . . . . . . . . . . . . . . . . . . . . . 10-8
10.5 Boom Extend Interlock System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
10.6 Boom Extend Interlock System Operation (10054 Only) . . . . . . . . . . . . . . . . . . . 10-10
10.6.1 Extend Interlock Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
10.6.2 Outrigger Interlock Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
10.7 Stabil-TRAK™ System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
10.7.1 Stabil-TRAK™ System Test Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
10.7.2 Stabil-TRAK™ System Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
(6042/8042/10042) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
(10054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
10.10 Boom/Outrigger Interlock System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
10.10.1 System Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
6036, 6042, 8042, 10042, 10054 10-1

10.11 Stabil-TRAK™ Hydraulic Circuit Operation and Troubleshooting . . . . . . . . . . . 10-25

10.11.1 Stabil-TRAK™ Cylinder Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
10.11.2 Hydraulic Circuit Operation - FREE PIVOT Mode, Rod Oil Out . . . . . . . . 10-28
10.11.3 Hydraulic Troubleshooting - FREE PIVOT Mode, Rod Oil Out . . . . . . . . . 10-29
10.11.4 Hydraulic Circuit Operation - FREE PIVOT Mode, Base Oil Out . . . . . . . 10-30
10.11.5 Hydraulic Troubleshooting - FREE PIVOT Mode, Base Oil Out . . . . . . . . 10-31
10.11.6 Hydraulic Circuit Operation - SLOW PIVOT Mode, Rod Oil Out. . . . . . . . 10-32
10.11.7 Hydraulic Troubleshooting - SLOW PIVOT Mode, Rod Oil Out . . . . . . . . 10-33
10.11.8 Hydraulic Circuit Operation - SLOW PIVOT Mode, Base Oil Out . . . . . . . 10-34
10.11.9 Hydraulic Troubleshooting - SLOW PIVOT Mode, Base Oil Out. . . . . . . . 10-35
10.11.10 Hydraulic Circuit Operation - LOCKED MODE . . . . . . . . . . . . . . . . . . . . . 10-36
10.11.11 Hydraulic Circuit Operation - LOCKED MODE, Frame Level Right . . . . . 10-36
10.11.12 Hydraulic Troubleshooting - LOCKED MODE, Will Not Frame Level Right 10-37
10.11.13 Hydraulic Circuit Operation - LOCKED MODE, Frame Level Left . . . . . . 10-38
10.11.14 Hydraulic Troubleshooting - LOCKED MODE, Will Not Frame Level Left 10-39
10.12 Boom Extend System Hydraulic Circuit Operation and Troubleshooting . . . . . 10-40
10.12.1 Troubleshooting Symptom Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
10.12.2 Hydraulic Circuit Operation - Extend Interlock Mode . . . . . . . . . . . . . . . . 10-42
10.12.3 Hydraulic Troubleshooting - Extend Interlock Mode . . . . . . . . . . . . . . . . . 10-42
10.12.4 Hydraulic Circuit Operation - Outrigger Interlock Mode . . . . . . . . . . . . . . 10-44
10.12.5 Hydraulic Troubleshooting - Outrigger Interlock Mode . . . . . . . . . . . . . . . 10-44
10-2 6036, 6042, 8042, 10042, 10054

10.1 STABIL-TRAK™ SYSTEM

locations of the major assemblies of the Stabil-TRAK™
system. The following illustration identifies the
STABIL-TRAK™
CYLINDER
STABIL-TRAK™
MANIFOLD
FRAME LEVEL
CYLINDER
BOOM PROXIMITY
SWITCH
MH2962
Model 10054 Shown MH2961
6036, 6042, 8042, 10042, 10054 10-3

10.2 BOOM EXTEND INTERLOCK

SYSTEM COMPONENT
TERMINOLOGY (10054 ONLY)
locations of the major assemblies of the boom extend
interlock system. The following illustration identifies the
BOOM EXTEND SENSOR
OUTRIGGER CYLINDER
PRESSURE SWITCH (2)
~
BOOM LOCKOUT
VALVE
MH3002 MH3001
10-4 6036, 6042, 8042, 10042, 10054

10.3 STABIL-TRAK™ DESCRIPTION The stabilizing system operates via an interface between:
• Boom proximity switch (2),
Patented rear axle lock or Stabil-TRAK™system works
to stabilize vehicle under various conditions. Appropriate • Park brake switch,
Operation and Safety Manual contains basic • Service brake switch,
Stabil-TRAK™information; a copy of Operation and
Safety Manual should always be available in the storage • Gear selector in (N) NEUTRAL,
compartment located in the cab • Hydraulic circuits,
. • Electrical circuits and
• Five solenoid-operated valves on
Stabil-TRAK™manifold (3)
~
1
MAQ1060
The operator’s instrument cluster Stabil-TRAK™light (1)

will be ON when the Stabil-TRAK™system is in the
LOCKED mode.
MH2990
Frame level cylinder (4) is also involved in

Stabil-TRAK™system, but only passively, as
hydraulic oil travels between frame level cylinder
2 and Stabil-TRAK™manifold to accommodate
Stabil-TRAK™system operation.
MH2970
The Stabil-TRAK™lock system will be activated when
the boom angle is greater than 40° and one or more of
the following functions are activated:
• Engaging the Parking Brake Switch
• Placing the Travel Select Lever in (N) NEUTRAL
3 • Depressing and holding the Service Brake
• Model 10054 Only: Lowering both outriggers
onto solid terrain, and extending the boom
beyond a point between the “E” and “F” boom
extend letters (approximately 40ft [12 m])
With the boom lowered to an angle of less than 40°, the
rear axle lock system is not active and none of these
functions will affect the Stabil-TRAK™system.
MH2980
MH2980
6036, 6042, 8042, 10042, 10054 10-5

10.4 STABIL-TRAK™ OPERATION

H 7
10.4.1 Understanding Stabil-TRAK™ System G
F
The following is a description of modes in the patented
E
Stabil-TRAK™system. The vehicle may operate in any 5 D
one of the following modes.
C
8 B
8
A
7
5
6 6
OH0603
OH0703
Model 10054 has an additional boom extend interlock
system. This system prevents boom from being extended
a. Free Pivot Mode beyond a point between “E” and “F” boom extend letters
Boom below 40° (5), Stabil-TRAK™system is in FREE (approximately 40' [12 m]), unless both outriggers have
PIVOT MODE (6). Rear axle is allowed to pivot freely. been lowered onto solid terrain.
Frame level control will function normally with or without Once this system has been activated, vehicle will
outriggers down. Stabil-TRAK indicator will be OFF (7). automatically place Stabil-TRAK™system in LOCKED
MODE. System will remain in LOCKED MODE, until
b. Slow Pivot Mode boom has been retracted. (Refer to Section 10.6, “Boom
Boom above 40° (5), Stabil-TRAK™system is now in Extend Interlock System Operation (10054 Only)”, for
SLOW PIVOT MODE (8). In this mode, rear axle is more information.)
UNLOCKED and is allowed to pivot, but will respond Frame level control will function slower than normal in this
SLOWLY to changes in terrain. Stabil-TRAK™indicator mode with or without the outriggers down.
(7) will be OFF when:
• Transmission is in gear
• Service brake is disengaged
Frame level control function will act normally in this mode.
c. Locked Mode
With boom above 40° (5) and by activating one or more
of functions (as follows), Stabil-TRAK™system is in
LOCKED 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 control lever in (N) Neutral
• Depressing and holding service brake pedal
10-6 6036, 6042, 8042, 10042, 10054

10.4.2 Stabil-TRAK™ Solenoid Valves 10.4.3 Logic Wiring Harness (10054 Only)
There are five Stabil-TRAK™solenoid valves installed in The Model 10054 uses an additional logic wiring harness,
the Stabil-TRAK™manifold, attached to the stabilizer that includes all wiring, fuses and relays needed for the
cylinder above the left side of the rear axle. operation of the boom interlock, Stabil-TRAK™and
If a solenoid valve is suspected of malfunctioning, outrigger systems.
disconnect the coil wiring lead and test the coil for proper The logic harness has a fuse panel (1) that is attached to
resistance (7-9 ohms) and for proper voltage from the the fuse panel (2) from cab harness. The logic harness
harness (12 VDC). Replace the solenoid coil if open or includes all the additional relays (3 through 10) and fuses
shorted to ground. (11 and 12) required for the operation of the boom
Also inspect the valve cartridge, o-rings, and the other interlock, Stabil-TRAK™and outrigger systems.
hydraulic and electrical components in the circuit to Refer to Section 10.9, “Stabil-TRAK™Boom Interlock
accurately determine the cause of the problem. Electrical Circuit Operation and Troubleshooting
All solenoid coils are identical and can be interchanged (10054),” for electrical troubleshooting information.
for diagnostic purposes.
7.5 7.5
3 6
20 10
10
4 7
10
16 15
5 8
18 10
14
7.5 7.5
15
9
40 7.5
17
10
11
MT3131 2 1
12
MH4111
Note: DO NOT interchange solenoid valves 4A (14),

4B (15), 12A (16) or 12B (17) with solenoid valve 3 (18). No. Volt Circuit Protected
These valves will fit into the other locations, but are 3 12 Volt Park Brake Interlock Relay
configured differently internally and will not operate 4 12 Volt Boom Extend Relay
properly if interchanged. Outrigger Lockout Relay (SN 13198 through 17984)
5 12 Volt
Cartridge valves 4A (14), 4B (15), 12A (16) and Blank (SN 17985 & After)
12B (17) are identical and can be interchanged for 6 12 Volt Stabil-TRAK Interlock Relay
diagnostic proposes. 7 12 Volt Stabil-TRAK Lock Up Relay
Note: Make sure 0.060 orifices are in place when 8 12 Volt Boom Extend Interlock Relay
installing solenoid valves 4A (14) and 4B (15). 9 12 Volt Right Outrigger Lock Relay
In general, if there is a problem with the Stabil-TRAK™ 10 12 Volt Left Outrigger Lock Relay
system beyond common electrical troubles, the involved 7.5
11 Boom/Outrigger Interlock
electrical and hydraulic circuits should each be checked Amp
and the exact source of the problem diagnosed before 7.5
12 Boom/Outrigger Interlock
any parts are replaced. Amp
6036, 6042, 8042, 10042, 10054 10-7

10.4.4 Relay Testing 10.4.5 Outrigger Pressure Switches

If after checking the electrical system, a relay is suspect,
(10054 Only)
test the relay as follows:
a. Testing
machine, fully retract the boom, lower the boom, If after checking the electrical system, a pressure switch
place the travel select lever in the (N) NEUTRAL is suspect, test the switch as follows:
position, engage the parking brake, straighten all
2. Place a Do Not Operate Tag on both the ignition key place the travel select lever in the (N) NEUTRAL
switch and steering wheel, stating that the machine position, engage the parking brake, straighten all
2. Lower the outriggers onto firm terrain, and shut the
4. Properly disconnect the battery. engine OFF.
19
18
15
14
OH2431
5. Fuse block relays (3 through 10) are located in fuse

block and is mounted behind right side console
access panel (14). To gain access, remove
screws (15) that secure right side panel in place.
16 86 87
87A 17
85
30
MN1820
MH4121
6. Remove suspect relay from fuse panel.

4. Disconnect the pressure switch wiring connector
7. Apply proper voltage to relay coil at terminal 86 (16) (18) from the harness connector (19).
and attach the ground (-) probe to terminal 85 (17),
ground. An audible click should be heard indicating 5. Check for continuity across the red and black wires at
that relay is functioning properly. the pressure switch wiring connector (18). If there is
8. When reassembling right side console access panel no continuity across the red and black wires, replace
(14), torque screws (15) to 3–5 lb-ft (13–22 Nm). the switch.
9. Properly connect the battery. 6. Remove Do Not Operate Tags from both ignition key
switch and steering wheel when done.
10. Close and secure rear engine compartment door.
10-8 6036, 6042, 8042, 10042, 10054

b. Removal 10.5 BOOM EXTEND INTERLOCK

1. Park the machine on a firm, level surface, level the SYSTEM DESCRIPTION
place the travel select lever in the (N) NEUTRAL Note: The boom interlock system is used only on the
position, engage the parking brake, straighten all Model 10054.
Boom extend interlock system is designed to provide
2. Lower the outriggers onto firm terrain, and shut the additional stability, allowing boom to be extended to its
engine OFF. maximum limits. Appropriate Operation and Safety
3. Place a Do Not Operate Tag on both the ignition key Manual contains boom extend interlock basic
switch and steering wheel, stating that the machine information. A copy of Operation and Safety Manual
should not be operated. should always be available in storage compartment
4. Open the rear door. Allow the system fluids to cool. located in cab.
6. Disconnect the pressure switch wiring connector 2
(18) from the harness connector (19)
20
MH2950
MH4131
~
7. Remove the outrigger pressure switch (20) from the
outrigger cylinder.
8. Wipe up any spilled hydraulic oil. MH4100
The interlock system operates via an interface between the

c. Installation
outrigger pressure switches (1), boom extend sensor (2),
1. Install pressure switch (20), and torque to 25–38 lb-ft boom lockout valve (3) and the logic wiring harness.
(34–41 Nm).
Boom extend interlock system can only be activated
2. Connect the pressure switch wiring connector (18) to when both outriggers are lowered onto firm terrain. Once
the harness connector (19). boom extend interlock system has been activated,
3. Properly connect the battery. vehicle will automatically place Stabil-TRAK™system in
4. Close and secure rear engine compartment door. LOCKED MODE. The Stabil-TRAK™system will remain
5. Remove the Do Not Operate Tags from both the in LOCKED MODE, until boom has been retracted.
ignition key switch and the steering wheel. (Refer to Section 10.4, “Stabil-TRAK™Operation,” for
more information.)
6036, 6042, 8042, 10042, 10054 10-9

10.6 BOOM EXTEND INTERLOCK

SYSTEM OPERATION (10054 ONLY) H
G 8
The ultimate purpose of this system is to add an extra 6 F
measure of stability, allowing the boom to be extended to E
its maximum limits. The boom extend interlock system D
may operate in one of the two following modes: C
B
10.6.1 Extend Interlock Mode A
EXTEND INTERLOCK MODE, limits boom extension (4)
7
to a point after letter “E” has appeared on side of boom
and before letter “F” appears. A sensor in boom will
automatically STOP boom from extending past this point
until outriggers have been lowered onto firm terrain.
Retract function will still operate normally in this mode.
OH0644
H
G
10.6.2 Outrigger Interlock Mode
F OUTRIGGER INTERLOCK MODE, allows for full boom
extension (6) only as long as both outriggers (7) have
4 E
been lowered onto firm terrain (outriggers DOWN). Once
D this condition is met, the boom is allowed to extend to its
C full limits.
B As the boom is extended past the “F” boom extend letter,
A the vehicle will automatically place the Stabil-TRAK™
system in the LOCKED MODE. It will remain in this mode
until the boom has been retracted to a point where the
5 boom extend sensor is activated.
With outrigger interlock engaged additional systems are
automatically activated that enhance stability of vehicle:
• Stabil-TRAK is in the LOCKED Mode.
• Transmission has been DECLUTCHED.
OH0633 • Parking brake is ENGAGED.
• Outrigger RAISE function is inoperable.
With the outriggers RAISED (5) and the boom inside of
the extension limit (4) the vehicle will function normally. • Stabil-TRAK light will be ON (8)
The Stabil-TRAK system will perform as designed. Other effects you will experience while the outrigger
Note: As an added measure of safety, ALWAYS interlock is engaged:
remember to shift the Travel Select Lever to the (N) • With Stabil-TRAK active, frame level will be slower
NEUTRAL position, move the neutral lock lever to than normal.
NEUTRAL LOCK position, and engage the park brake
• Outriggers are still allowed to lower to adjust for any
when lowering the outriggers. changes in outrigger footing.
Not until the boom has been retracted past the extension
limit will any of these conditions change.
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.
10-10 6036, 6042, 8042, 10042, 10054

10.7 STABIL-TRAK™ SYSTEM TEST 10.7.2 Stabil-TRAK™ System

Test Procedures
Note: The operator must know that the Stabil-TRAK™
If Steps 1 through 9 prove positive, the Stabil-TRAK™
system is active and functioning properly.
system is functioning properly, and vehicle can be
To test the function of the Stabil-TRAK™system, read returned to service. If any of these steps indicate that the
the Stabil-TRAK™System Test instructions and follow Stabil-TRAK™system is not functioning properly, follow
Steps 1 through 9 of Section 10.7.2, “Stabil-TRAK™ procedures in Section 10.11, “Stabil-TRAK™Hydraulic
System Test Procedures.” Circuit Operation and Troubleshooting,” to repair system.
10.7.1 Stabil-TRAK™ System Test

Instructions
• Test the Stabil-TRAK™system with the vehicle
on a level surface.
• Remove any attachment from the quick attach
before performing the test.
• DO NOT extend the boom at any time during the
test. Perform the test with the boom fully retracted.
• DO NOT raise the boom above 60° for Steps 3-6.
• DO NOT raise the boom above 45° for Steps 7-9.
• Follow Steps 1 through 9 of the Stabil-TRAK™
system test procedure exactly as written.
Note: If the Stabil-TRAK™ light goes OFF and the front
left tire lowers to the ground at any time during Steps 4
through 7, the test was not performed properly or the
Stabil-TRAK™ system is not functioning properly.
Carefully repeat the steps starting with Step 1.
If Stabil-TRAK™light goes OFF and front left tire lowers
to ground consistently during Steps 4 through 7, the
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.
6036, 6042, 8042, 10042, 10054 10-11

Stabil-TRAK System Test Procedures
Step 1
a. Place the vehicle on a level surface with 0° level.
b. Have the boom fully retracted and horizontal.
c. Place an 8in (203 mm) wood or cement block in front of the front left tire.
d. Enter the vehicle.
e. Fasten the seat belt.
f. Turn the key to the RUN position.
FREE PIVOT MODE
g. Check to be sure the Stabil-TRAK™light is OFF.
OH2500
Step 2
a. Start the engine.
b. Turn the parking brake switch OFF.
c. Move the range select lever to (1) FIRST gear.
d. Move the travel select lever to the (F) FORWARD position.
e. Drive the vehicle up on the block.
f. Use the frame level control to level the vehicle back to 0°.
Step 3
a. Depress the service brake pedal.
b. Move the travel select lever to the (N) NEUTRAL position.
c. Raise the boom to exactly 60°. The Stabil-TRAK™light should come ON when the boom angle is at
Service Brake Test
about 40° and remain ON.

Step 4
a. Use your left foot to depress the service brake pedal.
b. With range select lever in (2) SECOND gear, move travel select lever to (R) REVERSE position.
c. Ease your left foot partially off the service brake pedal, make sure that the Stabil-TRAK™light
remains ON.
d. With your right foot, increase the engine rpm slightly, as necessary, just enough to back the vehicle
LOCKED MODE
off the block. While backing off the block, the front left tire should remain off the ground.
IMPORTANT: Perform Steps 5 thru 9 with the engine rpm at idle.
Step 5
a. Keep the service brake pedal depressed.
b. Move the travel select lever to the (N) NEUTRAL position.
Neutral Test
c. Take your foot off the service brake pedal. The Stabil-TRAK™light should remain ON and the front
left tire should remain off the ground.
Step 6
Park Brake Test
a. With the travel select lever in the (N) NEUTRAL position, engage the parking brake switch.
b. Move the travel select lever to the (F) FORWARD position. The Stabil-TRAK™light should remain
ON and the front left tire should remain off the ground.
10-12 6036, 6042, 8042, 10042, 10054

Stabil-TRAK System Test Procedures
Step 7
a. With the parking brake switch ON, move the travel select lever to the (N) NEUTRAL position.
b. Lower the boom to exactly 45°.
c. Frame level the vehicle no more than 5° to the left.
d. Frame level the vehicle back to 0°.
e. Frame level the vehicle no more than 5° to the right.
LOCKED MODE
Note: Observe that frame level will be slower than normal during this test.
f. The Stabil-TRAK™light should remain ON and the front left tire should remain off the ground. The
front left tire should not raise or lower during frame level.
g. Frame level back toward 0°, leaving the vehicle leveled to the right approximately 1° to 2°.
Step 8
a. Depress the service brake pedal.
b. Disengage the parking brake switch.
c. With the range select lever in (1) FIRST gear, move the travel select lever to the (R) REVERSE
position.
d. Release the service brake pedal to deactivate the Stabil-TRAK™system.
PIVOT
SLOW
MODE
e. The Stabil-TRAK™light should go OFF.

f. The front left tire should return to the ground while the vehicle travels in reverse.
g. Depress the service brake pedal to stop the vehicle.
LOCKED
Step 9
MODE
a. With the service brake pedal depressed and the boom angle exactly 45° move the range select
lever to (3) THIRD gear.
b. Move the travel select lever to (F) FORWARD.
c. Release the service brake pedal to deactivate the Stabil-TRAK™system. The Stabil-TRAK™light
should go OFF.
d. Slowly drive the vehicle forward against the block to stop the vehicle from moving forward.
e. With the front left tire against the block, frame level the vehicle no more than 5° to the left.
f. Check that front left tire remains on ground. It is normal for front left tire to raise slightly when
SLOW PIVOT MODE
leveling to left, but tire should immediately lower when frame level function is stopped.
g. Frame level the vehicle back to 0° and pause briefly.
h. Frame level the vehicle no more than 5° to the right.
i. Check that the front right tire remains on the ground. It is normal for the front right tire to raise
slightly when leveling to the right, but the tire should immediately lower when the frame level function
is stopped.
j. Frame level the vehicle back to 0°.
k. Depress the service brake pedal.
l. Shift the travel select lever to (N) NEUTRAL.
m. Lower the boom.
6036, 6042, 8042, 10042, 10054 10-13

10.8 STABIL-TRAK™ BOOM INTERLOCK ELECTRICAL CIRCUIT OPERATION AND

TROUBLESHOOTING (6042/8042/10042)
Note: Before using the 6042, 8042 and 10042 Stabil-
TRAK System Troubleshooting chart and diagrams,
complete the Section 10.7.2, “Stabil-TRAK™ System
Test Procedures,” to determine what part of the system
is not functioning properly.
6042, 8042 and 10042 Stabil-TRAK™ System Troubleshooting

FREE PIVOT SLOW PIVOT LOCKED
MODE MODE MODE
Refer to Section , “6042, 8042 Refer to Section , “6042, 8042
Refer to Section , “6042, 8042
and 10042 Stabil-TRAK™Elec- and 10042 Stabil-TRAK™Elec-
and 10042 Stabil-TRAK™Elec-
trical Circuit FREE PIVOT trical Circuit SLOW PIVOT
trical Circuit LOCKED MODE.”
Mode.” Mode.”
Machine Ignition On Ignition On Ignition On
Conditions Boom Below 40° Boom Above 40° Boom Above 40°
Switch/ Boom Retracted Boom Extended Boom Extended
Relay PB & SB Released PB & SB Released PB & SB Applied
Solenoid Trans. in Forward or Reverse Trans. in Forward or Reverse & Trans. in Neutral
Solenoid 12A E DE DE
Solenoid 12B E DE DE
Solenoid 3 DE DE E
Solenoid 4A DE E DE
Solenoid 4B DE E DE
Boom Angle Sensor C O O
Boom Switch Relay E DE DE
Stabilizer Lock Relay DE DE E
Stabilizer Light OFF (DE) OFF (DE) ON (E)
Ignition Switch C C C
Park Brake Switch O O C
Service Brake Switch O O C
Secondary Function Manifold
E E DE
Park Brake Solenoids
Park Brake Disengage Relay E E DE
Neutral Start Relay DE DE E
Definitions:
PB = Park Brake
SB = Service Brake
DE = De-energized
E = Energized
C = Closed
O = Open
10-14 6036, 6042, 8042, 10042, 10054

+ +
10A 40A 7.5A 10A 7.5A 10A 10A
C
26A 46 O 24
Ignition Switch
3C 7
To Boom + 39
Service Angle 10
Horn
Brake Sensor -
Switch
BLU
Electrical Circuit
BRN
BLK 114B
24A C
FREE PIVOT Mode
34
42A 157
1 A B C 30
To 30 86 Stabilizer
86 Back-Up
Fuel 10 Lock
Alarm 30
Shutoff 85 Relay 48 86
45B 85 Relay 35 2T 87A 87 Boom
O 87A 87 Switch
6036, 6042, 8042, 10042, 10054

47 85 Relay
Park 87A 87
2BB 31 DE
1 Brake
153A 2CC 40B
Switch To 35
2 Back-Up 28 E
40
Alarm 2AA
41B 152B
6042, 8042 and 10042 Stabil-TRAK™
111 114B 40
40A DE
152A1 47
45A2 45 45 28
41A 45 114 1
102B 111
To 2HH Stabilizer
47 28
Instrument 153 Light
47A 47B 40
Panel 28A 28B
E 111
107A 107B 111A SOL. SOL.
41 113A
4A 4B SOL.
30 30 3
86 Park 86 SOL. SOL.
41
Neutral 12A 12B
Brake Start
Disengage DE
41B 41A 85 85 Relay DE
87A 87 Relay 87A 87 114A
Secondary
2K E
Conditions
Function 2M 2N
PB B PB A Manifold 113B 106 DE 2T
113 2FF 2CC
Park Brake 2L 2P
FREE PIVOT MODE
Solenoids To
E 2HH 2EE 112A Starter
E
2F 2E 114A
112

2D
DIODE PACK DIODE PACK
CONSOLE/
STABILIZER
112 113 & ENGINE 104A 150A 101A 2DD RELAY LOCATIONS
1. Ignition “ON”
HARNESS
9 CONNECTORS 105A 103A 102A
B+ 153
3. Boom Retracted
2. Boom Below 40°
8 105 105
FORWARD GEAR 150 105 Transmission Outrigger
7 101 101 Headlight
GEAR 103 101 Switch 7.5 7.5
6 150 150 Relay Optional
F GEAR 105 150
Lights 1 Washer/Wiper
5
N GEAR 101 20 10
R 4
NEUTRAL 112 103 103 103 Stabilizer
3 Light Park Brake
REVERSE 102A 102 102 10
SHIFTER 102 102 Switch Disengage
REVERSE ZF 2 FORWARD Relay Relay Steer Select
104 104 104 104 Switch
TRANSMISSION
1 E
B+ 113 10
Horn/Heater
Stabilizer Neutral
Lock Start 15
Relay Relay Instrument
LEGEND DE DE Panel
10
DE = De-energized 7
2J Light Swtch
Boom Back-up Relay
E = Energized 1
4. PB & SB Released
104B Upper Y1 Y3 Y2 Switch Alarm

3 Y1 Y3 Y2 Transmission Relay Relay
7.5
O = Open 103B
Connectors Main
2 E
C = Closed 102B
ZF Transmission WG 98
40
= Active Circuit (Heavy Line) 4
105B
Lower
= Inline Harness Connection 5
101B Y6 Y5 Y4 Transmission
5. Transmission in Fwd. or Rev.
6 Connectors
= Component/Bulkhead Connection 150B Y6 Y5 Y4
7
2H
MH5740
10-15
+ +
10A 40A 7.5A 10A 7.5A 10A 10A
C
10-16
26A 46 O 24
Ignition Switch
3C 7
To Boom + 39
Service Angle 10
Horn
Brake Sensor -
Switch
BLU
BRN
Conditions
BLK 114B
24A O
34
42A 157
SLOW PIVOT MODE
1 A B C 30
To 30 86 Stabilizer
86 Back-Up
Fuel 10 Lock
Alarm 30
O 87A 87 Switch
47 85 Relay
Park 87A 87
2BB 31 DE
1 Brake
153A 2CC 40B
Switch To 35
2 Back-Up 28 DE
40
Alarm 2AA
41B 152B
111 114B 40
40A DE
152A1 47
45A2 45 45 28
3. Boom Extended
41A 45 114 1
2. Boom Above 40°
102B 111
To 2HH Stabilizer
47 28
47A 47B 40
Panel 28A 28B
E 111
107A 107B 111A SOL. SOL.
41 113A
4A 4B SOL.
30 30 3
41
Neutral 12A 12B
Brake Start
Disengage DE
41B 41A 85 85 Relay E
87A 87 Relay 87A 87 114A
Secondary
Function 2M 2N 2K DE
PB B PB A Manifold 113B 106 DE 2T
113 2FF 2CC
Park Brake 2L 2P
Solenoids To
E 2HH 2EE 112A Starter
E
2F 2E 114A
112

4. PB & SB Released
2D
CONSOLE/
STABILIZER
HARNESS
B+ 153
8 105 105 Outrigger
FORWARD GEAR 150 105 Transmission
Headlight
7 101 101 7.5 7.5
GEAR 103 101 Switch
150 150 Relay Optional
6 150
F GEAR 105 Lights 1 Washer/Wiper
5
N GEAR 101 20 10
R 4
NEUTRAL 112 103 103 Stabilizer
103
3 Light Park Brake
SHIFTER REVERSE 102A 102 102 Switch Disengage 10
102 102
ZF 2 Relay Relay Steer Select
REVERSE FORWARD 104 104 104 Switch
TRANSMISSION 104
1 E
B+ 113 10
Horn/Heater
Stabilizer Neutral
Lock Start 15
LEGEND DE DE Panel
10
DE = De-energized 7 Light Swtch
2J Relay
1
Boom Back-up
E = Energized Upper
104B Y1 Y3 Y2 Switch Alarm 7.5
3 Y1 Y3 Y2 Transmission Relay Relay
O = Open 103B
Connectors Main
2 DE
C = Closed 102B 40
4
= Active Circuit (Heavy Line) 105B
Lower
6 Connectors
7
Electrical Circuit
SLOW PIVOT Mode
2H
MH5760
6042, 8042 and 10042 Stabil-TRAK™
6036, 6042, 8042, 10042, 10054

+ +
10A 40A 7.5A 10A 7.5A 10A 10A
C
26A 46 24
Ignition Switch C
3C 7
To Boom + 39
Service Angle 10
Horn
Brake Sensor -
Switch LOCKED MODE
BLU
BRN
Electrical Circuit
BLK 114B
24A O
34
42A 157
1 A B C 30
To 30 86 Stabilizer
86 Back-Up
Fuel 10 Lock
Alarm 30
87A 87 Switch
C
6036, 6042, 8042, 10042, 10054

47 85 Relay
Park 87A 87
2BB 31 E
1 Brake
153A 2CC 40B
Switch To 35
2 Back-Up 28 DE
40
Alarm 2AA
41B 152B
6042, 8042 and 10042 Stabil-TRAK™
111 114B 40
40A E
152A1 47
45A2 45 45 28
41A 45 114 1
102B 111
To 2HH Stabilizer
47 28
47A 47B 40
Panel 28A 28B
DE 111
107A 107B 111A SOL. SOL.
41 113A
4A 4B SOL.
30 30 3
41
Neutral 12A 12B
Brake Start
Disengage E
41B 41A 85 85 Relay DE
87A 87 Relay 87A 87 114A
Secondary
2K DE
Conditions
Function 2M 2N
PB B PB A Manifold 113B 106 E 2T
113 2FF 2CC
LOCKED MODE
Park Brake 2L 2P
Solenoids To
DE 2HH 2EE 112A Starter
DE
2F 2E 114A
112

2D
CONSOLE/
STABILIZER
HARNESS
B+ 153
3. Boom Extended
8
2. Boom Above 40°
GEAR 150 105 105 105 Transmission Outrigger

FORWARD
Headlight
7 101 101 7.5 7.5
GEAR 103 101 Switch
6 150 150 Relay Optional
F GEAR 105 150 Lights 1 Washer/Wiper
5
N GEAR 101 20 10
R 4
NEUTRAL 112 103 103 Stabilizer
103
3 Light Park Brake
REVERSE 102A 102 102 Switch Disengage 10
SHIFTER 102 102
ZF 2 Relay Relay Steer Select
REVERSE FORWARD 104 104 104 Switch
TRANSMISSION 104 DE
1
B+ 113 10
Horn/Heater
Stabilizer Neutral
Lock Start 15
LEGEND E E Panel
10
DE = De-energized 7 Light Swtch
4. PB & SB Applied
2J Relay
E = Energized 1
Boom Back-up
104B Upper Y1 Y3 Y2 Switch Alarm
Relay Relay
7.5
O = Open 3 Y1 Y3 Y2 Transmission
103B
Connectors Main
2 DE
C = Closed 102B
5. Transmission in Neutral
40
4
= Active Circuit (Heavy Line) 105B
Lower
6 Connectors
7
2H
MH5770
10-17
10.9 STABIL-TRAK™ BOOM INTERLOCK ELECTRICAL CIRCUIT OPERATION AND

TROUBLESHOOTING (10054)
Note: Before using the 10054 Stabil-TRAK System
Troubleshooting chart and diagrams, complete Section
10.7.2, “Stabil-TRAK™ System Test Procedures,” and
Section 10.10, “Boom/Outrigger Interlock System Test,”,
to determine what part of the system is not functioning
properly.
10054 Stabil-TRAK™ System Troubleshooting

BOOM EXTEND MODE 1 BOOM EXTEND MODE 2 BOOM EXTEND MODE 3
Refer to the mode Section Refer to the mode Section
Refer to the mode Section , “10054
, “10054 Stabil-TRAK™ , “10054 Stabil-TRAK™
Stabil-TRAK™ Electrical Circuit
Electrical Circuit Boom Electrical Circuit Boom
Boom Extend Mode 3.”
Extend Mode 1.” Extend Mode 2.”
Ignition On Ignition On
Machine Ignition On
Boom Below 40° Boom Below 40°
Conditions Boom Below 40°
Boom Extended To Boom Extended Beyond
Boom Retracted
Switch/ 42 Series Extension Limit 42 Series Extension Limit
PB Released
Relay PB Released PB Applied By Interlock Sys.
Trans. Fwd. or Rev.
Solenoid Trans. Fwd. or Rev. Trans. In Neutral By Interlock Sys.
Outriggers Raised
Outriggers Raised Outriggers Lowered
Solenoid 12A E E DE
Stabil-TRAK Components Affected By
Solenoid 12B E E DE
Solenoid 3 DE DE E
Boom Interlock System
Solenoid 4A DE DE DE
Solenoid 4B DE DE DE
Boom Angle Sensor C C O
Boom Switch Relay E E DE
Stabilizer Lock Relay DE DE E
Stabilizer Light OFF (DE) OFF (DE) ON (E)
Ignition Switch C C C
Park Brake Switch O O O
Park Brake Light OFF (DE) OFF (DE) ON (E)
BOOM EXTEND INTERLOCK SYSTEM TROUBLESHOOTING
Boom Extend Interlock Sensor C O O
Boom Extend Interlock Relay E DE DE
Boom Extend Lockout Relay E DE DE
Outrigger Pressure Switches O O C
Left Outrigger Lockout Relay DE E E
Right Outrigger Lockout Relay DE E E
Stabilizer Interlock Relay DE DE E
Stabilizer Lock-Up Relay DE DE E
Extend Circuit Solenoid Valve E E E
Secondary Function Manifold
E E DE
Park Brake Solenoids
Park Brake Interlock Relay DE DE E
Park Brake Disengage Relay E E DE
10-18 6036, 6042, 8042, 10042, 10054

Note: If an outrigger is raised or a pressure switch is

defective, boom on the 10054 will not extend beyond the H
42 Series extension limit. G
Definitions: F
Boom Retracted = Less than 42 Series extension limit E
Boom Extended = Boom at 42 Series extension limit or it D
m
greater (See Figure at Right). Li C
B
n
PB = Park Brake
io
A
ns
DE = De-energized
42 Series Exte
E = Energized
C = Closed
O = Open
MH6110
6036, 6042, 8042, 10042, 10054 10-19

+ 3
+
3B 3 3C O
10A 40A 7.5A 7.5A 10A 10A 7.5A
10-20
C
To C
Boom + + Boom
26A 3C Horn Angle Extend
Ignition Switch 24 3A 3B Left Right
7 Sensor - - Interlock
39 Sensor Outrigger Outrigger
BLU 10 7.5A 7.5A Cylinder Cylinder
BLU
BRN BRN Pressure Pressure
24A BLK BLK
60A 56A Switch Switch
C
O E 57
60
42A 1 60B 60E Right 56
34 A B C A B C 56
30 49 Outrigger
86 Back-Up DE Left 50C
Park Stabilizer Outrigger Switch
Brake Alarm Boom 2R
1 To 85 Relay Lock 30
Switch
Switch 87A 87 7 Relay 86 Switch
Fuel Relay E
Boom Extend Mode 1
30 64
2 Shutoff 2BB 31 86 Stabilizer 30
85 48 86 62
Lock-Up 87A 87 65A 58
152B To 85 Relay DE 68
153A 87A 87 30
Back-Up 35 85 86 Boom
87A 87 56
Alarm Extend
45A 40B 23 Lockout
85
28 66 87A 87 Relay
45B 35
41B
47 2B2 50C
2B3 55
50B
152A1 67
30
Boom 86
Extend
2C1 50B 71
Interlock 71A DE
10054 Stabil-TRAK™ Electrical Circuit
85
152A2 Relay 87A 87
152A 30
86 2CC
152A3 70C Stabilizer 2T 71B
DE
Interlock
E 30
85 Relay 71 DE 86 Right
1 87A 87 2AA 58 Outrigger
111 40
70A Park Brake 40A 65A Lock
85
Light 114B 30 87A 87 Relay
DE DE 86 Left
2HH 102B
2C2 Outrigger
52 Lock
85
70B 1 87A 87 Relay
28
30
86 Park 45A2 45 45 Stabilizer 2A1
Brake 45 114 47
DE 28 2A2
Interlock Light
MODE 1
85 61
87A 87 Relay 153 63
Conditions
111 47 28A 28B

E 2A3
51A 51B 107B 113A 47A 47B 40
2B2 30 SOL. SOL.
86 Park SOL. SOL. 12A 12B
51 Brake 4A 4B 62
Disengage 64
85 114A
51C 51D Secondary 87A 87 Relay 2B3
Function E
DE Extend Left Left Right Right
Manifold 113B 40 Circuit Outrigger Outrigger Outrigger Outrigger
113 2L 2P Solenoid DOWN UP DOWN UP
PB B PB A Park Valve
2M 2N Solenoid Solenoid Solenoid Solenoid
Brake
2EE 2D 2E 2F 2G
Solenoids SOL. 2H
3
E
114A E
2K1 2K2 112
DE
2K

3. Boom Retracted
2. Boom Below 40°
2D
DIODE PACK DIODE PACK RELAY LOCATIONS
CONSOLE/
STABILIZER
112 113 & ENGINE 104A 150A 101A 2DD
Transmission Open Fuse
HARNESS Headlight Park Brake Stabilizer
9 CONNECTORS 105A 103A 102A Switch 7.5 7.5 Interlock Interlock
B+ 153
Relay Optional Relay Relay
8 105 105
FORWARD GEAR 150 105 Lights 1 Washer/Wiper DE DE
7 101 101
GEAR 103 101 20 10
6 150 150 150
F GEAR 105 Stabilizer Boom Stabilizer
5 Light Park Brake Extend
N GEAR 101 10 Lock Up
Switch Disengage Lockout
4 Relay Relay Steer Select Relay
R NEUTRAL 112 103 103 Relay
103 Switch E
3 E DE
REVERSE 102A 102 102
SHIFTER 102 102 10
REVERSE ZF 2 FORWARD 104 104 104 104
TRANSMISSION
1 Horn/Heater Boom
B+ 113 Stabilizer Neutral
Lock Start 15 Extend
Relay Relay Interlock
Instrument Relay
DE DE Panel E
LEGEND 10
4. PB Released
Light Swtch
DE = De-energized Boom Back-up Relay 7.5 Right
Switch Alarm Boom/Outrigger Outrigger
7 7.5 Lock
E 2J Relay Relay Interlock
6. Outriggers Raised
= Energized Relay
1 Upper Main
104B Y1 Y3 Y2 E 7.5 DE
O = Open 3 Y1 Y3 Y2 Transmission 40
103B Boom/Outrigger
C = Closed 2
Connectors Interlock
102B
= Active Circuit (Heavy Line) ZF Transmission WG 98 Left
4
105B Outrigger
Lower Lock
101B Y6 Y5 Y4 Transmission Relay
6
Connectors Y6 Y5 Y4
DE
= Component/Bulkhead Connection 150B
7
2H
MH5861
6036, 6042, 8042, 10042, 10054

+ 3
+
3B 3 3C O
10A 40A 7.5A 7.5A 10A 10A 7.5A
C O
To
Boom + + Boom
39 Sensor Outrigger Outrigger MODE 2
BLU
Conditions
24A BLK BLK
C 60A 56A Switch Switch
O E 57
60
42A 1 60B 60E Right 56
34 A B C A B C 56
30 49 Outrigger
86 Back-Up DE Left 50C
Brake Alarm Boom 2R
1 To 85 Relay Lock 30
Switch
Switch 87A 87 7 Relay 86 Switch
Fuel Relay DE
30 64
2 Shutoff 86 Stabilizer 30
2BB 31 85 48 86 62
Lock-Up 87A 87 65A 58
152B To 85 Relay DE 68
87A 87 35 85 30
153A Back-Up 87A 87 86 Boom
56
Extend
6036, 6042, 8042, 10042, 10054

Alarm 40B 23 Lockout
45A 85
87A 87 Relay
35 28 66
41B 45B
47 2B2 50C
2B3
2. Boom Below 40°
50B 55
152A1 67
30
Boom 86
Extend
2C1 50B 71
Interlock
85 71A E
152A2 Relay 87A 87
152A 30
86 2CC
152A3 70C Stabilizer 2T 71B
DE
Interlock
DE 30
85 Relay 71 E 86 Right
111 40
85
3. Boom Ext. To 42 Foot Ext. Limit
DE DE 86 Left
2HH 102B
2C2 Outrigger
52 Lock
85
70B 1 87A 87 Relay
28
30
Brake 45 114 47
DE 28 2A2
Interlock Light
85 61
87A 87 Relay 153 63
111 47 28A 28B
E 2A3
51A 51B 107B 113A 47A 47B 40
2B2 30 SOL. SOL.
51 Brake 4A 4B 62
Disengage 2B3 64
85 114A
51C 51D Secondary 87A 87 Relay
E
Function DE Extend Left Left Right Right
4. PB Released
Brake 2EE
Solenoids SOL. 2H 2D 2E 2F 2G
3
E
6. Outriggers Raised
114A E
2K1 2K2 112
2K DE

2D
CONSOLE/
STABILIZER
112 113 & ENGINE 104A 150A 101A 2DD
B+ 153
8 105 105
FORWARD GEAR 150 105 Lights 1 Washer/Wiper DE DE
7 101 101
GEAR 103 101 20 10
6 150 150 150
103 Switch DE
3 E DE
SHIFTER 102 102 10
TRANSMISSION
1 Horn/Heater Boom
Instrument Relay
DE DE Panel DE
LEGEND 10
Light Swtch
7 7.5 Lock
E = Energized 2J Relay Relay Interlock
Main Relay
1 Upper
104B Y1 Y3 Y2 E 7.5 DE
O = Open Y1 Y3 Y2
3 Transmission 40 Boom/Outrigger
103B
C = Closed 2
102B
4
105B Outrigger
Lower Lock
101B Y6 Y5 Y4 Transmission Relay
6 Connectors DE
7
2H
MH5871
10-21
Boom Extend Mode 2
+ 3
+
3B 3 3C C
10A 40A 7.5A 7.5A 10A 10A 7.5A
10-22
C O
To
Boom + + Boom
39 Sensor Outrigger Outrigger
42A BLU
24A O BLK BLK
60A 56A Switch Switch
O DE 57
60
1 60B 60E Right 56
34 A B C A B C 56
30 49 Outrigger
86 Back-Up E Left 50C
Brake Alarm Boom 2R
1 To 85 Relay Lock 30 Switch Switch
Switch 87A 87 7 Relay 86 DE
Boom Extend Mode 3
Fuel Relay
30 64
2 Shutoff 86 Stabilizer 30
2BB 31 85 48 86 62
Lock-Up 87A 87 65A 58
153A 85 Relay E 68
152B To 87A 87 30
35 85 86 Boom
Back-Up 87A 87 56
Extend
Alarm 40B 23 Lockout
45A 85
28 66 87A 87 Relay
45B 35
47 2B2 50C
41B 2B3
55
50B
152A1 67
30
Boom 86
Extend 50A
2C1 50B 71
Interlock
85 71A E
152A2 Relay 87A 87
152A 30
86 2CC
70C Stabilizer 2T 71B
E 152A3 Interlock
DE 30
85 Relay 71 E 86 Right
111 40
85
2HH E E 86 Left
102B Outrigger
2C2
52 Lock
85
70B 1 87A 87 Relay
28
MODE 3
30
Conditions
Brake 45 114 47
E 28 2A2
Interlock Light
85 61
87A 87 Relay 153 63
111 47 28A 28B
DE 2A3
51A 51B 107B 113A 47A 47B 40
2B2 30 SOL. SOL.
51 Brake 4A 4B 62
Disengage 64
85 114A Outrigger 2B3
51C 51D Secondary 87A 87 Relay
DE
Lockout
Function DE Relay Extend Left Left Right Right
Brake 2EE DE
Solenoids SOL. 2H 2D 2E 2F 2G
3
DE
114A E
2. Boom Below 40°
2K1 2K2 112

2K E

2D
CONSOLE/
STABILIZER
112 113 & ENGINE 104A 150A 101A 2DD
B+ 153
8 105 105
FORWARD GEAR 150 105 Lights 1 Washer/Wiper
E E
7 101 101
GEAR 103 101 20 10
6 150 150 150
103 Switch DE
3 DE E
SHIFTER 102 102 10
TRANSMISSION
1 Horn/Heater Boom
Instrument Relay
E E Panel DE
LEGEND 10
Light Swtch
7 7.5 Lock
E = Energized 2J Relay Relay Interlock
3. Boom Ext. Beyond 42 Foot Ext. Limit 6. Outriggers Lowered
Main Relay
1 Upper
104B Y1 Y3 Y2 DE 7.5 E
O = Open 3 Y1 Y3 Y2 Transmission 40
103B Boom/Outrigger
C = Closed 2
102B
4
105B Outrigger
Lower Lock
5
4. PB Applied By Interlock Sys.
= Inline Harness Connection 101B Y6 Y5 Y4 Transmission Relay

6 Connectors E
7
2H
MH5881
5. Trans. in Neutral By Interlock Sys.
6036, 6042, 8042, 10042, 10054

10.10 BOOM/OUTRIGGER INTERLOCK

SYSTEM TEST
Before performing the following Boom/Outrigger Interlock
System Test, perform Section 10.7, “Stabil-TRAK™
System Test,” to determine if the Stabil-TRAK™system
is working properly. If necessary, repair Stabil-TRAK™
system before testing boom/outrigger interlock system.
10.10.1 System Test Procedures

If Steps 1 through 5 prove positive, the Boom/Outrigger
Interlock System is functioning properly, and the vehicle
can be returned to service. 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.
6036, 6042, 8042, 10042, 10054 10-23

Boom/Outrigger Interlock System Test Procedures
Step 1
EXTEND
MODE 1
a. Place the vehicle with no load on a hard, level surface such as blacktop or concrete.
BOOM
b. Fasten your seat belt.

Step 2
a. With outriggers in the raised position and the boom in a horizontal position, extend the boom. The
boom should extend until the letter “E” appears and then should STOP. If the boom extends beyond
the letter “F”, retract the boom fully and have the system repaired before using the vehicle again.
EXTEND
MODE 2
b. Attempt to frame level the vehicle to the right and left; it should frame level normally.
BOOM
Step 3
a. Lower both outriggers to the ground. DO NOT lift the front wheels of the vehicle off the ground at this
time. The Stabil-TRAK™light should come ON when the outriggers are lowered.
b. With the boom still in a horizontal position, extend the boom.
c. Attempt to raise both outriggers; they should not rise. If the outriggers rise, STOP and retract the
boom and have the system repaired before using the vehicle again.
d. If the outriggers cannot be raised, attempt to lower the outriggers fully until both front wheels are off
the ground; the outriggers should lower.
Step 4
a. Place the travel select lever in the (F) FORWARD position and the gear select lever in the (1) FIRST
gear position.
b. Attempt to accelerate the vehicle; the vehicle should not move.
c. If the vehicle attempts to move, STOP and have the system repaired before using the vehicle again.
EXTEND
MODE 3
BOOM
IMPORTANT: Perform Steps 5 thru 9 with the engine rpm at idle.

Step 5
a. Attempt to frame level the vehicle to the right and left; it should frame level, but at a SLOWER speed
than normal.
b. The Stabil-TRAK™light should remain ON.
c. Return the vehicle to a level position.
Step 6
a. Place the travel select lever in the (N) NEUTRAL position, move the neutral lock lever to the
NEUTRAL LOCK position.
b. Fully retract the boom.
c. Raise the outriggers.
EXTEND
MODE 1
BOOM
d. Engage the parking brake switch, shut the engine OFF and remove the key.
e. Exit the vehicle using both handholds.
10-24 6036, 6042, 8042, 10042, 10054

10.11 STABIL-TRAK™ HYDRAULIC

CIRCUIT OPERATION AND
TROUBLESHOOTING
The function of the Stabil-TRAK™system varies under
different operating conditions. The basic modes include The hydraulic operation and troubleshooting information
the FREE PIVOT MODE, SLOW PIVOT MODE and for each of these modes will be described on the
LOCKED MODE. following pages.
Troubleshooting Symptom Chart
Symptom Conditions Reference
With the boom below 40°, when Ignition ON, engine running Refer to Section 10.11.2, “Hydraulic Circuit
leveling the frame to right, left front Boom angle is below 40° Operation - FREE PIVOT Mode, Rod Oil
tire comes off the ground. Out,” and Section 10.11.3, “Hydraulic
Travel select lever is in (F) FORWARD or
Troubleshooting - FREE PIVOT Mode,
(R) REVERSE
Rod Oil Out.”
Park brake OFF
Service brake DISENGAGED
With the boom below 40°, when Ignition ON, engine running Refer to Section 10.11.4, “Hydraulic Circuit
leveling the frame to left, right front Boom angle is below 40° Operation - FREE PIVOT Mode, Base Oil
tire comes off the ground. Out,” and Section 10.11.5, “Hydraulic
Troubleshooting - FREE PIVOT Mode,
(R) REVERSE
Base Oil Out.”
Park brake OFF
While traveling, ride feels spongy Ignition ON, engine running Refer to Section 10.11.6, “Hydraulic
(riding on 3 wheels). Boom angle is above 40° Circuit Operation - SLOW PIVOT Mode,
Rod Oil Out,” and Section 10.11.7,
“Hydraulic Troubleshooting - SLOW
(R) REVERSE
PIVOT Mode, Rod Oil Out.”
Park brake OFF
Stabil-TRAK™light in instrument Ignition ON, engine running Refer to Section 10.11.10, “Hydraulic
cluster is not ON. Boom angle is above 40° Circuit Operation - LOCKED MODE,”
and Section 10.11.12, “Hydraulic
Travel select lever is in (N) NEUTRAL, or
Troubleshooting - LOCKED MODE, Will
Park brake ON or Service brake ENGAGED
Not Frame Level Right,” or Section
10.11.14, “Hydraulic Troubleshooting—
LOCKED MODE, Will Not Frame
Level Left.”
With the boom above 40°, when Ignition ON, engine running Refer to Section 10.11.11, “Hydraulic
leveling the frame to right, left front Boom angle is above 40° Circuit Operation - LOCKED MODE,
tire comes off the ground. Frame Level Right,” and Section
Travel select lever is in (N) NEUTRAL, or
10.11.12, “Hydraulic Troubleshooting -
Park brake ON or Service brake ENGAGED
LOCKED MODE, Will Not Frame
Level Right.”
With the boom above 40°, when Ignition ON, engine running Refer to Section 10.11.13, “Hydraulic
leveling the frame to left, right front Boom angle is above 40° Circuit Operation - LOCKED MODE,
tire comes off the ground. Frame Level Left,” and Section 10.11.14,
Travel select lever is in (N) NEUTRAL, or Park
“Hydraulic Troubleshooting - LOCKED
brake ON or Service brake ENGAGED
MODE, Will Not Frame Level Left.”
6036, 6042, 8042, 10042, 10054 10-25

10.11.1 Stabil-TRAK™ Cylinder Oil Flow

In the FREE PIVOT and SLOW PIVOT MODES, oil flow
from the stabilizer cylinder will be in one of two directions; 1
ROD OIL OUT or BASE OIL OUT.
ROD OIL OUT flow will occur when the left side of the
rear axle is lower than the right side (left wheel in a
2
pothole, or the right wheel passing over an obstruction),
causing the cylinder to extend (1).
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
10-26 6036, 6042, 8042, 10042, 10054

6036, 6042, 8042, 10042, 10054 10-27

10.11.2 Hydraulic Circuit Operation - FREE PIVOT Mode, Rod Oil Out
FRAME
LEVEL MAIN CONTROL
CYLINDER VALVE
LFT/LWR
EXT/RET
T
FRAME
ATTACH
SWAY
AUX
TILT
P
IN
BYPASS
T
CHECK
VALVE
TM
STABIL-TRAK
CYLINDER G3
G2 FTR V
3 DE
2A
.030 DIA.
PBG HYDRAULIC
C
PSG G
RESERVOIR
2B PLT T
P
3 PS PB
1
12B 4B 4A 12A
SECONDARY
E DE DE E FUNCTION
MANIFOLD
.060 DIA. .060 DIA.
100 PSI
2
PUMP
T HYDRAULIC
STABIL-TRAK TM G1 P OIL COOLER
MANIFOLD
Pressure SOLENOID COIL 4
STATE BYPASS
Return CHECK
VALVE
Suction DE DE-ENERGIZED
MAQ3052
E ENERGIZED
Load Sense
Conditions: Operation:
• Boom angle is below 40° When the conditions are met, solenoids 12A and 12B are
• Rear axle pivots freely energized. As the left side of the rear axle moves down,
the rod extends, forcing hydraulic oil out from the rod end
• Travel select lever in (F) FORWARD or (R) of the Stabil-TRAK™cylinder (1). The oil then flows
REVERSE position through the solenoid-operated valves 12B (2) and
• Park brake OFF 12A (3), to the base side of the Stabil-TRAK™cylinder.
• Service brake DISENGAGED 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.
10-28 6036, 6042, 8042, 10042, 10054

10.11.3 Hydraulic Troubleshooting - FREE PIVOT Mode, Rod Oil Out
Conditions: When frame leveling right, left front

tire comes off the ground
• Ignition ON, Refer to Section 10.8, “Stabil-TRAK™
engine running Boom Interlock Electrical Circuit
Operation and Troubleshooting (6042/
• Boom angle is Not
Check electrical wiring. OK
8042/10042),” or Section 10.9,
below 40° “Stabil-TRAK™Boom Interlock
Electrical Circuit Operation and
• Travel select lever Troubleshooting (10054).”
in (F) FORWARD If OK
or (R) REVERSE
• Park brake OFF
• Service brake Check solenoid coils 12A and 12B on
Not
the Stabil-TRAK™manifold for correct OK
Replace solenoid(s).
DISENGAGED
resistance (7-9 ohms).
If OK
Remove solenoid cartridges 12A and 12B

Not
from Stabil-TRAK™manifold and inspect OK
Clean passages or replace cartridge(s).
for debris or damage.
If OK
Inspect check valves on Not

Replace check valve(s).
frame level cylinder. OK
6036, 6042, 8042, 10042, 10054 10-29

10.11.4 Hydraulic Circuit Operation - FREE PIVOT Mode, Base Oil Out
FRAME
LEVEL MAIN CONTROL
CYLINDER VALVE
LFT/LWR
EXT/RET
T
FRAME
ATTACH
SWAY
AUX
TILT
P
IN
BYPASS
T
CHECK
VALVE
TM
STABIL-TRAK
CYLINDER
G2 G3 FTR V
3 DE
2A
.030 DIA.
PBG HYDRAULIC
C
PSG G
RESERVOIR
2B PLT T
P
2 PS PB
1 12B 4B 4A 12A
SECONDARY
E DE DE E FUNCTION
MANIFOLD
.060 DIA. .060 DIA.
100 PSI
3
PUMP
T HYDRAULIC
MANIFOLD
STATE BYPASS
Return CHECK
VALVE
MAQ3062
E ENERGIZED
Load Sense
Conditions: Operation:
• Boom angle is below 40° When the conditions are met, solenoids 12A and 12B are
• Rear axle pivots freely energized. As the left side of the rear axle moves down,
the rod is forced up, forcing hydraulic oil out from the base
• Travel select lever in (F) FORWARD or (R) end of the Stabil-TRAK™cylinder (1). The oil then flows
REVERSE position through the solenoid-operated valves 12A (2) and
• Park brake OFF 12B (3), to the rod side of the Stabil-TRAK™cylinder.
• Service brake DISENGAGED Because the volume of oil needed on the rod side is less
than 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.
10-30 6036, 6042, 8042, 10042, 10054

10.11.5 Hydraulic Troubleshooting - FREE PIVOT Mode, Base Oil Out
Conditions: With boom below 40°, when frame

leveling to left, the right front tire
• Ignition ON, comes off the ground.
engine running
• Boom angle is Refer to Section 10.8, “Stabil-TRAK™
below 40° Boom Interlock Electrical Circuit
Not
Operation and Troubleshooting (6042/
• Travel select Check electrical wiring. 8042/10042),” or Section 10.9,
OK
lever in (F) “Stabil-TRAK™Boom Interlock
FORWARD or Electrical Circuit Operation and
(R) REVERSE Troubleshooting (10054).”
If OK
• Park brake ON
• Service brake Check solenoid coils 12A and 12B on
the Stabil-TRAK™manifold for correct Not Replace solenoid(s).
DISENGAGED OK
If OK
Remove solenoid cartridges 12A

and 12B from Stabil-TRAK™manifold Not Clean passages or replace
and inspect for debris or damage. OK cartridge(s).
If OK

6036, 6042, 8042, 10042, 10054 10-31

10.11.6 Hydraulic Circuit Operation - SLOW PIVOT Mode, Rod Oil Out
FRAME
LEVEL MAIN CONTROL
CYLINDER VALVE
LFT/LWR
EXT/RET
T
FRAME
ATTACH
SWAY
AUX
TILT
P
IN
BYPASS
T
CHECK
VALVE
TM
STABIL-TRAK
CYLINDER
G2 G3 FTR V
3 DE
2A
.030 DIA.
PBG HYDRAULIC
C
PSG G
RESERVOIR
2B PLT T
P
PS PB
1
12B 4B 4A 12A
SECONDARY
DE E E DE FUNCTION
MANIFOLD
.060 DIA. 2 5 .060 DIA. 100 PSI
3 4 PUMP
T HYDRAULIC
MANIFOLD
Pressure SOLENOID COIL
Return STATE 6 BYPASS
CHECK
VALVE
MAQ3072
E ENERGIZED
Load Sense
Conditions: The 0.060 inch orifices (3 and 4) in solenoid-operated
• Boom angle is above 40° valves 4A (5) and 4B (2) will slow the movement of the
rear axle in reaction to terrain changes. The frame level
• Park brake OFF will react normally in this mode.
• Service brake DISENGAGED Because of greater volume of oil required, extra oil is
• Travel select lever in (F) FORWARD or (R) required from system through the 100 psi (7 bar) reducing
REVERSE position cartridge (6) in the Stabil-TRAK™manifold. Restrictions
Operation: produce the slow movement, or SLOW PIVOT mode.
As the boom is raised above 40°, the boom proximity

switch is deactivated, causing solenoids 12A and 12B to
de-energize and solenoids 4A and 4B to energize. This
allows oil to flow from the rod end of the 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.
10-32 6036, 6042, 8042, 10042, 10054

10.11.7 Hydraulic Troubleshooting - SLOW PIVOT Mode, Rod Oil Out
Conditions: While traveling, ride feels spongy

(riding on 3 wheels).
• Ignition ON,
engine running
Refer to Section 10.8, “Stabil-TRAK™
• Boom angle is Boom Interlock Electrical Circuit
above 40° Operation and Troubleshooting (6042/
Not
Check electrical wiring. OK
8042/10042),” or Section 10.9,
• Travel select “Stabil-TRAK™Boom Interlock
lever in (F) Electrical Circuit Operation and
FORWARD or Troubleshooting (10054).”
If OK
(R) REVERSE
• Park brake OFF
• Service brake Check solenoid coils 4A and 4B on the
Not
Stabil-TRAK™manifold for correct Replace solenoid(s).
DISENGAGED OK
If OK
Remove solenoid cartridges 4A and 4B Not

from Stabil-TRAK™manifold and inspect OK
If OK
Inspect check valves on frame level Not

cylinder. OK
6036, 6042, 8042, 10042, 10054 10-33

10.11.8 Hydraulic Circuit Operation - SLOW PIVOT Mode, Base Oil Out
FRAME
LEVEL MAIN CONTROL
CYLINDER VALVE
LFT/LWR
EXT/RET
T
FRAME
ATTACH
SWAY
AUX
TILT
P
IN
BYPASS
T
CHECK
VALVE
TM
STABIL-TRAK
CYLINDER
G2 G3 FTR V
3 DE
2A
.030 DIA.
PBG HYDRAULIC
C
PSG G
RESERVOIR
2B PLT T
P
PS PB
1 12B 4B 4A 12A
SECONDARY
DE E E DE FUNCTION
MANIFOLD
.060 DIA. 5 2 .060 DIA. 100 PSI
4
3 PUMP
T HYDRAULIC
MANIFOLD
Pressure 6
SOLENOID COIL
STATE BYPASS
Return CHECK
VALVE
MAQ3082
E ENERGIZED
Load Sense
Conditions: The 0.060 inch orifices (3 and 4) in solenoid-operated
• Boom angle is above 40° valves 4A and 4B will slow the movement of the rear axle
in reaction to terrain changes. The frame level will react
• Park brake OFF normally in this mode.
• Service brake DISENGAGED Because of greater volume of oil in base end, extra oil is
• Travel select lever in (F) FORWARD or (R) returned to the tank through the 100 psi (7 bar) reducing
REVERSE position cartridge (6) in the Stabil-TRAK™manifold. Restrictions
Operation: produce slow movement, or SLOW PIVOT mode.
As the boom is raised above 40°, the boom proximity

switch is deactivated causing solenoids 12A and 12B to
de-energize and solenoids 4A and 4B to energize. This
allows oil to flow from the base end of the 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.
10-34 6036, 6042, 8042, 10042, 10054

10.11.9 Hydraulic Troubleshooting - SLOW PIVOT Mode, Base Oil Out
Conditions: While traveling, ride feels spongy

(riding on 3 wheels).
• Ignition ON,
engine running
Not
Check electrical wiring. OK 8042/10042),” or Section 10.9,
• Travel select “Stabil-TRAK™Boom Interlock
lever in (F) Electrical Circuit Operation and
FORWARD or If OK Troubleshooting (10054).”
(R) REVERSE
• Park brake OFF
Check solenoid coils 4A and 4B in the
Not
• Service brake Stabil-TRAK™manifold for correct OK
Replace solenoid(s).
DISENGAGED resistance (7-9 ohms).
If OK
Remove solenoid coils 4A and 4B from Not

Stabil-TRAK™manifold and inspect OK
If OK

6036, 6042, 8042, 10042, 10054 10-35

10.11.10 Hydraulic Circuit Operation - 10.11.11 Hydraulic Circuit Operation -

LOCKED MODE LOCKED MODE, Frame Level Right
When joystick control is placed in frame level mode,
a. Conditions:
cables activate the frame level valve in the main control
• Boom angle is above 40° valve assembly. As the joystick is moved to the right, the
• Park brake ON, or service brake ENGAGED, or frame level spool valve is shifted, allowing oil to flow
travel select lever in (N) NEUTRAL through the valve, to the Stabil-TRAK™manifold, port V.
Oil entering the Stabil-TRAK™manifold at port V flows
b. Operation: through solenoid cartridge valve 3 (5), through a 0.030 inch
orifice (6) and check valve 2A (7), to the base end of the
When the conditions are met, solenoids 4A, 4B, 12A
Stabil-TRAK™cylinder (8). The orifice slows the
and 12B are de-energized and solenoid 3 is energized.
movement of the frame level.
In the LOCKED MODE, oil is prevented from flowing
through the Stabil-TRAK™manifold due to check valves Some of this oil is diverted to the pilot line of check valve
in solenoid-operated valves 4A (1), 4B (2), 12A (3), 2B (9), opening the valve.
and 12B (4). Rod end oil from the Stabil-TRAK™cylinder flows
through check valve 2B (9), opened by pilot pressure in
the Stabil-TRAK™manifold. The oil then flows through
cartridge valve 3 (5), out of the Stabil-TRAK™manifold at
port FTR, through a check valve (10), to the rod end of the
frame level cylinder (11).
Oil from the base end of the frame level cylinder flows
through a piloted-open check valve (12) and back
through the frame level spool valve in the frame level
section of the main control valve, dumping the returned
oil to the reservoir.
Pressurized oil entering Stabil-TRAK™manifold at port P
is stopped at the four closed solenoid-operated valves 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.
10-36 6036, 6042, 8042, 10042, 10054

10.11.12 Hydraulic Troubleshooting - LOCKED MODE, Will Not Frame Level Right
12
FRAME
LEVEL MAIN CONTROL
CYLINDER VALVE
LFT/LWR
EXT/RET
T
FRAME
ATTACH
SWAY
AUX
TILT
11 P
BYPASS
IN
T
CHECK
VALVE
STABIL-TRAK
TM
10
CYLINDER
G2 G3 FTR V
7 6
3 E
2A
9 .030 DIA.
C
PBG HYDRAULIC
PSG G
2B 5 PLT T
RESERVOIR
P
8 3 PS PB
12B 4B 4A 12A
SECONDARY
DE DE DE DE FUNCTION
1 MANIFOLD
.060 DIA. .060 DIA.
4 2 100 PSI
PUMP
T HYDRAULIC
MANIFOLD
BYPASS
Return STATE 13 CHECK
VALVE
MAQ3092
E ENERGIZED
Load Sense
Conditions: With boom above 40°, when frame

leveling to right, left front tire comes
• Ignition ON, engine off the ground. Refer to Section 10.8, “Stabil-TRAK™
running Boom Interlock Electrical Circuit
• Boom angle is Operation and Troubleshooting (6042/
Not
Check electrical wiring. OK 8042/10042),” or Section 10.9,
above 40° “Stabil-TRAK™Boom Interlock
• Travel select Electrical Circuit Operation and
lever in (N) Troubleshooting (10054).”
If OK
NEUTRAL, or
park brake ON
or service brake Check solenoid cartridge 3 in the Not
Stabil-TRAK™manifold. Replace cartridge.
ENGAGED OK
If OK
Inspect check valves 2A and 2B Not

on the Stabil-TRAK™cylinder. OK
6036, 6042, 8042, 10042, 10054 10-37

10.11.13 Hydraulic Circuit Operation - Oil from rod end of the frame level cylinder flows through
LOCKED MODE, Frame Level Left the check valve (3) opened by incoming pilot pressure oil,
to the FTR port of the Stabil-TRAK™manifold.
a. Conditions Oil entering at port FTR flows through solenoid valve 3 (4)
• Boom angle is above 40° through check valve 2B (5), to the rod end of the Stabil-
TRAK™cylinder (6). Some of this oil is diverted to the
• Park brake ON, or service brake ENGAGED, or
pilot line of check valve 2A (7), opening the valve.
travel select lever in (N) NEUTRAL
Oil from the base end of the Stabil-TRAK™cylinder flows
b. Operation through check valve 2A (7) and through a 0.030 inch orifice
(8). This orifice slows the movement of the frame level.
When the joystick control is placed in the frame level mode, The oil then flows through solenoid-operated valve 3 (4),
cables activate the frame level valve in the main control through port V, to the frame level spool valve in the main
valve assembly. As the joystick is moved to the right, the control valve. Oil flows through the valve, dumping the
frame level spool valve is shifted, allowing oil to flow returned oil to the reservoir.
through the valve, through the check valve (1) to the base
end of the frame level cylinder (2). Pressurized oil entering Stabil-TRAK™manifold at port P
is stopped at the four closed solenoid-operated valves 4A
Some of this oil is diverted to the pilot line of the check (9), 4B (10), 12A (11), and 12B (12). At this time pilot
valve (3) on the return side of the frame level cylinder, pressure will cause the 100 psi relief valve (13) to change
opening the valve. position, allowing the excess oil to vent to the reservoir.
10-38 6036, 6042, 8042, 10042, 10054

10.11.14 Hydraulic Troubleshooting - LOCKED MODE, Will Not Frame Level Left
FRAME
LEVEL MAIN CONTROL
CYLINDER 1 VALVE
LFT/LWR
EXT/RET
T
FRAME
ATTACH
SWAY
AUX
TILT
P
2
IN
BYPASS
T
CHECK
TM 3 4 VALVE
STABIL-TRAK
CYLINDER
G2 G3 FTR V
7 8
3 E
2A
5 .030 DIA.
C
PBG HYDRAULIC
PSG G
RESERVOIR
2B PLT T
P
11 PS PB
6
12B 4B 4A 12A
SECONDARY
DE DE FUNCTION
DE DE
9 MANIFOLD
.060 DIA. .060 DIA.
12 10 100 PSI
PUMP
T HYDRAULIC
MANIFOLD
STATE BYPASS
Return CHECK
VALVE
MAQ3102
E ENERGIZED
Load Sense
Conditions: With boom above 40°, when frame

leveling to left, the right front tire
• Ignition ON, comes off the ground.
engine running
Not 8042/10042),” or Section 10.9,
• Travel select Check electrical wiring. OK
“Stabil-TRAK™Boom Interlock
lever in (N) Electrical Circuit Operation and
NEUTRAL, or If OK Troubleshooting (10054),”
park brake ON
or service brake
ENGAGED
Check solenoid cartridge 3 in Not
Replace cartridge.
the Stabil-TRAK™manifold. OK
If OK
Inspect check valves 2A and 2B Not

OK
on the Stabil-TRAK™cylinder.
6036, 6042, 8042, 10042, 10054 10-39

10.12 BOOM EXTEND SYSTEM

HYDRAULIC CIRCUIT OPERATION
AND TROUBLESHOOTING
The function of the boom extend interlock system varies
under different operating conditions. The basic modes
include the EXTEND INTERLOCK MODE and
OUTRIGGER INTERLOCK MODE.
Hydraulic operation and troubleshooting information
for each of these modes will be described on the
following pages.
10.12.1 Troubleshooting Symptom Chart
Symptom Conditions Reference

Refer to 10.12.2Hydraulic Circuit Operation
With both outriggers RAISED, the Ignition ON, engine running - Extend Interlock Mode10-42 and 10.12.3
boom will not extend. Both outriggers RAISED Hydraulic Troubleshooting - Extend
Interlock Mode10-42
Refer to Section 10.12.4, “Hydraulic

With both outriggers lowered onto Ignition ON, engine running Circuit Operation - Outrigger Interlock
firm terrain, the boom will not extend Mode,” and Section 10.12.5, “Hydraulic
to its full limits. Both outriggers lowered onto firm terrain Troubleshooting - Outrigger
Interlock Mode.”
10-40 6036, 6042, 8042, 10042, 10054

6036, 6042, 8042, 10042, 10054 10-41

10.12.2 Hydraulic Circuit Operation - valve (5), causing it to close. This prevents oil flow to the
Extend Interlock Mode extend/retract cylinder (6), preventing the boom from
being extended further.
Operation:
Retract function is still allowed, as oil flow through boom
When the outriggers in the RAISED position, the
lockout valve reversed, forcing pilot-operated check valve
outrigger pressure switches (1 and 2) are open.
(7) and counterbalance valve (8) to open.The oil flow will
As the boom is extended past the boom extend switch, cause the pilot-operated valve (5) to open, returning oil to
the switch opens, de-energizing the boom lockout the main control valve (9) and reservoir (10).
solenoid (3). This allows pressurized oil to flow through
the valve body (4) to the piston side of the pilot-operated
10.12.3 Hydraulic Troubleshooting - Extend Interlock Mode
Conditions: When engaging the boom extend

• Ignition ON, controls, the boom does not extend.
engine running
• Outriggers RAISED
• Travel select lever in Check electrical wiring. Not
Boom Interlock Electrical Circuit
OK
(F) FORWARD or Operation and Troubleshooting (10054),”
(R) REVERSE
• Park brake OFF If OK
• Service brake
DISENGAGED Check solenoid coil from the boom
Not Replace solenoid.
lockout valve for correct resistance OK
(7-9 ohms).
If OK
Remove solenoid cartridge from boom

lockout valve and inspect Not
OK
Clean passages or replace cartridge.
If OK
Inspect check valves Not

on extend/retract cylinder. OK
10-42 6036, 6042, 8042, 10042, 10054

EXTEND/RETRACT CYLINDER BOOM LOCKOUT VALVE
8 5
C1
6 3
7
DE
4
T
V1
T P
OUTRIGGER
VALVE
LFT/LWR
EXT/RET
T
FRAME
ATTACH
SWAY
AUX
TILT
P
BYPASS
IN
T
MAIN CONTROL CHECK
VALVE VALVE
HYDRAULIC
RESERVOIR
LS
10
B2 A2 A1 B1
E R E R
PUMP
HYDRAULIC
OIL COOLER
BYPASS
CHECK
VALVE
1 2
R.H.
OUTRIGGER L.H.
CYLINDER

Return STATE
E ENERGIZED
Load Sense MH3191
6036, 6042, 8042, 10042, 10054 10-43

10.12.4 Hydraulic Circuit Operation - As the boom extends past the boom extend switch, the
Outrigger Interlock Mode switch opens. The boom extend lockout solenoid
valve (3), remains energized by the circuit provided by
Operation:
the outrigger pressure switches.
When the outriggers are lowered onto firm terrain,
Pressurized oil flows to the base of the pilot-operated
pressure within the outrigger cylinders close the outrigger
valve (4), opening the valve and allowing oil to flow to the
pressure switches (1 and 2), energizing the boom extend
extend/retract cylinder (5).
lockout solenoid valve (3).
10.12.5 Hydraulic Troubleshooting - Outrigger Interlock Mode
Conditions: Boom will not extend to its full limits.

• Both outriggers lowered onto
firm terrain. Refer to Section 10.9,
“Stabil-TRAK™Boom
Note: When the outrigger Check electrical wiring. Not
Interlock Electrical Circuit
OK
interlock mode is engaged, the Operation and
following systems are If OK Troubleshooting (10054),”
automatically activated:
• Stabil-TRAK™system is in
LOCKED MODE.
(Refer to Section 10.4,
Check outrigger pressure switches for Not
Replace switch(es).
“Stabil-TRAK™Operation,” proper operation. OK
for more information.)
• Transmission has
If OK
been DECLUTCHED.
• Park brake ENGAGED.
Check solenoid coil from the boom
• Outrigger RAISE function has lockout valve for correct resistance
Not
Replace solenoid.
OK
been DISABLED. However, the (7-9 ohms).
LOWER function is still active,
to allow for any changes in If OK
outrigger footing.
Remove solenoid cartridge from boom
Not Clean passages or replace
lockout valve and inspect OK cartridge.
If OK

extend/retract cylinder. OK Replace check valve(s).
10-44 6036, 6042, 8042, 10042, 10054

EXTEND/RETRACT CYLINDER BOOM LOCKOUT VALVE
5
4
C1
T 3
V1
T P
OUTRIGGER
VALVE
LFT/LWR
EXT/RET
T
FRAME
ATTACH
SWAY
AUX
TILT
P
BYPASS
IN
T
MAIN CONTROL CHECK
VALVE VALVE
HYDRAULIC
RESERVOIR
LS
B2 A2 A1 B1
E R E R
PUMP
HYDRAULIC
OIL COOLER
BYPASS
CHECK
VALVE
1 2
R.H.
OUTRIGGER L.H.
CYLINDER

Return STATE
E ENERGIZED
Load Sense MH3201
6036, 6042, 8042, 10042, 10054 10-45

10-46 6036, 6042, 8042, 10042, 10054

31200796
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Poland P.I. Castellbisbal Sur SE - 176 27 Jarfalla
Phone: +48 (0)914 320 245 08755Castellbisbal, Barcelona Sweden
Fax: +48 (0)914 358 200 Spain Phone: +46 (0)850 659 500
Phone: +34 93 772 4 700 Fax: +46 (0)850 659 534
Fax: +34 93 771 1762
www.jlg.com

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What are the different machine configurations discussed in the manual?

What are the different machine configurations discussed in the manual?

What sections does the manual cover?

What sections does the manual cover?

Service Manual

8042, 10042 & 10054

An Oshkosh Corporation Company

September 28, 2012 - A - Original Issue Of Manual

31200796 6036, 6042, 8042, 10042, 10054 i

ii 6036, 6042, 8042, 10042, 10054 31200796

6036, 6042, 8042, 10042, 10054 i

ii 6036, 6042, 8042, 10042, 10054

6036, 6042, 8042, 10042, 10054 iii

iv 6036, 6042, 8042, 10042, 10054

PARAGRAPH TITLE PAGE

6036, 6042, 8042, 10042, 10054 1-1

1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS

1-2 6036, 6042, 8042, 10042, 10054

1.6 SAFETY INSTRUCTIONS 1.6.3 General Hazards

6036, 6042, 8042, 10042, 10054 1-3

1.6.4 Operational Hazards FLUID FLAMABILTITY: DO NOT service the fuel or

1-4 6036, 6042, 8042, 10042, 10054

PARAGRAPH TITLE PAGE

6036, 6042, 8042, 10042, 10054 2-1

2.1 REPLACEMENT PARTS AND 2.2 THREAD LOCKING COMPOUND

Note: Loctite® 243TM can be substituted in place of

Before ordering parts or initiating service inquiries, make

2-2 6036, 6042, 8042, 10042, 10054

2.3 TORQUE CHARTS

2.3.1 SAE Fastener Torque Chart

6036, 6042, 8042, 10042, 10054 2-3

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

2-4 6036, 6042, 8042, 10042, 10054

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

6036, 6042, 8042, 10042, 10054 2-5

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

2-6 6036, 6042, 8042, 10042, 10054

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

6036, 6042, 8042, 10042, 10054 2-7

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

2-8 6036, 6042, 8042, 10042, 10054

2.3.2 Metric Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

Sq mm KN [N.m] [N.m] [N.m]

6036, 6042, 8042, 10042, 10054 2-9

2.3.2 Metric Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

2-10 6036, 6042, 8042, 10042, 10054

2.3.2 Metric Fastener Torque Chart (Continued)

Values for Magni Coated Fasteners (Ref 4150701)*

6036, 6042, 8042, 10042, 10054 2-11

2.3.2 Metric Fastener Torque Chart (Continued)

Values for Magni Coated Fasteners (Ref 4150701)*

2-12 6036, 6042, 8042, 10042, 10054

2.3.3 Hydraulic Hose Torque Chart Flats Method: