Skytrak 10054

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

EFFECTIVITY PAGE
DATE REVISION DESCRIPTION

August 12, 2015 A Original Issue Of Manual
October 21, 2015 B Revise pages ii, 2-15, 2-17, 2-18, 2-20 thru 2-23, 3-49, 5-18, 7-12, 7-13, Revise pages
8-6 thru 8-29, 9-4, 9-5, Add pages 9-9, 9-13, 9-14, 9-23, 9-24, 9-27, 9-29, 9-30, Revise
page 9-31, Add pages 9-32 thru 34, 10-5, 10-7, 10-15, 10-17, 10-18.
January 04, 2017 C Revised pages 2-4 thru 2-78, 4-5, 4-8 thru 4-12, 7-8 thru 7-11, 8-6 thru 8-37, 8-43, 8-44,
9-4 thru 9-18, 9-20, 9-35 thru 9-94, 10-7
July 31, 2017 D Revised page 2-12, pages 7-9 thru 7-16, 9-43 thru 9-45
6036, 6042, 8042, 10042, 10054 31211015 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.
Maximum engine power can be found on the decals (2) located on the inside of the side engine compartment doors.
(8042, 10042, 10054)
2 1
ULTRA LOW
XXXhp (XXkW) @ XXXX RPM SULFUR DIESEL
FUEL ONLY
S < 15 mg/kg
XXXXXXXXXX_A
1001125387 A
OH5603
XXXhp (XXkW) @ XXXX RPM 2

XXXXXXXXXX_A
(6036, 6042)
ii 31211015 6036, 6042, 8042, 10042, 10054

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3 Fluid Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.4 Fluid and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.5 Service and Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.7 Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2.8 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.9 Hydraulic Connection Assembly and Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
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 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3.9 Quick Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.5 Cab Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
6036, 6042, 8042, 10042, 10054 31211015 i

Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Axle, Drive Shaft and Wheel Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3 Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.4 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.5 Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.6 Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.7 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.8 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.3 Specifications and Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.4 Engine Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.6 Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.7 Engine Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
7.8 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
7.10 Isolation Coupler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Section 8 .......................................................................
Hydraulic Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.3 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.5 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.6 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
8.7 Hydraulic System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
8.8 Valves and Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40
8.9 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
ii 31211015 6036, 6042, 8042, 10042, 10054

Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 Electrical Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.5 Electrical System Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.6 Dielectric Grease Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
9.7 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
9.8 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
9.9 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
9.10 Window Wiper/Washer Windshield Wiper Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
9.11 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
9.12 Solenoids, Sensors and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
9.13 Display Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
9.14 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
9.15 Machine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
9.16 Analyzer Software Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
9.17 Telematics Gateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43
9.18 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-50
9.19 Machine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-51
9.20 Engine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-55
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
10.6 Boom Extend Interlock System Operation (10054 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
10.7 Stabil-TRAK™ System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
10.8 Stabil-TRAK™ Electrical Circuit Operation and Troubleshooting (6042/8042/10042) . . . . . . . . . 10-15
10.9 Stabil-TRAK™ and Boom Interlock Electrical Circuit Operation and Troubleshooting (10054) . 10-19
10.10 Boom/Outrigger Interlock System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
10.11 Stabil-TRAK™ Hydraulic Circuit Operation and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
10.12 Boom Extend System Hydraulic Circuit Operation and Troubleshooting . . . . . . . . . . . . . . . . . . . . 10-42
6036, 6042, 8042, 10042, 10054 31211015 iii

iv 31211015 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 31211015 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 the
accomplishing service and repair procedures. Following the steering wheel before attempting to perform any service or
procedures in this manual will help assure safety and maintenance. Remove key and disconnect battery leads.
equipment reliability.
Read, understand and follow the information in this manual, 1.5 SAFETY INFORMATION
and obey all locally approved safety practices, procedures,
rules, codes, regulations and laws. To avoid possible death or injury, carefully read, understand
and comply with all safety messages.
These instructions cannot cover all details or variations in the
equipment, procedures, or processes described, nor provide In the event of an accident, know where to obtain medical
directions for meeting every possible contingency during assistance and how to use a first-aid kit and fire extinguisher/
operation, maintenance, or testing. When additional fire suppression system. Keep emergency telephone
information is desired consult your local authorized service numbers (fire department, ambulance, rescue squad/
distributor. paramedics, police department, etc.) nearby. If working
alone, check with another person routinely to help assure
Many factors contribute to unsafe conditions: carelessness, personal safety.
fatigue, overload, inattentiveness, unfamiliarity, even drugs
and alcohol, among others. For optimal safety, encourage
1.5.1 Safety Alert System and Signal Words
everyone to think, and to act, safely.
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
DANGER
operation of the machine. All references to the right side, left
side, front and rear are given from the operator seat looking in DANGER indicates an imminently hazardous situation
a forward direction. which, if not avoided, will result in death or serious injury.
Supplementary information is available from JLG in the form
of Service Bulletins, Service Campaigns, Service Training
Schools, the manufacturer website, other literature, and WARNING
through updates to the manual itself.
1.2 DISCLAIMER WARNING indicates a potentially hazardous situation which,

if not avoided, could result in death or serious injury.
All information in this manual is based on the latest product
information available at the time of publication. The
manufacturer reserves the right to make changes and CAUTION
improvements to its products, and to discontinue the
manufacture of any product, at its discretion at any time
without public notice or obligation. CAUTION indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate injury.
1.3 OPERATION & SAFETY MANUAL
The mechanic must not operate the machine until the
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 31211015 6036, 6042, 8042, 10042, 10054

Safety Practices
1.6 SAFETY INSTRUCTIONS 1.6.3 General Hazards

SOLVENTS: Only use approved solvents that are known to be
Following are general safety statements to consider before
safe for use.
performing maintenance procedures on the telehandler.
Additional statements related to specific tasks and HOUSEKEEPING: Keep the work area and operator cab clean,
procedures are located throughout this manual and are 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 injury
For all safety messages, carefully read, understand and follow may seem. Know the location of a First Aid Kit, and know how
the instructions before proceeding. to use it.
CLEANLINESS: Wear eye protection, and clean all
1.6.1 Personal Hazards components with a high-pressure or steam cleaner before
PERSONAL SAFETY GEAR: Wear all the protective clothing attempting service.
and personal safety gear necessary to perform the job safely. When removing hydraulic components, plug hose ends and
This might include heavy gloves, safety glasses or goggles, connections to prevent excess leakage and contamination.
filter mask or respirator, safety shoes or a hard hat. Place a suitable catch basin beneath the machine to capture
LIFTING: NEVER lift a heavy object without the help of at fluid run-off.
least one assistant or a suitable sling and hoist. It is good practice to avoid pressure-washing electrical/
electronic components. In the event pressure-washing the
1.6.2 Equipment Hazards machine is needed, ensure the machine is shut down before
pressure-washing. Should pressure-washing be utilized to
LIFTING OF EQUIPMENT: Before using any lifting equipment
wash areas containing electrical/electronic components, it is
(chains, slings, brackets, hooks, etc.), verify that it is of the
recommended a maximum pressure of 750 psi (52 bar) at a
proper capacity, in good working order, and is properly
minimum distance of 12 in (30,5 cm) away from these
attached.
components. If electrical/electronic components are
NEVER stand or otherwise become positioned under a sprayed, spraying must not be direct and for brief time
suspended load or under raised equipment. The load or periods to avoid heavy saturation.
equipment could fall or tip.
Check and obey all Federal, State and/or Local regulations
DO NOT use a hoist, jack or jack stands only to support regarding waste storage, disposal and 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 31211015 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 materials.
ENGINE: Stop the engine before performing any service
unless specifically instructed otherwise. NEVER drain or store fluids in an open container. Engine fuel
and hydraulic fluid are flammable and can cause a fire and/or
VENTILATION: Avoid prolonged engine operation in
explosion.
enclosed areas without adequate ventilation.
DO NOT mix gasoline or alcohol with diesel fuel. The mixture
SOFT SURFACES AND SLOPES: NEVER work on a machine
can cause an explosion.
that is parked on a soft surface or slope. The machine must be
on a hard level surface, with the wheels blocked before PRESSURE TESTING: When conducting any test, only use test
performing any service. equipment that is correctly calibrated and in good condition.
Use the correct equipment in the proper manner, and make
FLUID TEMPERATURE: NEVER work on a machine when the
changes or repairs as indicated by the test procedure to
engine, cooling or hydraulic systems are hot. Hot
achieve the desired result.
components and fluids can cause severe burns. Allow
systems to cool before proceeding. LEAVING MACHINE: Lower the forks or attachment to the
ground before leaving the machine.
FLUID PRESSURE: Before loosening any hydraulic or diesel
fuel component, hose or tube, turn the engine OFF. Wear TIRES: Always keep tires inflated to the proper pressure to
heavy, protective gloves and eye protection. NEVER check help prevent tipover. DO NOT over-inflate tires.
for leaks using any part of your body; use a piece of NEVER use mismatched tire types, sizes or ply ratings.
cardboard or wood instead. If injured, seek medical attention Always use matched sets according to machine
immediately. Diesel fluid leaking under pressure can specifications.
explode. Hydraulic fluid and diesel fuel leaking under
MAJOR COMPONENTS: Never alter, remove, or substitute any
pressure can penetrate the skin, cause infection, gangrene
items such as counterweights, tires, batteries or other items
and other serious personal injury.
that may reduce or affect the overall weight or stability of the
Engine fuel lines are pressurized. DO NOT attempt repairs machine.
unless specific training has been completed. Refer to the
BATTERY: DO NOT charge a frozen battery.Charging a frozen
engine manufacturers’ manual for specific details
battery may cause it to explode. Allow the battery to thaw
concerning the fuel system.
before jump-starting or connecting a battery charger.
Relieve all pressure before disconnecting any component,
part, line or hose. Slowly loosen parts and allow release of 1.7 SAFETY DECALS
residual pressure before removing any part or component.
Before starting the engine or applying pressure, use Check that all safety decals are present and readable on the
components, parts, hoses and pipes that are in good machine. Refer to the Operation & Safety Manual supplied
condition, connected properly and are tightened to the with machine for information.
proper torque. Capture fluid in an appropriate container and
dispose of in accordance with prevailing environmental
regulations.
COOLANT SYSTEM 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.
Properly disconnect battery(s) prior to service the fuel or
hydraulic systems.
1-4 31211015 6036, 6042, 8042, 10042, 10054

Section 2
General Information and Specifications
Contents

2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.1 Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.2 Hydraulic Cylinder Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.3 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.2.4 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.2.5 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.3 Fluid Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.4 Fluid and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.5 Service and Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.5.1 Every 10 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.5.2 First 50 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.5.3 Every 50 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.5.4 First 250 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.5.5 Every 250 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.5.6 First 500 Hours or 1 Year. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.5.7 Every 500 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.5.8 Every 750 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.5.9 Every 1000 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.5.10 Every 1500 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.5.11 Every 2000 Hours or 2 Year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.5.12 Every 4000 Hours or 3 Years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.6.1 50 Hour. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.6.2 250 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.6.3 1000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
2.7 Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2.8 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.8.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.8.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
6036, 6042, 8042, 10042, 10054 31211015 2-1

2.9 Hydraulic Connection Assembly and Torque Specification . . . . . . . . . . . . . . . . . . . . . . . 2-31

2.9.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
2.9.2 Assembly Instructions for American Standard Pipe Thread Tapered Connections 2-33
2.9.3 Assembly Instructions for British Standard Pipe Thread Tapered Connections. 2-35
2.9.4 Assembly Instructions for 37° (JIC) Flare Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
2.9.5 Assembly Instructions for 45° SAE Flare Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
2.9.6 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings. . . . . . . . . . . . . . . . . . . 2-40
2.9.7 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS) . . 2-42
2.9.8 Assembly Instructions for Bulkhead (BH) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
2.9.9 Assembly Instructions for O-Ring Boss (ORB) Fittings . . . . . . . . . . . . . . . . . . . . . . . . 2-48
2.9.10 Assembly Instructions for Adjustable Port End Metric Fittings . . . . . . . . . . . . . . . . 2-56
2.9.11 Assembly Instructions for Metric ISO 6149 Port Assembly Stud Ends . . . . . . . . . 2-64
2.9.12 Assembly Instructions for Adjustable Port End (BSPP) Fittings . . . . . . . . . . . . . . . . 2-66
2.9.13 Assembly Instructions for Flange Connections (FL61 and FL62) . . . . . . . . . . . . . . 2-74
2.9.14 Double Wrench Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
2.9.15 FFWR and TFFT Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78
2.9.16 Adjustable Stud End Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78
2.9.17 O-ring Installation (Replacement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78
2-2 31211015 6036, 6042, 8042, 10042, 10054

2.1 REPLACEMENT PARTS AND WARRANTY

INFORMATION
Model
Serial Number
Maximum Weight Without Attachments (lbs/kg)

Year Of Manufacture
MaximumCapacity (lbs/kg)*
1
* Ref er to load capac it y chart for truck w ith attac hment, and individual load rat ings stamped
on fork s, if equipped. Us e low est capac ity of all ratings .
A s released from fac tory this t ruck meets des ign sp ec ific at io ns in A NSI \ ITSDF B56.6-2011
1001154575A
Manufactured by
JLG Indus tries Inc.
McConnellsburg, PA
17233-9533 USA
MAQ1570
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.
6036, 6042, 8042, 10042, 10054 31211015 2-3

2.2 SPECIFICATIONS
2.2.1 Travel Speeds
TRANSMISSION 6036 6042 8042 10042 /10054

3.6 mph 3.6 mph 3.6 mph 3.7 mph
First Gear
(5,8 km/hr) (5,8 km/hr) (5,8 km/hr) (6,0 km/hr)
6.1 mph 6.1 mph 5.8 mph 6.1 mph
Second Gear
(9,8 km/hr) (9,8 km/hr) (9,3 km/hr) (9,8 km/hr)
14.5 mph 14.5 mph 13.8 mph 14.5 mph
Third Gear
(23,3 km/hr) (23,3 km/hr) (23 km/hr) (23,3 km/hr)
19.5 mph 19 mph 19.0 mph 20.0 mph
Fourth Gear
(31.4 km/hr) (30,6 km/hr) (30,6 km/hr) (32,2 km/hr)
2.2.2 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 14.0 Less than 18.0 Less than 17.0 Less than 17.0 Less than 18.0
Boom Retract Less than 15.0 Less than 18.0 Less than 16.0 Less than 16.0 Less than 16.0
Boom Lift Retracted Less than 12.0 Less than 15.0 Less than 17.0 Less than 17.0 Less than 17.0
Boom Lower Retracted Less than 10.0 Less than 11.0 Less than 17.0 Less than 17.0 Less than 15.0
Attachment Tilt - Up 5 5 7.5 7.5 8
Attachment Tilt - Down 6 6 8 8 10
Frame Level Left to Right
12 - 14 12.0 - 14.0 12.0 - 14.0 12.0 - 14.0 12.0 - 14.0
with Boom Down
Frame Level Left to Right
with Boom Above 40° and
— 23.0 - 33.0 23.0 - 33.0 23.0 - 33.0 23.0 - 33.0
Emergency Brake
Engaged
Frame Level Right to Left
12 - 14 12.0 - 14.0 12.0 - 14.0 12.0 - 14.0 12.0 - 14.0
with Boom Down
Frame Level Right to Left
with Boom Above 40° and
— 26.0 - 52.0 26.0 - 52.0 26.0 - 52.0 26.0 - 52.0
Emergency Brake
Engaged
Outrigger - Left or Right,
— — — 4.0 - 9.0 4.0 - 9.0
UP or DOWN
Outrigger - Left and Right,
— — — 4.0 - 10.0 4.0 - 10.0
UP or DOWN
2-4 31211015 6036, 6042, 8042, 10042, 10054

2.2.3 Electrical System
Battery
Type, Rating 12 BCI, Negative (-) Ground, Maintenance Free
Quantity 1
Cold Cranking Amps 3.8 Liter - 950 CCA @ 0° F (-18° C)
Reserve Capacity 205 Minutes @ 80° F (27° C)
Group/Series Group 31 - 950
Alternator 12V, 135 Amps
2.2.4 Engine Performance Specifications
Description 6036 & 6042 6036 & 6042 6036 & 6042
If Equipped for ULS If Equipped for LS If Equipped w/ 74hp (55kW)
Engine Make/Model Cummins Turbo QSF3.8 Cummins Turbo QSF3.8 Cummins Turbo QSF3.8
3 3
Displacement 232 in (3,8 liters) 232 in (3,8 liters) 232 in3 (3,8 liters)
Low Idle (no load) 1000 rpm 1000 rpm 1000 rpm
High Idle (no load) 2500 rpm 2500 rpm 2500 rpm
Horsepower 85 hp (63 kW) @ 2500 rpm 85 hp (63 kW) @ 2500 rpm 74 hp (55 kW) @ 2500 rpm
Peak Torque 340 lb-ft (461 Nm) @ 1400 rpm 340 lb-ft (461 Nm) @ 1400 rpm 295 lb-ft (400 Nm) @ 1300 rpm
Fuel Delivery High Pressure Common Rail (HPCR) Fuel Injection
Air Cleaner Dry Type, Replaceable Primary and Safety Elements
Description 8042, 10042 & 10054 8042, 10042 & 10054 8042, 10042 & 10054
If Equipped for ULS If Equipped for LS If Equipped w/ 74hp (55kW)
Engine Make/Model Cummins Turbo QSF3.8 Cummins Turbo QSF3.8 Cummins Turbo QSF3.8
3 3
Displacement 232 in (3,8 liters) 232 in (3,8 liters) 232 in3 (3,8 liters)
Low Idle 1000 rpm 1000 rpm 1000 rpm
High Idle 2500 rpm 2500 rpm 2500 rpm
Horsepower 110 hp (82 kW) @ 2500 rpm 110 hp (82 kW) @ 2500 rpm 74 hp (55 kW) @ 2500 rpm
Peak Torque 348 lb-ft (472 Nm) @ 1500 rpm 348 lb-ft (472 Nm) @ 1500 rpm 295 lb-ft (400 Nm) @ 1300 rpm
Fuel Delivery High Pressure Common Rail (HPCR) Fuel Injection
Air Cleaner Dry Type, Replaceable Primary and Safety Elements
Note: No adjustment of the throttle is required. The engine Low Idle and High Idle are controlled by the engine ECM and cannot be
adjusted without Cummins programing tools.
6036, 6042, 8042, 10042, 10054 31211015 2-5

2.2.5 Tires
Note: Standard wheel lug nut torque is 350 - 400 lb-ft (474 - 542 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 70 psi (4,8 bar)
13.0 x 24 G-2/L2 Bias Ply Traction 12 Ply
Foam - Approx 542 lb (246 kg)
13.0 x 24 Solid Tires NA NA NA
15.5 x 25 G2/L-2 Bias Ply Traction 12 Ply
370/75x28 DuraForce 14 Ply
b. 6042

Star Rating
G-2/L-2 Bias Ply Traction
13.0 x 24 12 Ply Foam - Approx 542 lb (246 kg)
TG/G-3 Bias Ply Grader Foam - Approx 542 lb (246 kg)
15.5 x 25 G-2/L-2 Bias Ply Traction 12 Ply
c. 8042

Star Rating
d. 10042 & 10054

Star Rating
2-6 31211015 6036, 6042, 8042, 10042, 10054

2.3 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 -12 114 -24 45
API CJ-4 Plus SAE 5W-30 15 114 -10 45
Engine Crankcase CES-20081
SAE 10W-30 10 104 -24 40
Fully Synthetic**
SAE 15W-40 -40 104 -40 40
MobilFluid 424 10W-30 15 120 -10 49
Transmission and Transfer Case MobilFluid LT 75W-80 -20 15 -29 -10
Refer to ZF TE-ML-03 for additional fluids.
MobilFluid 424* 10W-30 15 120 -10 49
Mobilfluid LT* 75W-80 -20 15 -29 -10
Axle Differential and Wheel End API GL4 with LS Additives
or 75W-90 -20 114 -29 45
API GL5 with LS Additives
MobilFluid 424 10W-30 15 120 -10 49
Hydraulic System
Exxon Univis HVI 26 -20 120 -29 49
Boom Wear Pad Grease Extreme Pressure Grease NLGI Grade 000 -31 122 -35 50
NLGI Grade 2 EP
or
Grease Fittings Extreme Pressure Grease NLGI Grade 3 EP 5 122 -15 50
with Moly
Additive
Boom Chain Lubricant Gear Oil 80W-90 -40 115 -40 46
Ethylene Glycol 50/50 Mix Standard
Engine Coolant
and Water 60/40 Mix Cold Weather
EN590
ASTM D975 Grade 2-D Ultra Low Sulfur
Fuel
ASTM D975 Grade 1-D (S <15 mg/kg)
(Maximum B5 Biodiesel)
Diesel Exhaust Fluid (DEF)
ISO22241-1 32.5% Urea
85 hp (63 kW) or 110 hp (82 kW)
Brake Fluid
Mobil ATF-D/M -20 114 -29 45
(SN 0160074878 to Present)
Air Conditioning Refrigerant R-134A Tetrafluoroethane
Note: *Friction Modifier may be added to axle differentials, see Section 2.4, “Fluid and Lubricant Capacities”.
**See Note on page 2-12 for details.
6036, 6042, 8042, 10042, 10054 31211015 2-7

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
API CI-4 Multigrade SAE 5W-30 -15 70 -26 21
Engine Crankcase
CES-20078 SAE 10W-30 -9 70 -22 21
SAE 15W-40 5 120 -15 49
Mobilfluid 424 10W-30 15 120 -10 49
Transmission and Transfer Case MobilFluid LT 75W-80 -20 15 -29 -10
Refer to ZF TE-ML-03 for additional fluids.
MobilFluid 424 10W-30 15 120 -10 49
Mobilfluid LT* 75W-80 -20 15 -29 -10
Axle Differential and Wheel End API GL4 with LS Additives
or 75W-90 -20 114 -29 45
API GL5 with LS Additives
MobilFluid 424 10W-30 15 120 -10 49
Hydraulic System
Exxon Univis HVI 26 -20 120 -29 49
Boom Wear Pad Grease Extreme Pressure Grease NLGI Grade 000 -31 122 -35 50
NLGI Grade 2 EP
or
Grease Fittings Extreme Pressure Grease NLGI Grade 3 EP 5 122 -15 50
with Moly
Additive
Boom Chain Lubricant Gear Oil 80W-90 -40 115 -40 46
Ethylene Glycol 50/50 Mix Standard
Engine Coolant
and Water 60/40 Mix Cold Weather
EN590
ASTM D975 Grade 2-D Low Sulfur
Fuel
ASTM D975 Grade 1-D (S < 500 mg/kg)
(Maximum B5 Biodiesel)
Brake Fluid
Mobil ATF-D/M -20 114 -29 45
(SN 0160074878 to Present)
Air Conditioning Refrigerant R-134A Tetrafluoroethane
Note: *Friction Modifier may be added to axle differentials, see Section 2.4, “Fluid and Lubricant Capacities”.
2-8 31211015 6036, 6042, 8042, 10042, 10054

2.4 FLUID AND LUBRICANT CAPACITIES
Engine Crankcase Oil

Capacity w/Filter Change 12.7 quart (12,0 liter)
Fuel Tank
Capacity 35.6 gallon (132,5 liter)
DEF Tank (if equipped for ULS 85 or 110 hp (63kW or 82kW)
Capacity 5 gallon (19 liter)
Cooling System
System Capacity 5 gallon (19 liter)
Hydraulic System
System Capacity
6036, 6042 & 8042 45 gallon (170,3 liter)
10042 & 10054 52 gallon (196,8 liter)
Reservoir Capacity to Full Mark 20.2 gallon (76,5 liter)
Transmission
Capacity with Filter Change 19 quart (18 liter)
Axles
Differential Housing Capacity
6036 & 6042 6.6 quart (6,3 liter)
8042, 10042 & 10054
Front Axle 12.5 quart (11,8 liter)
Rear Axle 12.7 quart (12 liter)
Wheel End Capacity
6036 & 6042 1.85 quart (1,75 liter)
8042
Front Axle 2.2 quart (2,1 liter)
Rear Axle 2.2 quart (2,1 liter)
10042 &10054
Front Axle 2.1 quart (2 liter)
Rear Axle 2.2 quart (2,1 liter)
Window Washer Bottle (if equipped)
Capacity 2.2 quart (2,1 liter)
Air Conditioning System (if equipped)
Capacity 1.9 lbs (0,86 kg)
6036, 6042, 8042, 10042, 10054 31211015 2-9

2.5 SERVICE AND MAINTENANCE

SCHEDULES
Note: If hour and year intervals are listed, perform maintenance at interval that occurs first.
2.5.1 Every 10 Hours
OC0960 OC0970 OC0910 OC0920 OC0930 OC0890
Drain Fuel/Water Check Engine Check Engine Oil Check Hydraulic Check Check Tire
Separator Coolant Level Level Oil Level Transmission Oil Condition and
Level Pressure
OC0950 OC0880 OC0940 OC0900
Check Air Cleaner Check Fuel Level Check DEF Level Check Brake Fluid
(if equipped for Level
ULS/85 or 110 HP) (SN 0160074878 to
Present)
2.5.2 First 50 Hours
OC1000 OC0990
Check Boom Chain Check Wheel Lug

Tension Nut Torque
G
MP
OC1020 OC1010
Check Washer Lubrication

Fluid Schedule
2.5.4 First 250 Hours
OC1040 OC1050 OC1070
Change Axle Oil Change Wheel End Change

Oil Transmission Fluid
and Filter
2-10 31211015 6036, 6042, 8042, 10042, 10054

G
MP
OC1010 OC1110 OC1130 OC1090 OC1080
Lubrication Check Axle Oil Check Wheel End Check Boom Wear Check Boom
Schedule Level Oil Level Pads Chains
2.5.6 First 500 Hours or 1 Year
OC1140
Change Engine Oil

and Filter (if
equipped for ULS)
OC1160 OC1170 OC1150 OC0990
Check Fan Belt Change Engine Oil Check Battery Check Wheel Lug
and Filter (if Not Torque
equipped for LS)
OCXXX6
Change
Hydraulic Fluid
6036, 6042, 8042, 10042, 10054 31211015 2-11

G
MP
OC1200 OC1010 OC1040 OC1050 OC1070 OC1000
Check Air Intake Lubrication Change Axle Oil Change Wheel Change Check Boom
System Schedule End Oil Transmission Fluid Chain Tension
and Filter
OCXXX7 OC1210 OC1170 OC1220
Grease Boom Check Park Brake Change Engine Oil Change

Chains and Filter (if Fuel Filters
equipped for ULS,
see note)
Note: If using fully synthetic oil, metal engine oil filter and fuel consumption is less than 11.4 liter per hour (3 gallon per hour), oil
change intervals are 1,000 hours or 1 year. If any of the following are present, conventional oil, plastic engine oil filter or fuel
consumption is greater than 11.4 liter per hour (3 gallon per hour), oil change intervals are 500 hours or 6 months.
OC1230
Change Hydraulic
Fluid and Filters
2.5.11 Every 2000 Hours or 2 Year
OC1240 OC1250 OC1310
Change Engine Change Change Engine

Coolant DEF Tank Filter Coolant and Clean
(if equipped for DEF Engine
ULS/85 or 110 HP) Coolant Strainer
(if equipped for
ULS/85 or 110HP)
2-12 31211015 6036, 6042, 8042, 10042, 10054

2.5.12 Every 4000 Hours or 3 Years
OC1260
Change
DEF Pump Filter
(if equipped for
ULS/85 or 110HP)
2.5.13 Every 5000 Hours or 4 Years
OC1270
Engine Valve Lash

Adjustment
6036, 6042, 8042, 10042, 10054 31211015 2-13

2.6 LUBRICATION SCHEDULES
2.6.1 50 Hour
a. 6036 & 6042
EVERY
50
OH5721
2-14 31211015 6036, 6042, 8042, 10042, 10054

b. 8042 & 10042
EVERY
50
OH5731
6036, 6042, 8042, 10042, 10054 31211015 2-15

c. 10054
EVERY
50
OH5711
2-16 31211015 6036, 6042, 8042, 10042, 10054

2.6.2 250 Hour
a. 6036 & 6042
EVERY
250
6042 ONLY
OA1820
6036, 6042, 8042, 10042, 10054 31211015 2-17

b. 8042, 10042 & 10054
EVERY
250
OH4172
2-18 31211015 6036, 6042, 8042, 10042, 10054

2.6.3 1000 Hour
EVERY
1000
OH4181
6036, 6042, 8042, 10042, 10054 31211015 2-19

2.7 THREAD LOCKING COMPOUND
JLG PN Loctite® ND Industries Description

0100011 242™ Vibra-TITE™121 Medium Strength (Blue)
1001095650 243™ Vibra-TITE™122 Medium Strength (Blue)
0100019 271™ Vibra-TITE™140 High Strength (Red)
0100071 262™ Vibra-TITE™131 Medium - High Strength (Red)
Note: Loctite® 243™ can be substituted in place of Loctite® 242™. Vibra-TITE™ 122 can be substituted in place of Vibra-TITE™ 121.
2-20 31211015 6036, 6042, 8042, 10042, 10054

2.8 TORQUE CHARTS
2.8.1 SAE Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)
SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque
Tensile (Loctite® 242™ or Torque
Clamp Torque Torque
Size TPI Bolt Dia Stress 271™ or (Loctite® 262™ or
Load (Dry) Lubricated
Area Vibra-TITE™ Vibra-TITE™ 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 31211015 2-21

2.7.1 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 Clamp (Loctite® 242™ or 271™ (Loctite® 262™ or
Size TPI Bolt Dia (Dry or Loctite® 263)
Stress Area Load or Vibra-TITE™ 111 or Vibra-TITE™ 131)
K=0.20
140) 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
2-22 31211015 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 (Dry)
K=0.17
140) 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 31211015 2-23


SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Torque Torque
Torque
Size TPI Bolt Dia (Dry or Loctite® 263)
K=0.17
140) 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
2-24 31211015 6036, 6042, 8042, 10042, 10054


SOCKET HEAD CAP SCREWS
Torque
Torque
Clamp (Loctite® 242™ or 271™
Tensile Torque (Loctite® 262™ or
Size TPI Bolt Dia Load See or Vibra-TITE™ 111 or
Stress Area (Dry) K=0.17 Vibra-TITE™ 131)
Note 4 140) or Precoat® 85
K=0.15
K=0.16
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 31211015 2-25

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

SOCKET HEAD CAP SCREWS
Torque
Torque
Clamp (Loctite® 242™ or 271™
Tensile Torque (Loctite® 262™ or
Size TPI Bolt Dia Load See or Vibra-TITE™ 111 or
Stress Area (Dry) K=0.17 Vibra-TITE™ 131)
Note 4 140) or Precoat® 85
K=0.15
K=0.16
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
2-26 31211015 6036, 6042, 8042, 10042, 10054

2.8.2 Metric Fastener Torque Chart

CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS
Torque
Torque
Clamp Torque (Loctite® 242™ or
Tensile (Loctite® 262™ or
Size Pitch Load See (Dry or Loctite® Torque (Lube) 271™ or Vibra-
Stress Area 271™ or
Note 4 263™) TITE™ 111
Vibra-TITE™ 131)
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 31211015 2-27

2.7.2 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
Clamp Torque
Torque (Lube or Loctite®
Tensile Load (Loctite® 262™ or
Size Pitch (Dry or Loctite® 263™) 242™ or 271™ or
Stress Area See Vibra-TITE™ 131)
Note 4 K=0.20 Vibra-TITE™ 111 or
K=0.15
140) 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
2-28 31211015 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
(Lube or Loctite®
Clamp Torque (Loctite® 262™ or
Tensile ™) 242™ or 271™ or
Size Pitch Load (Dry or Loctite® 263 Vibra-TITE™ 131)
Stress Area Vibra-TITE™ 111 or
See Note 4 K=0.17 K=0.15
140)
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 31211015 2-29

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
Clamp Torque (Lube or Loctite®
Tensile (Loctite® 262™ or
Size Pitch ™
Load See (Dry or Loctite® 263 ) 242 or 271™ or
™
Stress Area Vibra-TITE™ 131)
Note 4 K=0.17 Vibra-TITE™ 111 or
K=0.15
140) 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
2-30 31211015 6036, 6042, 8042, 10042, 10054

2.9 HYDRAULIC CONNECTION ASSEMBLY SAE - 45° flare per SAE J512
AND TORQUE SPECIFICATION
2.9.1 Definitions
a. Tapered Thread Types
NPTF - National tapered fuel (dry seal) per SAE J476/J512

MAE9030
ORFS - O-ring face seal per SAE J1453
MAE9000 MAE9040
MBTL - Metric flareless bite type fitting, pressure rating L

BSPT - British standard pipe tapered per ISO7-1
(medium) per ISO 8434, DIN 2353
MBTS - Metric flareless bite type fitting, pressure rating S (high)
per ISO 8434, DIN 2353
MAE9050
MAE9010
BH - Bulkhead connection – JIC, ORFS, MBTL, or MBTS types

b. Straight Thread Types, Tube and Hose Connections
JIC - 37° flare per SAE J514
MAE9060
MAE9020
6036, 6042, 8042, 10042, 10054 31211015 2-31

c. Straight Thread Types, Port Connections d. Flange Connection Types

FL61 - Code 61 flange per SAE J518, ISO 6162
ORB - O-ring boss per SAE J1926, ISO 11926
FL62 - Code 62 flange per SAE J518, ISO 6162
MPP - Metric pipe parallel o-ring boss per SAE J2244,
ISO 6149, DIN 3852
MAE9090
MAE9070
e. Tightening Methods
MFF - Metric flat face port per ISO 9974-1 Torque - Application of a twisting force to the applicable
connection by use of a precise measurement instrument
BSPP - British standard parallel pipe per ISO 1179-1, (i.e. torque wrench).
DIN 3852-2
Finger Tight (Hand Tight) - The point where the connector
will no longer thread onto the mating part when tightened
by hand or fingers. Finger Tight is relative to user strength
and will have some variance. The average torque applied by
this method is 4 Nm (3 ft-lbs).
TFFT - Turns From Finger Tight; Application of a preload to a
connection by first tightening the connection by
hand (fingers) and applying an additional rotation counted
by a defined number of turns by use of a tool.
FFWR (Flat method) - Flats From Wrench Resistance;
Application of a preload to a connection by tightening to
the point of initial wrench resistance and turning the nut a
described number of flats. A flat is one side of the hexagonal
tube nut and equates to 1/6 of a turn.
f. Assembly and Torque Specifications

MAE9080
Prior to selecting the appropriate torque from the tables
within this section, it is necessary to properly identify the
connector being installed.
g. General Tube Type Fitting Assembly Instructions

1. Take precautions to ensure that fittings and mating
components are not damaged during storage, handling
or assembly. Nicks and scratches in sealing surfaces can
create a path for leaks which could lead to component
contamination and/or failure.
2. When making a connection to tubing, compression or
flare, inspect the tube in the area of the fitting
attachment to ensure that the tube has not been
damaged.
2-32 31211015 6036, 6042, 8042, 10042, 10054

3. The assembly process is one of the leading causes for 6. Refer to the appropriate section in this manual for more
contamination in air and hydraulic systems. specific instructions and procedures for each type of
Contamination can prevent proper tightening of fittings fitting connection.
and adapters from occurring.
a. Avoid using dirty or oily rags when handling fittings. 2.9.2 Assembly Instructions for American
Standard Pipe Thread Tapered
b. If fittings are disassembled, they should be cleaned
and inspected for damage. Replace fittings as
Connections
necessary before reinstalling. 1. Inspect components to ensure male and female port
c. Sealing compounds should be applied where threads are free of rust, splits, dirt, foreign matter, or
specified; however, care should be taken not to burrs.
introduce sealant into the system. 2. Apply a suitable thread sealant, such as Loctite 567, to
d. Avoid applying sealant to the area of the threads the male pipe threads if not already applied. Ensure the
where the sealant will be forced into the system. first 1 to 2 threads are uncovered to prevent system
This is generally the first two threads of a fitting. contamination.
e. Sealant should only be applied to the male threads. 3. Assemble connection hand tight.
f. Straight thread fittings do not require sealants. 4. Mark fittings, male and female.
O-rings or washers are provided for sealing.
g. When replacing or installing an o-ring, care is to be
taken while transferring the o-ring over the threads
as it may become nicked or torn. When replacing an NOTICE
o-ring on a fitting, the use of a thread protector is
recommended. Over tightening may cause deformation of the pipe
fitting and damage to the joining fitting, flange or
h. When installing fittings with o-rings, lubrication
component may occur.
shall be used to prevent scuffing or tearing of the
o-ring. Refer to Section 2.9.17, “O-ring Installation
(Replacement),” for procedure.
4. Take care to identify the material of parts to apply the
correct torque values. NOTICE
a. Verify the material designation in the table headings
Never back off (loosen) pipe threaded connectors to
b. If specifications are given only for steel fittings and achieve alignment. Meet the minimum required turns
components, the values for alternate materials shall and use the last turn for alignment.
be as follows:
Aluminum and Brass - reduce steel values by 35% 5. Rotate male fitting the number of turns as per below
Stainless Steel - Use the upper limit for steel. mentioned table. Refer to Section 2.9.15, “FFWR and
5. To achieve the specified torque, the torque wrench is to TFFT Methods,” for procedure.
be held perpendicular to the axis of rotation.
Note: TFFT values provided in below mentioned table are
applicable for the following material configurations:
a. Steel fittings with steel mating components
b. Steel fittings with aluminum or brass mating
components
c. Aluminum or brass fittings with steel mating
components
d. Aluminum or brass fittings with aluminum or brass
mating components.
MAE9100
6036, 6042, 8042, 10042, 10054 31211015 2-33

a. NPTF Pipe Thread
MAE9110
TYPE/FITTING IDENTIFICATION
Turns From Finger Tight
Thread Size ØA*
Material Dash Size (TFFT)**
(UNF) (in) (mm)
2 1/8 - 27 0.40 10.24 2 to 3
4 1/4 - 18 0.54 13.61 2 to 3
STEEL, ALUMINUM, OR 6 3/8 - 18 0.67 17.05 2 to 3
BRASS FITTINGS
8 1/2 - 14 0.84 21.22 2 to 3
WITH STEEL,
ALUMINUM, OR 12 3/4 - 14 1.05 26.56 2 to 3
BRASS
16 1 - 11 1/2 1.31 33.22 1.5 to 2.5
MATING
COMPONENTS 20 1 1/4 - 11 1/2 1.65 41.98 1.5 to 2.5
24 1 1/2 - 11 1/2 1.89 48.05 1.5 to 2.5
32 2 - 11 1/2 2.37 60.09 1.5 to 2.5
NOTE: * ØA thread dimension for reference only.

** Refer to Section 2.9.15, “FFWR and TFFT Methods,” for TFFT procedure requirements.
2-34 31211015 6036, 6042, 8042, 10042, 10054

2.9.3 Assembly Instructions for British

Standard Pipe Thread Tapered
Connections
1. Inspect components to ensure male and female port
NOTICE
threads are free of rust, splits, dirt, foreign matter, or Never back off (loosen) pipe threaded connectors to
burrs. achieve alignment. Meet the minimum required turns
2. Apply a suitable thread sealant, such as Loctite 567, to and use the last turn for alignment.
the male pipe threads if not already applied. Ensure the 5. Rotate male fitting the number of turns as per below
first 1 to 2 threads are uncovered to prevent system mention table.
contamination.
Note: TFFT values provided in below table are applicable for
3. Assemble connection hand tight.
the following material configurations:
4. Mark fittings, male and female.
a. Steel fittings with steel mating components
NOTICE b. Steel fittings with aluminum or brass mating

components
c. Aluminum or brass fittings with steel mating
Over tightening may cause deformation of the pipe
components
fitting and damage to the joining fitting, flange or
component may occur. d. Aluminum or brass fittings with aluminum or brass
mating components.
a. BSPT Pipe Thread
MAE9120
Turns From Finger Tight
Thread Size ØA* (TFFT)**
Material Dash Size
(BSPT) (in) (mm)
2 1/8 - 28 0.38 9.73 2 to 3
4 1/4 - 19 0.52 13.16 2 to 3
STEEL, ALUMINUM, OR
BRASS FITTINGS 6 3/8 - 19 0.66 16.66 2 to 3
WITH STEEL, 8 1/2 - 14 0.83 20.96 2 to 3
ALUMINUM, OR 12 3/4 - 14 1.04 26.44 2 to 3
BRASS 16 1 - 11 1.31 33.25 1.5 to 2.5
MATING
20 1 1/4 - 11 1.65 41.91 1.5 to 2.5
COMPONENTS
24 1 1/2 - 11 1.88 47.80 1.5 to 2.5
32 2 - 11 2.35 59.61 1.5 to 2.5
NOTE: * ØA thread dimension for reference only.

** Refer to Section 2.9.15, “FFWR and TFFT Methods,” for TFFT procedure requirements.
6036, 6042, 8042, 10042, 10054 31211015 2-35

2.9.4 Assembly Instructions for 37° (JIC) Flare 2. Align tube to fitting and start threads by hand.
Fittings
1. Inspect the flare for obvious visual squareness and
concentricity issues with the tube OD. Ensure that
NOTICE
surface is smooth, free of rust, weld and brazing splatter, The torque method should NOT be used on lubricated or
splits, dirt, foreign matter, or burrs. If necessary, replace oily fittings. No lubrication or sealant is required. The
fitting or adapter. lubrication would cause increased clamping force and
cause fitting damage.
NOTICE 3. Torque assembly to value listed in below mentioned
table while using the Double Wrench Method.
DO NOT force a misaligned or short hose/tube into
alignment. It puts undesirable strain onto the joint Note: Torque values provided in below table are segregated
eventually leading to leakage. based on the material configuration of the connection.
a. 37° Flare (JIC) Thread - Steel
MAE9130
TYPE/FITTING IDENTIFICATION Flats From

Thread ØA* ØB* [Ft-Lb] [Nm] Wrench
Dash Size Resistance
Material Size (F.F.W.R)**
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.28 7.00 0.31 7.75 6 7 7 8 9 10 --

3 3/8-24 0.34 8.60 0.37 9.50 8 9 10 11 12 14 --
4 7/16-20 0.39 10.00 0.44 11.10 13 14 14 18 19 19 1-1/2 to 1-3/4
5 1/2-20 0.46 11.60 0.50 12.70 14 15 15 19 20 21 1 to 1-1/2
6 9/16-18 0.51 13.00 0.56 14.30 22 23 24 30 31 33 1 to 1-1/2
STEEL FITTINGS
WITH STEEL 8 3/4-16 0.69 17.60 0.75 19.10 42 44 46 57 60 63 1-1/2 to 1-3/4
MATING
10 7/8-14 0.81 20.50 0.87 22.20 60 63 66 81 85 89 1 to 1-1/2
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 0.97 24.60 1.06 27.00 84 88 92 114 120 125 1 to 1-1/2
THREADS
14 1 3/16-12 1.11 28.30 1.19 30.10 100 105 110 136 142 149 1 to 1-1/2
16 1 5/16-12 1.23 31.30 1.31 33.30 118 124 130 160 168 176 3/4 to 1
20 1 5/8-12 1.54 39.20 1.63 41.30 168 176 185 228 239 251 3/4 to 1
24 1 7/8-12 1.80 45.60 1.87 47.60 195 205 215 264 278 291 3/4 to 1
32 2 1/2-12 2.42 61.50 2.50 63.50 265 278 292 359 377 395 3/4 to 1
NOTE: * ØA and ØB thread dimensions for reference only.

** Refer to Section 2.9.15, “FFWR and TFFT Methods,” for FFWR procedure requirements.
2-36 31211015 6036, 6042, 8042, 10042, 10054

b. 37° Flare (JIC) Thread - Aluminum Brass
MAE9130
TYPE/FITTING IDENTIFICATION Flats From

Thread ØA* ØB* [Ft-Lb] [Nm] Wrench
Dash Size Resistance
Material Size (F.F.W.R)**
2 5/16-24 0.28 7.00 0.31 7.75 4 4 5 5 6 7 --

3 3/8-24 0.34 8.60 0.37 9.50 5 6 7 7 8 9 --
4 7/16-20 0.39 10.00 0.44 11.10 8 9 9 11 12 13 1-1/2 to 1-3/4
5 1/2-20 0.46 11.60 0.50 12.70 9 10 10 12 13 14 1 to 1-1/2
ALUMINUM/BRASS 6 9/16-18 0.51 13.00 0.56 14.30 14 15 16 19 20 21 1 to 1-1/2

FITTINGS OR
8 3/4-16 0.69 17.60 0.75 19.10 27 29 30 37 39 41 1-1/2 to 1-3/4
ALUMINUM/BRASS
MATING 10 7/8-14 0.81 20.50 0.87 22.20 39 41 43 53 56 58 1 to 1-1/2
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 0.97 24.60 1.06 27.00 55 57 60 74 78 81 1 to 1-1/2
THREADS 14 1 3/16-12 1.11 28.30 1.19 30.10 65 68 72 88 93 97 1 to 1-1/2
16 1 5/16-12 1.23 31.30 1.31 33.30 77 81 84 104 109 114 3/4 to 1
20 1 5/8-12 1.54 39.20 1.63 41.30 109 115 120 148 155 163 3/4 to 1
24 1 7/8-12 1.80 45.60 1.87 47.60 127 133 139 172 180 189 3/4 to 1
32 2 1/2-12 2.42 61.50 2.50 63.50 172 181 189 234 245 257 3/4 to 1

** Refer to ,Section 2.9.15, “FFWR and TFFT Methods,” for FFWR procedure requirements.
6036, 6042, 8042, 10042, 10054 31211015 2-37

2.9.5 Assembly Instructions for 45° SAE Flare

Fittings
1. Inspect the flare for obvious visual squareness and
concentricity issues with the tube OD. Ensure that
surface is smooth, free of rust, weld and brazing splatter,
splits, dirt, foreign matter, or burrs. If necessary, replace
fitting or adapter.
NOTICE
DO NOT force a misaligned or short hose/tube into
alignment. It puts undesirable strain onto the joint
eventually leading to leakage.
2. Align tube to fitting.

3. Tighten fitting by hand until hand tight.
NOTICE
The torque method should NOT be used on lubricated or
oily fittings. No lubrication or sealant is required. The
lubrication would cause increased clamping force and
Torque fitting to value listed in below table while using the

Double Wrench Method outlined in this section.
Note: Torque values provided in below table are segregated
based on the material configuration of the connection.
‘Aluminum/brass fittings or aluminum/brass mating
components’ indicate either the following material
configurations:
a. Steel fittings with aluminum or brass mating
components
b. Aluminum or brass fittings with steel mating
components
c. Aluminum or brass fittings with aluminum or brass
mating components.
2-38 31211015 6036, 6042, 8042, 10042, 10054

a. 45° Flare (SAE)
MAE9140
STEEL
TYPE/FITTING IDENTIFICATION TORQUE

Thread ØA* ØB* [Ft-Lb] [Nm]
Dash Size
Material Size
4 7/16-20 0.39 9.90 0.44 11.10 13 14 14 18 19 19

STEEL FITTINGS
6 5/8-18 0.56 14.30 0.63 15.90 22 23 24 30 31 33
WITH STEEL MATING
COMPONENTS; 8 3/4-16 0.69 17.50 0.75 19.10 42 44 46 57 60 62
UN-LUBRICATED
THREADS 10 7/8-14 0.81 20.60 0.87 22.20 60 63 66 81 85 89
12 1 1/16-14 0.98 25.00 1.06 27.00 84 88 92 114 119 125
ALUMINUM BRASS

Thread ØA* ØB* [Ft-Lb] [Nm]
Dash Size
Material Size
ALUMINUM/BRASS 4 7/16-20 0.39 9.90 0.44 11.10 8 9 9 11 12 12

FITTINGS OR 6 5/8-18 0.56 14.30 0.63 15.90 14 15 15 19 20 20
ALUMINUM/BRASS
MATING 8 3/4-16 0.69 17.50 0.75 19.10 27 29 30 37 39 41
COMPONENTS;
UN-LUBRICATED 10 7/8-14 0.81 20.60 0.87 22.20 39 41 43 53 56 58
THREADS
12 1 1/16-14 0.98 25.00 1.06 27.00 55 58 61 75 79 83
6036, 6042, 8042, 10042, 10054 31211015 2-39

2.9.6 Assembly Instructions for O-Ring Face

Seal (ORFS) Fittings
1. Ensure proper o-ring is installed. If o-ring is missing
install per o-ring Installation (replacement). Refer to
Section 2.9.17, “O-ring Installation (Replacement),” for
procedure.
2. Ensure that surface is smooth, free of rust, weld and
brazing splatter, splits, dirt, foreign matter, or burrs. If
necessary, replace fitting or adapter.
NOTICE
Care to be taken when lubricating o-ring. Avoid adding
oil to the threaded connection of the fitting. The
3. Pre-lubricate the o-ring with hydraulic oil.

4. Place the tube assembly against the fitting body so that
the flat face comes in contact with the o-ring. Hand
thread the nut onto the fitting body.
5. Torque nut to value listed in below mentioned table
while using the Double Wrench Method. Refer to
Section 2.9.15, “FFWR and TFFT Methods,” for procedure
if using the FFWR method.
Note: Torque values provided in below table are segregated
based on the material configuration of the connection.
Aluminum/brass fittings or aluminum/brass mating
components’ indicate either the following
material configurations:
a. Steel fittings with aluminum or brass mating
components
b. Aluminum or brass fittings with steel mating
components
c. Aluminum or brass fittings with aluminum or brass
mating components.
2-40 31211015 6036, 6042, 8042, 10042, 10054

a. O-ring Face Seal (ORFS)
MAE9150
STEEL

Thread
Dash ØA* ØB* [Ft-Lb] [Nm] Tube Swivel &
Material Size
Size Nuts Hose Ends
4 9/16-18 0.51 13.00 0.56 14.20 18 19 20 25 26 27 1/4 to 1/2 1/2 to 3/4
6 11/16-16 0.63 15.90 0.69 17.50 30 32 33 40 43 45 1/4 to 1/2 1/2 to 3/4
STEEL FITTINGS 8 13/16-16 0.75 19.10 0.81 20.60 40 42 44 55 57 60 1/4 to 1/2 1/2 to 3/4
WITH 10 1-14 0.94 23.80 1.00 25.40 60 63 66 81 85 89 1/4 to 1/2 1/2 to 3/4
STEEL MATING
12 1 3/16-12 1.11 28.20 1.19 30.10 85 90 94 115 122 127 1/4 to 1/2 1/2 to 3/4
COMPONENTS;
UN-LUBRICATED 16 1 7/16-12 1.34 34.15 1.44 36.50 110 116 121 149 157 164 1/4 to 1/2 1/2 to 3/4
THREADS 20 1 11/16-12 1.59 40.50 1.69 42.90 150 158 165 203 214 224 1/4 to 1/2 1/2 to 3/4
24 2-12 1.92 48.80 2.00 50.80 230 242 253 312 328 343 1/4 to 1/2 1/2 to 3/4
32 2 1/2-12 2.43 61.67 2.50 63.50 375 394 413 508 534 560 1/4 to 1/2 1/2 to 3/4
ALUMINUM/BRASS
FLATS FROM
WRENCH
RESISTANCE
(F.F.W.R)**
Thread
ØA* ØB* [Ft-Lb] [Nm]
Dash Size Tube Swivel &
Material
Size Nuts Hose Ends
4 9/16-18 0.51 13.00 0.56 14.20 12 13 13 16 18 18 1/4 to 1/2 1/2 to 3/4

6 11/16-16 0.63 15.90 0.69 17.50 20 21 22 27 28 30 1/4 to 1/2 1/2 to 3/4
ALUMINUM/BRASS 8 13/16-16 0.75 19.10 0.81 20.60 26 28 29 35 38 39 1/4 to 1/2 1/2 to 3/4
FITTINGS OR
ALUMINUM/BRASS 10 1-14 0.94 23.80 1.00 25.40 39 41 43 53 56 58 1/4 to 1/2 1/2 to 3/4
MATING 12 1 3/16-12 1.11 28.20 1.19 30.10 55 58 61 75 79 83 1/4 to 1/2 1/2 to 3/4
COMPONENT;
16 1 7/16-12 1.34 34.15 1.44 36.50 72 76 79 98 103 107 1/4 to 1/2 1/2 to 3/4
UN-LUBRICATED
THREADS 20 1 11/16-12 1.59 40.50 1.69 42.90 98 103 108 133 140 146 1/4 to 1/2 1/2 to 3/4
24 2-12 1.92 48.80 2.00 50.80 12 13 13 16 18 18 1/4 to 1/2 1/2 to 3/4
32 2 1/2-12 2.43 61.67 2.50 63.50 20 21 22 27 28 30 1/4 to 1/2 1/2 to 3/4

6036, 6042, 8042, 10042, 10054 31211015 2-41

2.9.7 Assembly Instructions for DIN 24° Flare

Bite Type Fittings (MBTL and MBTS)
NOTICE
A non-square tube end can cause improperly seated
fittings and leakage.
6. Inspect the components to ensure free of
contamination, external damage, rust, splits, dirt,
foreign matter, or burrs. Ensure tube end is visibly
square. If necessary, replace fitting or tube.
7. Lubricate thread and cone of fitting body or hardened
pre-assembly tool, as well as the progressive ring and
nut threads.
8. Slip nut and progressive ring over tube, assuring that
they are in the proper orientation.
9. Push the tube end into the coupling body.
10. Slide collet into position and tighten until finger tight.
Mark nut and tube in the finger-tight position. Tighten
nut to the number of flats listed while using the Double
Wrench Method. The tube must not turn with the nut.
2-42 31211015 6036, 6042, 8042, 10042, 10054

a. DIN 24° CONE (MBTL & MBTS)
MAE9160
DIN 24° CONE FLARELESS BITE FITTING

(WITH OR WITHOUT O-RING)
Tube Thread Torque Flats From
ØA* ØB* C* ØD*
O.D. M Size [Ft-Lb] [Nm] Wrench
Material Type
Resistance
(mm) (Metric) (mm) (mm) (mm) (mm) Min Nom Max Min Nom Max (F.F.W.R)**
6 M12 x 1.5 10.50 12.00 7.00 6.20 1.5 to 1.75
8 M14 x 1.5 12.50 14.00 7.00 8.20 1.5 to 1.75
FFWR is the recommended method of
10 M16 x 1.5 14.50 16.00 7.00 10.20 fitting assembly. 1.5 to 1.75
DIN 12 M18 x 1.5 16.50 18.00 7.00 12.20 1.5 to 1.75
Torque values are application specific
24° CONE 15 M22 x 1.5 20.50 22.00 7.00 15.20 due to variability in the fitting supplier, 1.5 to 1.75
FLARELESS coating, lubrication, and other physical
BITE (MBTL) 18 M26 x 1.5 24.50 26.00 7.50 18.20 characteristic of the connection. 1.5 to 1.75
FITTING 22 M30 x 2 27.90 30.00 7.50 22.20 1.5 to 1.75
Consult Engineering on the
28 M36 x 2 33.90 36.00 7.50 28.20 generation of torque values for the 1.5 to 1.75
particular application.
35 M45 x 2 42.90 45.00 10.50 35.30 1.5 to 1.75
42 M52 x 2 49.90 52.00 11.00 42.30 1.5 to 1.75
STEEL Tube Thread Torque Flats From

ØA* ØB* C* ØD*
FITTINGS WITH O.D. M Size [Ft-Lb] [Nm] Wrench
Type
STEEL MATING Resistance
COMPONENTS (mm) (Metric) (mm) (mm) (mm) (mm) Min Nom Max Min Nom Max (F.F.W.R)**
6 M14 x 1.5 12.50 14.00 7.00 6.20 1.5 to 1.75

FFWR is the recommended method of
8 M16 x 1.5 14.50 16.00 7.00 8.20 1.5 to 1.75
fitting assembly.
10 M18 x 1.5 16.50 18.00 7.50 10.20 1.5 to 1.75
DIN 12 M20 x 1.5 18.50 20.00 7.50 12.20 Torque values are application specific 1.5 to 1.75
24° CONE 14 M22 x 1.5 20.50 22.00 8.00 14.20 due to variability in the fitting supplier, 1.5 to 1.75
FLARELESS coating, lubrication, and other physical
16 M24 x 1.5 22.50 24.00 8.50 16.20 characteristics of the connection. 1.5 to 1.75
BITE (MBTS)
FITTING 20 M30 x 2 27.90 30.00 10.50 20.20 1.5 to 1.75
25 M36 x 2 33.90 36.00 12.00 25.20 Consult Engineering on the 1.5 to 1.75
generation of torque values for the
30 M42 x 2 39.90 42.00 13.50 30.20 1.5 to 1.75
particular application.
38 M52 x 2 49.90 52.00 16.00 38.30 1.5 to 1.75
NOTE: * ØA, ØB,C, & ØD thread dimensions for reference only.

6036, 6042, 8042, 10042, 10054 31211015 2-43

2.9.8 Assembly Instructions for Bulkhead (BH)

Fittings
1. Ensure that threads and surface are free of rust, weld
and brazing splatter, splits, burrs or other foreign
material. If necessary, replace fitting or adapter.
2. Remove the locknut from the bulkhead assembly.
3. Insert the bulkhead side of the fitting into the panel or
bulkhead bracket opening.
4. Hand thread the locknut onto the bulkhead end of the
fitting body.
5. Torque nut onto fitting while using the Double Wrench
Method.
2-44 31211015 6036, 6042, 8042, 10042, 10054

a. Bulkhead Fittings (BH) - INCH
MAE9170
FASTENING JAM NUT

FOR BULKHEAD CONNECTORS
Thread Torque
Dash Size
Material Type [Ft-Lb] [Nm]
Size
(UNF) Min Nom Max Min Nom Max
4 9/16-18 15 16 17 20 22 23
6 11/16-16 25 27 28 34 37 38
8 13/16-16 55 58 61 75 79 83
O-RING FACE 10 1-14 85 90 94 115 122 127
SEAL (ORFS)
12 1 3/16-12 135 142 149 183 193 202
BULKHEAD
FITTING 14 1 5/16-12 170 179 187 230 243 254
16 1 7/16-12 200 210 220 271 285 298
20 1 11/16-12 245 258 270 332 350 366
24 2-12 270 284 297 366 385 403
Thread Torque
Dash Size
Type [Ft-Lb] [Nm]
Size
STEEL (UNF) Min Nom Max Min Nom Max
FITTINGS 3 3/8-24 8 9 9 11 12 12
4 7/16-20 13 14 14 18 19 19
5 1/2-20 20 21 22 27 28 30
6 9/16-18 25 27 28 34 37 38
8 3/4-16 50 53 55 68 72 75
37° FLARE (JLIC) 10 7/8-14 85 90 94 115 122 127
BULKHEAD
12 1 1/16-12 135 142 149 183 193 202
FITTING
14 1 3/16-12 170 179 187 230 243 254
16 1 5/16-12 200 210 220 271 285 298
20 1 5/8-12 245 258 270 332 350 366
24 1 7/8-12 270 284 297 366 385 403
32 2 1/2-12 310 326 341 420 442 462
6036, 6042, 8042, 10042, 10054 31211015 2-45

b. Bulkhead Fittings (BH) - METRIC
MAE9180
FASTENING JAM NUT

FOR BULKHEAD CONNECTORS
Connecting Thread Torque
Material Type Tube O.D. M Size [Ft-Lb] [Nm]
(mm) (metric) Min Nom Max Min Nom Max
6 M12 x 1.5 14 15 16 19 20 22
8 M14 x 1.5 17 18 19 23 24 26
10 M16 x 1.5 22 23 24 30 31 33
12 M18 x 1.5 35 37 39 47 50 53
DIN 24° CONE
FLARELESS BITE 15 M22 x 1.5 44 47 50 60 64 68
(MBTL) BULKHEAD 18 M26 x 1.5 70 75 80 95 102 108
FITTING
22 M30 x 2 115 120 125 156 163 169
28 M36 x 2 150 157 164 203 213 222
35 M45 x 2 155 162 169 210 220 229
42 M52 x 2 220 230 240 298 312 325
Connecting Thread Torque
STEEL Tube O.D. M Size
Type [Ft-Lb] [Nm]
FITTINGS
(mm) (metric) Min Nom Max Min Nom Max
6 M14 x 1.5 17 15 16 23 20 22
8 M16 x 1.5 22 18 19 30 24 26
10 M18 x 1.5 35 23 24 47 31 33
12 M20 x 1.5 40 35 37 54 47 50
DIN 24° CONE
FLARELESS BITE 14 M22 x 1.5 44 47 50 60 64 68
(MBTS) BULKHEAD 16 M24 x 1.5 70 75 80 95 102 108
FITTING 20 M30 x 2 115 120 125 156 163 169
25 M36 x 2 150 157 164 203 213 222
30 M42 x 2 155 162 169 210 220 229
38 M52 x 2 220 230 240 298 312 325
2-46 31211015 6036, 6042, 8042, 10042, 10054

This Page Intentionally Left Blank
6036, 6042, 8042, 10042, 10054 31211015 2-47

2.9.9 Assembly Instructions for O-Ring Boss

(ORB) Fittings
1. Inspect components to ensure that male and female
port threads are free of rust, splits, dirt, foreign matter,
or burrs.
2. Ensure proper o-ring is installed. If o-ring is missing
install per o-ring Installation (replacement). Refer to
Section 2.9.17, “O-ring Installation (Replacement),” for
procedure.
NOTICE

4. For non-adjustable and plugs, thread the fitting by hand
until contact.
5. For adjustable fittings, refer to Section 2.9.16,
“Adjustable Stud End Assembly,” for proper assembly.
6. Torque the fitting or nut to value while using the
Double Wrench Method.
a. The table headings identify the straight thread
o-ring port and the type on the other side of the
fitting. The torque will be applied to the straight
thread o-ring port.
b. Torque values are segregated based on the material
configuration of the connection. ‘Aluminum/brass
fittings or aluminum/brass mating components’
indicate either the following material
configurations:
• Steel fittings with aluminum or brass mating
components
• Aluminum or brass fittings with steel mating
components
• Aluminum or brass fittings with aluminum or brass
mating components.
7. Inspect to ensure the o-ring is not pinched and the
washer is seated flat on the counter bore of the port.
2-48 31211015 6036, 6042, 8042, 10042, 10054

a. O-ring Boss (ORB) - Table 1 of 6
MAE9190
HEX TYPE PLUGS & STUD ENDS

WITH 37° (JIC) OR L SERIES DIN (MBTL) OPPOSITE END
Thread Torque
ØA*
Material Dash Size Size [Ft-Lb] [Nm]
(UNF) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.31 7.93 (85) (90) (94) 10 10 11
3 3/8-24 0.37 9.52 (155) (163) (171) 18 18 19
4 7/16-20 0.44 11.11 22 23 24 29 31 33
5 1/2-20 0.50 12.70 23 25 26 32 34 35
STEEL FITTINGS 6 9/16-18 0.56 14.28 29 31 32 40 42 43
WITH STEEL 8 3/4-16 0.75 19.10 52 55 57 70 75 77
MATING
10 7/8-14 0.87 22.22 85 90 94 115 122 127
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (55) (58) (61) 6 7 7
3 3/8-24 0.37 9.52 (101) (106) (111) 11 12 13
4 7/16-20 0.44 11.11 14 15 16 19 20 22
5 1/2-20 0.50 12.70 15 16 17 20 22 23
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 19 20 21 26 27 28
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 34 36 37 46 49 50
MATING 10 7/8-14 0.87 22.22 55 58 61 75 79 83
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
NOTE: 1. * ØA thread OD dimension for reference only.

2. Removal torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque.
6036, 6042, 8042, 10042, 10054 31211015 2-49

b. O-ring Boss (ORB) - Table 2 of 6
MAE9190
STUD ENDS
WITH (ORFS) OR S ERIES DIN (MBTS) OPPOSITE END
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (85) (90) (94) 10 10 11
3 3/8-24 0.37 9.52 (155) (163) (171) 18 18 19
4 7/16-20 0.44 11.11 22 23 24 29 31 33
5 1/2-20 0.50 12.70 23 25 26 32 34 35
STEEL FITTINGS 6 9/16-18 0.56 14.28 29 31 32 40 42 43
WITH STEEL 8 3/4-16 0.75 19.10 52 55 57 70 75 77
MATING
10 7/8-14 0.87 22.22 85 90 94 115 122 127
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (55) (58) (61) 6 7 7
3 3/8-24 0.37 9.52 (101) (106) (111) 11 12 13
4 7/16-20 0.44 11.11 14 15 16 19 20 22
5 1/2-20 0.50 12.70 15 16 17 20 22 23
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 19 20 21 26 27 28
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 34 36 37 46 49 50
MATING 10 7/8-14 0.87 22.22 55 58 61 75 79 83
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

2-50 31211015 6036, 6042, 8042, 10042, 10054

c. O-ring Boss (ORB) - Table 3 of 6
MAE9210
ADJUSTABLE STUD END

WITH 37° (JIC) OR L SERIES DIN (MBTL) OPPOSITE END
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (85) (90) (94) 10 10 11
3 3/8-24 0.37 9.52 (155) (163) (171) 18 18 19
4 7/16-20 0.44 11.11 22 23 24 29 31 33
5 1/2-20 0.50 12.70 23 25 26 32 34 35
STEEL FITTINGS 6 9/16-18 0.56 14.28 29 31 32 40 42 43
WITH STEEL 8 3/4-16 0.75 19.10 52 55 57 70 75 77
MATING
10 7/8-14 0.87 22.22 85 90 94 115 122 127
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (55) (58) (61) 6 7 7
3 3/8-24 0.37 9.52 (101) (106) (111) 11 12 13
4 7/16-20 0.44 11.11 14 15 16 19 20 22
5 1/2-20 0.50 12.70 15 16 17 20 22 23
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 19 20 21 26 27 28
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 34 36 37 46 49 50
MATING 10 7/8-14 0.87 22.22 55 58 61 75 79 83
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

6036, 6042, 8042, 10042, 10054 31211015 2-51

d. O-ring Boss (ORB) - Table 4 of 6
MAE9220
ADJUSTABLE STUD END

WITH (ORFS) OR S SERIES DIN (MBTS) OPPOSITE END
Thread Torque
ØA*
2 5/16-24 0.31 7.93 -- -- -- -- -- --
3 3/8-24 0.37 9.52 -- -- -- -- -- --
4 7/16-20 0.44 11.11 15 16 17 20 22 23
5 1/2-20 0.50 12.70 30 32 33 40 43 45
STEEL FITTINGS 6 9/16-18 0.56 14.28 35 37 39 46 50 53
WITH STEEL 8 3/4-16 0.75 19.10 60 63 66 80 85 89
MATING
10 7/8-14 0.87 22.22 100 105 110 135 142 149
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
Thread Torque
ØA*
2 5/16-24 0.31 7.93 -- -- -- -- -- --
3 3/8-24 0.37 9.52 -- -- -- -- -- --
4 7/16-20 0.44 11.11 10 11 11 14 15 15
5 1/2-20 0.50 12.70 20 21 21 27 28 28
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 23 24 24 31 33 33
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 39 41 43 53 56 58
MATING 10 7/8-14 0.87 22.22 65 69 72 88 94 98
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

2-52 31211015 6036, 6042, 8042, 10042, 10054

e. O-ring Boss (ORB) - Table 5 of 6
MAE9230
TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (30) (32) (33) 3 4 4
3 3/8-24 0.37 9.52 (55) (58) (61) 6 7 7
4 7/16-20 0.44 11.11 10 11 11 14 15 15
5 1/2-20 0.50 12.70 14 15 16 19 20 22
STEEL FITTINGS 6 9/16-18 0.56 14.28 34 36 38 46 49 52
WITH STEEL 8 3/4-16 0.75 19.10 60 63 66 80 85 89
MATING
10 7/8-14 0.87 22.22 100 105 110 135 142 149
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (20) (21) (21) 2 2 2
3 3/8-24 0.37 9.52 (36) (38) (40) 4 4 5
4 7/16-20 0.44 11.11 6 7 7 8 9 9
5 1/2-20 0.50 12.70 9 10 10 12 14 14
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 22 24 25 30 33 34
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 39 41 43 53 56 58
MATING 10 7/8-14 0.87 22.22 65 69 72 88 94 98
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

6036, 6042, 8042, 10042, 10054 31211015 2-53

f. O-ring Boss (ORB) - Table 6 of 6
MAE9240
ZERO LEAK GOLD®

HOLLOW HEX PLUGS
Thread Torque
ØA*
2 5/16-24 0.31 7.93 2 3 4 3 4 5
3 3/8-24 0.37 9.52 3 4 5 4 5 7
4 7/16-20 0.44 11.11 7 8 9 9 11 12
5 1/2-20 0.50 12.70 9 10 11 12 14 15
6 9/16-18 0.56 14.28 11 12 13 15 16 18
STEEL FITTINGS WITH
STEEL MATING 8 3/4-16 0.75 19.10 28 30 32 38 41 43
COMPONENTS; 10 7/8-14 0.87 22.22 46 48 50 62 65 68
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 51 54 57 69 73 77
THREADS
14 1 3/16-12 1.19 30.10
16 1 5/16-12 1.31 33.30 Fitting size greater than -12 not typically specified on
Caterpillar applications.
20 1 5/8-12 1.63 41.30
Consult specific service procedure if
24 1 7/8-12 1.87 47.60 encountered.
32 2 1/2-12 2.50 63.50
Thread Torque
ØA*
2 5/16-24 0.31 7.93 2 3 4 3 4 5
3 3/8-24 0.37 9.52 3 4 5 4 5 7
4 7/16-20 0.44 11.11 7 8 9 9 11 12
5 1/2-20 0.50 12.70 9 10 11 12 14 15
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 11 12 13 15 16 18
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 28 30 32 38 41 43
MATING 10 7/8-14 0.87 22.22 46 48 50 62 65 68
COMPONENTS; 12 1 1/16-12 1.06 27.00 51 54 57 69 73 77
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10
16 1 5/16-12 1.31 33.30 Fitting size greater than -12 not typically specified on
Caterpillar applications.
20 1 5/8-12 1.63 41.30
Consult specific service procedure if
24 1 7/8-12 1.87 47.60 encountered.
32 2 1/2-12 2.50 63.50

2-54 31211015 6036, 6042, 8042, 10042, 10054

6036, 6042, 8042, 10042, 10054 31211015 2-55

2.9.10 Assembly Instructions for Adjustable

Port End Metric Fittings
threads and surfaces are free of rust, splits, dirt, foreign
matter, or burrs.
2. If o-ring is not pre-installed, install proper size, taking
care not to damage it. Refer to Section 2.9.17, “O-ring
Installation (Replacement),” for procedure.
NOTICE

4. For non-adjustable fittings and plugs, thread the fitting
by hand until contact.
a. The table headings identify the Metric port and the
type on the other side of the fitting. The torque will
be applied to the Metric port.
configurations:
components
components
mating components.
2-56 31211015 6036, 6042, 8042, 10042, 10054

a. Metric Flat Face Port (MFF) L Series - Table 1 of 3
MAE9260
MAE9250
FORM A (SEALING WASHER) FORM B (CUTTING FACE)

TYPE/FITTING STUD ENDS STUD ENDS
IDENTIFICATION WITH 37° (JIC) or L SERIES DIN (MBTL) WITH 37° (JIC) OR L SERIES DIN (MBTL)
OPPOSITE END OPPOSITE END
Thread Connecting Torque Torque
Material M Size Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 7 8 8 9 11 11 13 14 14 18 19 19
M12x1.5 8 15 16 17 20 22 23 22 23 24 30 31 33
M14x1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
STEEL FITTINGS
M16x1.5 12 33 35 36 45 47 49 48 51 53 65 69 72
WITH STEEL
MATING M18x1.5 15 41 43 45 55 58 61 59 62 65 80 84 88
COMPONENTS; M22x1.5 18 48 51 53 65 69 72 103 108 113 140 146 153
UN-LUBRICATED
M27x2 22 66 70 73 90 95 99 140 147 154 190 199 209
THREADS
M33x2 28 111 117 122 150 159 165 251 264 276 340 358 374
M42x2 35 177 186 195 240 252 264 369 388 406 500 526 550
M48x2 42 214 225 235 290 305 319 465 489 512 630 663 694
Material M Size Tube O.D

[Ft-Lb] [Nm] [Ft-Lb] [Nm]
M10x1 6 4 5 5 5 7 7 8 9 9 11 12 12
M12x1.5 8 10 11 11 14 15 15 14 15 16 19 20 22
ALUMINUM/BRASS
M14x1.5 10 17 18 19 23 24 26 21 22 23 28 30 31
FITTINGS OR M16x1.5 12 21 22 23 28 30 31 31 33 34 42 45 46
ALUMINUM/BRASS M18x1.5 15 27 28 29 37 38 39 38 40 42 52 54 57
MATING
COMPONENTS; M22x1.5 18 31 33 34 42 45 46 67 70 73 91 95 99
UN-LUBRICATED M27x2 22 43 45 47 58 61 64 91 96 100 123 130 136
THREADS
M33x2 28 72 76 79 98 103 107 163 171 179 221 232 243
M42x2 35 115 121 127 156 164 172 240 252 264 325 342 358
M48x2 42 139 146 153 188 198 207 302 318 332 409 431 450
6036, 6042, 8042, 10042, 10054 31211015 2-57

b. Metric Flat Face Port (MFF) L Series - Table 2 of 3
MAE9280
MAE9270

IDENTIFICATION WITH 37° (JIC) OR L SERIES DIN (MBTL) WITH 37° (JIC) OR L SERIES DIN (MBTL)

M10x1 6 13 14 14 18 19 19 13 14 15 18 19 20
M12x1.5 8 18 19 20 25 26 27 18 19 20 25 26 28
M14x1.5 10 33 35 36 45 47 49 30 31 32 40 42 44
STEEL FITTINGS
WITH STEEL M16x1.5 12 41 43 45 55 58 61 41 43 45 55 58 61
MATING M18x1.5 15 52 55 57 70 75 77 52 54 57 70 74 77
COMPONENTS; M22x1.5 18 92 97 101 125 132 137 66 70 73 90 95 99
UN-LUBRICATED M27x2 22 133 140 146 180 190 198 133 139 146 180 189 198
THREADS
M33x2 28 229 241 252 310 327 342 229 240 252 310 326 341
M42x2 35 332 349 365 450 473 495 332 348 365 450 473 495
M48x2 42 398 418 438 540 567 594 398 418 438 540 567 594

(UNF) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 8 9 9 11 12 12 8 9 9 11 12 12
M12x1.5 8 12 13 13 16 18 18 12 13 13 16 18 18
ALUMINUM/ M14x1.5 10 21 22 23 28 30 31 19 20 21 26 27 29
BRASS FITTINGS
OR ALUMINUM/ M16x1.5 12 27 28 29 37 38 39 26 28 29 36 38 39
BRASS M18x1.5 15 34 36 37 46 49 50 34 35 37 46 48 50
MATING M22x1.5 18 60 63 66 81 85 89 43 45 47 59 61 64
COMPONENTS; M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
UN-LUBRICATED
THREADS M33x2 28 149 157 164 202 213 222 149 157 164 202 213 222
M42x2 35 216 227 237 293 308 321 216 227 237 293 308 321
M48x2 42 259 272 285 351 369 386 259 272 285 351 369 386
2-58 31211015 6036, 6042, 8042, 10042, 10054

c. Metric Flat Face Port (MFF) L Series - Table 3 of 3
MAE9310
MAE9290 MAE9300
HIGH PRESSURE BANJO

BANJO FITTINGS FORM E (EOLASTIC
TYPE/FITTING FITTINGS
WITH L SERIES DIN (MBTL) SEALING RING)
IDENTIFICATION WITH L SERIES DIN (MBTL)
OPPOSITE END HOLLOW HEX PLUGS
OPPOSITE END
Thread Connecting Torque Torque Torque
Material M Size Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 13 14 14 18 19 19 13 14 14 18 19 19 9 10 10 12 14 14
M12x1.5 8 26 28 29 35 38 39 33 35 36 45 47 49 18 19 20 25 26 27
M14x1.5 10 37 39 41 50 53 56 41 43 45 55 58 61 26 28 29 35 38 39
STEEL FITTINGS
M16x1.5 12 44 46 48 60 62 65 59 62 65 80 84 88 41 43 45 55 58 61
WITH STEEL
MATING M18x1.5 15 59 62 65 80 84 88 74 78 81 100 106 110 48 51 53 65 69 72
COMPONENTS; M22x1.5 18 89 94 98 120 127 133 103 108 113 140 146 153 66 70 73 90 95 99
UN-LUBRICATED
M27x2 22 96 101 106 130 137 144 236 248 260 320 336 353 100 105 110 135 142 149
THREADS
M33x2 28 -- -- -- -- -- -- 266 280 293 360 380 397 166 175 183 225 237 248
M42x2 35 -- -- -- -- -- -- 398 418 438 540 567 594 266 280 293 360 380 397
M48x2 42 -- -- -- -- -- -- 516 542 568 700 735 770 266 280 293 360 380 397
M10x1 6 8 9 9 11 12 12 8 9 9 11 12 12 6 7 7 8 9 9
M12x1.5 8 17 18 19 23 24 26 21 22 23 28 30 31 12 13 13 16 18 18
ALUMINUM/ M14x1.5 10 24 26 27 33 35 37 27 28 29 37 38 39 17 18 19 23 24 26
BRASS FITTINGS
M16x1.5 12 29 30 31 39 41 42 38 40 42 52 54 57 27 28 29 37 38 39
OR ALUMINUM/
BRASS M18x1.5 15 38 40 42 52 54 57 48 51 53 65 69 72 31 33 34 42 45 46
MATING M22x1.5 18 58 61 64 79 83 87 67 70 73 91 95 99 43 45 47 58 61 64
COMPONENTS;
M27x2 22 62 66 69 84 89 94 153 161 169 207 218 229 65 69 72 88 94 98
UN-LUBRICATED
THREADS M33x2 28 -- -- -- -- -- -- 173 182 190 235 247 258 108 114 119 146 155 161
M42x2 35 -- -- -- -- -- -- 259 272 285 351 369 386 173 182 190 235 247 258
M48x2 42 -- -- -- -- -- -- 335 352 369 454 477 500 173 182 190 235 247 258
6036, 6042, 8042, 10042, 10054 31211015 2-59

d. Metric Flat Face Port (MFF) S Series - Table 1 of 3
MAE9320 MAE9330

IDENTIFICATION WITH (ORFS) OR S SERIES DIN (MBTS) WITH (ORFS) OR S SERIES DIN (MBTS)

Material M Size Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
M12x1.5 6 15 16 17 20 22 23 26 28 29 35 38 39
M14x1.5 8 26 28 29 35 38 39 41 43 45 55 58 61
M16x1.5 10 33 35 36 45 47 49 52 55 57 70 75 77
STEEL FITTINGS
M18x1.5 12 41 43 45 55 58 61 81 85 89 110 115 121
WITH STEEL
MATING M20x1.5 14 41 43 45 55 58 61 111 117 122 150 159 165
COMPONENTS; M22x1.5 16 48 51 53 65 69 72 125 132 138 170 179 187
UN-LUBRICATED
M27x2 20 66 70 73 89 95 99 199 209 219 270 283 297
THREADS
M33x2 25 111 117 122 150 159 165 302 317 332 410 430 450
M42x2 30 177 186 195 240 252 264 398 418 438 540 567 594
M48x2 38 214 225 235 290 305 319 516 542 568 700 735 770

M12x1.5 6 10 11 11 14 15 15 17 18 19 23 24 26
M14x1.5 8 17 18 19 23 24 26 27 28 29 37 38 39
ALUMINUM/ M16x1.5 10 21 22 23 28 30 31 34 36 37 46 49 50
BRASS FITTINGS
M18x1.5 12 27 28 29 37 38 39 53 56 58 72 76 79
OR ALUMINUM/
BRASS M20x1.5 14 27 28 29 37 38 39 72 76 79 98 103 107
MATING M22x1.5 16 31 33 34 42 45 46 81 86 90 110 117 122
COMPONENTS;
M27x2 20 43 45 47 58 61 64 129 136 142 175 184 193
UN-LUBRICATED
THREADS M33x2 25 72 76 79 98 103 107 196 206 216 266 279 293
M42x2 30 115 121 127 156 164 172 259 272 285 351 369 386
M48x2 38 139 146 153 188 198 207 335 352 369 454 477 500
2-60 31211015 6036, 6042, 8042, 10042, 10054

e. Metric Flat Face Port (MFF) S Series - Table 2 of 3
MAE9350
MAE9340

IDENTIFICATION WITH (ORFS) OR S SERIES DIN (MBTS) WITH (ORFS) OR S SERIES DIN (MBTS)

M10x1 6 26 28 29 35 38 39 26 28 29 35 38 39
M12x1.5 8 33 35 36 45 47 49 41 43 45 55 58 61
M14x1.5 10 52 55 57 70 75 77 52 55 57 70 75 77
STEEL FITTINGS
M16x1.5 12 66 70 73 90 95 99 66 70 73 90 95 99
WITH STEEL
MATING M18x1.5 15 92 97 101 125 132 137 92 97 101 125 132 137
COMPONENTS; M22x1.5 18 100 105 110 135 142 149 100 105 110 135 142 149
UN-LUBRICATED
M27x2 22 133 140 146 180 190 198 133 140 146 180 190 198
THREADS
M33x2 28 229 241 252 310 327 342 229 241 252 310 327 342
M42x2 35 332 349 365 450 473 495 332 349 365 450 473 495
M48x2 42 398 418 438 540 567 594 398 418 438 540 567 594

M10x1 6 17 18 19 23 24 26 17 18 19 23 24 26
M12x1.5 8 21 23 23 29 31 32 27 28 29 37 38 39
ALUMINUM/ M14x1.5 10 34 36 37 46 49 50 34 36 37 46 49 50
BRASS FITTINGS
M16x1.5 12 43 45 47 58 61 64 43 45 47 58 61 64
OR ALUMINUM/
BRASS M18x1.5 15 60 63 66 81 85 89 60 63 66 81 85 89
MATING M22x1.5 18 65 69 72 88 94 98 65 69 72 88 94 98
COMPONENTS;
M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
UN-LUBRICATED
THREADS M33x2 28 149 157 164 202 213 222 149 157 164 202 213 222
M42x2 35 216 227 237 293 308 321 216 227 237 293 308 321
M48x2 42 259 272 285 351 369 386 259 272 285 351 369 386
6036, 6042, 8042, 10042, 10054 31211015 2-61

f. Metric Flat Face Port (MFF) S Series - Table 3 of 3
MAE9310
MAE9290 MAE9300
HIGH PRESSURE BANJO

TYPE/FITTING FITTINGS
WITH S SERIES DIN (MBTS) SEALING RING)
IDENTIFICATION WITH S SERIES DIN (MBTS)
OPPOSITE END

M10x1 6 26 28 29 35 38 39 33 35 36 45 47 49 -- -- -- -- -- --
M12x1.5 8 37 39 41 50 53 56 41 43 45 55 58 61 -- -- -- -- -- --
M14x1.5 10 44 46 48 60 62 65 59 62 65 80 84 88 -- -- -- -- -- --
STEEL FITTINGS
M16x1.5 12 59 62 65 80 84 88 74 78 81 100 106 110 -- -- -- -- -- --
WITH STEEL
MATING M18x1.5 15 81 85 89 110 115 121 92 97 101 125 132 137 59 62 65 80 84 88
COMPONENTS; M22x1.5 18 89 94 98 120 127 133 100 105 110 135 142 149 -- -- -- -- -- --
UN-LUBRICATED
M27x2 22 100 105 110 135 142 149 236 248 260 320 336 353 -- -- -- -- -- --
THREADS
M33x2 28 -- -- -- -- -- -- 266 280 293 360 380 397 -- -- -- -- -- --
M42x2 35 -- -- -- -- -- -- 398 418 438 540 567 594 -- -- -- -- -- --
M48x2 42 -- -- -- -- -- -- 516 542 568 700 735 770 -- -- -- -- -- --

M10x1 6 17 18 19 23 24 26 21 22 23 28 30 31 -- -- -- -- -- --
M12x1.5 8 24 26 27 33 35 37 27 28 29 37 38 39 -- -- -- -- -- --
ALUMINUM/
BRASS M14x1.5 10 29 30 31 39 41 42 38 40 42 52 54 57 -- -- -- -- -- --
FITTINGS OR M16x1.5 12 38 40 42 52 54 57 48 51 53 65 69 72 -- -- -- -- -- --
ALUMINUM/ M18x1.5 15 53 56 58 72 76 79 60 63 66 81 85 89 38 40 42 52 54 57
BRASS
MATING M22x1.5 18 58 61 64 79 83 87 65 69 72 88 94 98 -- -- -- -- -- --
COMPONENTS; M27x2 22 65 69 72 88 94 98 153 161 169 207 218 229 -- -- -- -- -- --
UN-LUBRICATED M33x2 28 -- -- -- -- -- -- 173 182 190 235 247 258 -- -- -- -- -- --
THREADS
M42x2 35 -- -- -- -- -- -- 259 272 285 351 369 386 -- -- -- -- -- --
M48x2 42 -- -- -- -- -- -- 335 352 369 454 477 500 -- -- -- -- -- --
2-62 31211015 6036, 6042, 8042, 10042, 10054

6036, 6042, 8042, 10042, 10054 31211015 2-63

2.9.11 Assembly Instructions for Metric ISO

6149 Port Assembly Stud Ends
matter, or burrs.
2. If o-ring is not pre installed, install proper size, taking
Installation (Replacement).”
NOTICE

a. The table headings identify the Metric port and the
be applied to the Metric port.
configurations:
components
components
mating components.
2-64 31211015 6036, 6042, 8042, 10042, 10054

a. Metric Pipe Parallel O-Ring Boss (MPP)
MAE9370 MAE9380
MAE9360
TYPE/FITTING STUD ENDS WITH 37° (JIC) OR L SERIES STUD ENDS WITH (ORFS) OR S SERIES
IDENTIFICATION DIN (MBTL) OPPOSITE END DIN (MBTS) OPPOSITE END

M8 x 1 4 6 7 7 8 9 9 8 9 9 10 12 12
M10 x 1 6 11 12 12 15 16 16 15 16 17 20 22 23
M12 x 1.5 8 18 19 20 25 26 27 26 28 29 35 38 39
M14 x 1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
M16 x 1.5 12 30 32 33 40 43 45 41 43 45 55 58 61
STEEL FITTINGS M18 x 1.5 15 33 35 36 45 47 49 52 55 57 70 75 77
WITH STEEL M20 x 1.5 -- -- -- -- -- -- -- 59 62 65 80 84 88
MATING
M22 x 1.5 18 44 46 48 60 62 65 74 78 81 100 106 110
COMPONENTS;
UN-LUBRICATED M27 x 2 22 74 78 81 100 106 110 125 132 138 170 179 187
THREADS M30 x 2 -- 95 100 105 130 136 142 175 184 193 237 249 262
M33 x 2 25 120 126 132 160 171 179 230 242 253 310 328 343
M38 x 2 -- 135 142 149 183 193 202 235 247 259 319 335 351
M42 x 2 30 155 163 171 210 221 232 245 258 270 330 350 366
M48 x 2 38 190 200 209 260 271 283 310 326 341 420 442 462
M60 x 2 50 230 242 253 315 328 343 370 389 407 500 527 552
M8 x 1 4 4 5 5 5 7 7 5 6 6 7 8 8
M10 x 1 6 7 8 8 9 11 11 10 11 11 14 15 15
M12 x 1.5 8 12 13 13 16 18 18 17 18 19 23 24 26
M14 x 1.5 10 17 18 19 23 24 26 21 22 23 28 30 31
ALUMINUM/ M16 x 1.5 12 20 21 21 27 28 28 27 28 29 37 38 39
BRASS FITTINGS M18 x 1.5 15 21 22 23 28 30 31 34 36 37 46 49 50
OR ALUMINUM/ M20 x 1.5 -- -- -- -- -- -- -- 30 40 42 41 54 57
BRASS
M22 x 1.5 18 29 30 31 39 41 42 48 51 53 65 69 72
MATING
COMPONENTS; M27 x 2 22 48 51 53 65 69 72 81 86 90 110 117 122
UN-LUBRICATED M30 x 2 -- 62 65 68 84 88 92 114 120 125 155 163 169
THREADS M33 x 2 25 78 82 86 106 111 117 150 157 164 203 213 222
M38 x 2 -- 88 93 97 119 126 132 153 161 168 207 218 228
M42 x 2 30 101 106 111 137 144 150 159 168 176 216 228 239
M48 x 2 38 124 130 136 168 176 184 202 212 222 274 287 301
M60 x 2 50 150 157 164 203 213 222 241 253 265 327 343 359
6036, 6042, 8042, 10042, 10054 31211015 2-65

2.9.12 Assembly Instructions for Adjustable

Port End (BSPP) Fittings
matter, or burrs.
2. If o-ring is not pre installed, install proper size, taking
Installation (Replacement),” for instructions.
NOTICE

a. The table headings identify the BSPP port and the
be applied to the BSPP port.
configurations:
components
components
mating components.
2-66 31211015 6036, 6042, 8042, 10042, 10054

a. British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3
MAE9390 MAE9400
FORM A**(SEALING WASHER) FORM B** (CUTTING FACE)

TYPE/FITTING STUD ENDS WITH 37° (JIC) or STUD ENDS
IDENTIFICATION L SERIES DIN (MBTL) WITH 37° (JIC) OR L SERIES DIN (MBTL)
Torque Torque
Connecting
BSPP
Tube O.D.
Material Thread [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
(mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/8A 6 7 8 8 9 11 11 13 14 14 18 19 19
G 1/4A 8 26 28 29 35 38 39 26 28 29 35 38 39
STEEL FITTINGS G 1/4A 10 26 28 29 35 38 39 26 28 29 35 38 39
WITH STEEL G 3/8A 12 33 35 36 45 47 49 52 55 57 70 75 77
MATING G 1/2A 15 48 51 53 65 69 72 103 108 113 140 146 153
COMPONENTS; G 1/2A 18 48 51 53 65 69 72 74 78 81 100 106 110
UN-LUBRICATED G 3/4A 22 66 70 73 90 95 99 133 140 146 180 190 198
THREADS G 1A 28 111 117 122 150 159 165 243 255 267 330 346 362
G 1-1/4A 35 177 186 195 240 252 264 398 418 438 540 567 594
G 1-1/2A 42 214 225 235 290 305 319 465 489 512 630 663 694
Connecting Torque Torque

BSPP
Material Thread Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
G 1/8A 6 4 5 5 5 7 7 8 9 9 11 12 12
ALUMINUM/ G 1/4A 8 17 18 19 23 24 26 17 18 19 23 24 26
BRASS FITTINGS G 1/4A 10 17 18 19 23 24 26 17 18 19 23 24 26
OR ALUMINUM/ G 3/8A 12 21 22 23 28 30 31 34 36 37 46 49 50
BRASS
G 1/2A 15 31 33 34 42 45 46 67 70 73 91 95 99
MATING
COMPONENTS; G 1/2A 18 31 33 34 42 45 46 48 51 53 65 69 72
UN-LUBRICATED G 3/4A 22 42 45 47 57 61 64 86 91 95 117 123 129
THREADS G 1A 28 72 76 79 98 103 107 158 166 174 214 225 236
G 1-1/4A 35 115 121 127 156 164 172 259 272 285 351 369 386
NOTE: ** Non typical for Straight Male Stud Fittings, reference only.
6036, 6042, 8042, 10042, 10054 31211015 2-67

b. British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3
MAE9410 MAE9420
FORM A**(SEALING WASHER) FORM B** (CUTTING FACE)

TYPE/FITTING
STUD ENDS WITH 37° (JIC) OR STUD ENDS WITH 37° (JIC) OR
IDENTIFICATION
L SERIES DIN (MBTL) OPPOSITE END L SERIES DIN (MBTL) OPPOSITE END

BSPP
G Size
G 1/8A 6 13 14 14 18 19 19 13 14 14 18 19 19
G 1/4A 8 26 28 29 35 38 39 26 28 29 35 38 39
STEEL FITTINGS G 1/4A 10 26 28 29 35 38 39 26 28 29 35 38 39
WITH STEEL G 3/8A 12 52 55 57 70 75 77 52 55 57 70 75 77
MATING G 1/2A 15 66 70 73 90 95 99 66 70 73 90 95 99
COMPONENTS; G 1/2A 18 66 70 73 90 95 99 66 70 73 90 95 99
UN-LUBRICATED G 3/4A 22 133 140 146 180 190 198 133 140 146 180 190 198
THREADS G 1A 28 229 241 252 310 327 342 229 241 252 310 327 342
G 1-1/4A 35 332 349 365 450 473 495 332 349 365 450 473 495
G 1-1/2A 42 398 418 438 540 567 594 398 418 438 540 567 594

BSPP
G Size
G 1/8A 6 8 9 9 11 12 12 8 9 9 11 12 12
ALUMINUM/ G 1/4A 8 17 18 19 23 24 26 17 18 19 23 24 26
BRASS FITTINGS G 1/4A 10 17 18 19 23 24 26 17 18 19 23 24 26
OR ALUMINUM/ G 3/8A 12 34 36 37 46 49 50 34 36 37 46 49 50
BRASS
G 1/2A 15 43 45 47 58 61 64 43 45 47 58 61 64
MATING
COMPONENTS; G 1/2A 18 43 45 47 58 61 64 43 45 47 58 61 64
UN-LUBRICATED G 3/4A 22 86 91 95 117 123 129 86 91 95 117 123 129
THREADS G 1A 28 149 157 164 202 213 222 149 157 164 202 213 222
G 1-1/4A 35 216 227 237 293 308 321 216 227 237 293 308 321
2-68 31211015 6036, 6042, 8042, 10042, 10054

c. British Standard Parallel Pipe Port (BSPP) L Series - Table 3 of 3
MAE9310
MAE9290 MAE9300
HIGH PRESSURE BANJO

TYPE/FITTING FITTINGS WITH
WITH S SERIES DIN (MBTS) SEALING RING)
IDENTIFICATION S SERIES DIN (MBTS)
OPPOSITE END
Torque Torque Torque
BSPP Connecting
Material Thread Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
(mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/8A 6 13 14 14 18 19 19 13 14 14 18 19 19 10 11 11 13 15 15
G 1/4A 8 30 32 33 40 43 45 33 35 36 45 47 49 22 23 24 30 31 33
G 1/4A 10 30 32 33 40 43 45 33 35 36 45 47 49 22 23 24 30 31 33
STEEL FITTINGS
G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77 44 46 48 60 62 65
WITH STEEL
MATING G 1/2A 15 66 70 73 90 95 99 89 94 98 120 127 133 59 62 65 80 84 88
COMPONENTS; G 1/2A 18 66 70 73 90 95 99 89 94 98 120 127 133 59 62 65 80 84 88
UN-LUBRICATED
G 3/4A 22 92 97 101 125 132 137 170 179 187 230 243 254 103 108 113 140 146 153
THREADS
G 1A 28 -- -- -- -- -- -- 236 248 260 320 336 353 148 156 163 200 212 221
G 1-1/4A 35 -- -- -- -- -- -- 398 418 438 540 567 594 295 313.5 332 400 425 450
G 1-1/2A 42 -- -- -- -- -- -- 516 542 568 700 735 770 332 349 365 450 473 495
BSPP Connecting
Material Thread Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
G 1/8A 6 8 9 9 11 12 12 8 9 9 11 12 12 6 7 7 8 9 9
G 1/4A 8 20 21 21 27 28 28 21 22 23 28 30 31 14 15 16 19 20 22
ALUMINUM/
BRASS G 1/4A 10 20 21 21 27 28 28 21 22 23 28 30 31 14 15 16 19 20 22
FITTINGS OR G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50 29 30 31 39 41 42
ALUMINUM/ G 1/2A 15 43 45 47 58 61 64 58 61 64 79 83 87 38 40 42 52 54 57
BRASS
MATING G 1/2A 18 43 45 47 58 61 64 58 61 64 79 83 87 38 40 42 52 54 57
COMPONENTS; G 3/4A 22 60 63 66 81 85 89 111 117 122 150 159 165 67 70 73 91 95 99
UN-LUBRICATED G 1A 28 -- -- -- -- -- -- 153 161 169 207 218 229 96 101 106 130 137 144
THREADS
G 1-1/4A 35 -- -- -- -- -- -- 259 272 285 351 369 386 216 227 237 293 308 321
G 1-1/2A 42 -- -- -- -- -- -- 335 352 369 454 477 500 216 227 237 293 308 321
6036, 6042, 8042, 10042, 10054 31211015 2-69

d. British Standard Parallel Pipe Port (BSPP) S Series - Table 1 of 3
MAE9430 MAE9440
FORM A** (SEALING WASHER) FORM B** (CUTTING FACE)

TYPE/FITTING
STUD ENDS WITH (ORFS) OR STUD ENDS WITH (ORFS) OR
IDENTIFICATION
S SERIES DIN (MBTS) OPPOSITE END S SERIES DIN (MBTS) OPPOSITE END
BSPP Connecting Torque Torque

G Size (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/4A 6 26 28 29 35 38 39 41 43 45 55 58 61
G 1/4A 8 26 28 29 35 38 39 41 43 45 55 58 61
G 3/8A 10 33 35 36 45 47 49 66 70 73 90 95 99
STEEL FITTINGS
G 3/8A 12 33 35 36 45 47 49 66 70 73 90 95 99
WITH STEEL
MATING G 1/2A 14 48 51 53 65 69 72 111 117 122 150 159 165
COMPONENTS; G 1/2A 16 48 51 53 65 69 72 96 101 106 130 137 144
UN-LUBRICATED
G 3/4A 20 66 70 73 90 95 99 199 209 219 270 283 297
THREADS
G 1A 25 111 117 122 150 159 165 251 264 276 340 358 374
G 1-1/4A 30 177 186 195 240 252 264 398 418 438 540 567 594
G 1-1/2A 38 214 225 235 290 305 319 516 542 568 700 735 770
BSPP Connecting Torque Torque
G Size (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/4A 6 17 18 19 23 24 26 27 28 29 37 38 39
G 1/4A 8 17 18 19 23 24 26 27 28 29 37 38 39
ALUMINUM/ G 3/8A 10 21 22 23 28 30 31 43 45 47 58 61 64
BRASS FITTINGS
G 3/8A 12 21 22 23 28 30 31 43 45 47 58 61 64
OR ALUMINUM/
BRASS G 1/2A 14 31 33 34 42 45 46 72 76 79 98 103 107
MATING G 1/2A 16 31 33 34 42 45 46 62 66 69 84 89 94
COMPONENTS;
G 3/4A 20 43 45 47 58 61 64 129 136 142 175 184 193
UN-LUBRICATED
THREADS G 1A 25 72 76 79 98 103 107 163 171 179 221 232 243
G 1-1/4A 30 115 121 127 156 164 172 259 272 285 351 369 386
G 1-1/2A 38 139 146 153 188 198 207 335 352 369 454 477 500
2-70 31211015 6036, 6042, 8042, 10042, 10054

e. British Standard Parallel Pipe Port (BSPP) S Series - Table 2 of 3
MAE9460
MAE9450
FORM E* (EOLASTIC SEALING RING) FORM G/H*** (O-RING W/ RETAINING

TYPE/FITTING STUD ENDS AND HEX TYPE PLUGS RING) STUD ENDS & ADJUSTABLE
IDENTIFICATION WITH (ORFS) or S SERIES DIN (MBTS) STUD ENDS WITH (ORFS) OR
OPPOSITE END S SERIES DIN (MBTS) OPPOSITE END

BSPP
G Size
G 1/4A 6 41 43 45 55 58 61 26 28 29 35 38 39
G 1/4A 8 41 43 45 55 58 61 26 28 29 35 38 39
G 3/8A 10 59 62 65 80 84 88 52 55 57 70 75 77
STEEL FITTINGS
G 3/8A 12 59 62 65 80 84 88 52 55 57 70 75 77
WITH STEEL
MATING G 1/2A 14 85 90 94 115 122 127 66 70 73 90 95 99
COMPONENTS; G 1/2A 16 85 90 94 115 122 127 66 70 73 90 95 99
UN-LUBRICATED
G 3/4A 20 133 140 146 180 190 198 133 140 146 180 190 198
THREADS
G 1A 25 229 241 252 310 327 342 229 241 252 310 327 342
G 1-1/4A 30 332 349 365 450 473 495 332 349 365 450 473 495
G 1-1/2A 38 398 418 438 540 567 594 398 418 438 540 567 594

BSPP
G Size
G 1/4A 6 27 28 29 37 38 39 17 18 19 23 24 26
G 1/4A 8 27 28 29 37 38 39 17 18 19 23 24 26
ALUMINUM/ G 3/8A 10 38 40 42 52 54 57 34 36 37 46 49 50
BRASS FITTINGS
G 3/8A 12 38 40 42 52 54 57 34 36 37 46 49 50
OR ALUMINUM/
BRASS G 1/2A 14 55 58 61 75 79 83 43 45 47 58 61 64
MATING G 1/2A 16 55 58 61 75 79 83 43 45 47 58 61 64
COMPONENTS;
G 3/4A 20 86 91 95 117 123 129 86 91 95 117 123 129
UN-LUBRICATED
THREADS G 1A 25 149 157 164 202 213 222 149 157 164 202 213 222
G 1-1/4A 30 216 227 237 293 308 321 216 227 237 293 308 321
G 1-1/2A 38 259 272 285 351 369 386 259 272 285 351 369 386
NOTE: * Typical for Straight Male Stud Fittings

***Typical for Adjustable Fittings.
6036, 6042, 8042, 10042, 10054 31211015 2-71

f. British Standard Parallel Pipe Port (BSPP) L Series - Table 3 of 3
MAE9290 MAE9300
MAE9470
BANJO FITTINGS HIGH PRESSURE BANJO

TYPE/FITTING JIS/BSPP O-RING
WITH S SERIES DIN (MBTS) FITTINGS WITH S SERIES
IDENTIFICATION ONLY
OPPOSITE END DIN (MBTS) OPPOSITE END

BSPP Connecting
Material Thread Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
G 1/4A 6 30 32 33 40 43 45 33 35 36 45 47 49
G 1/4A 8 30 32 33 40 43 45 33 35 36 45 47 49
G 3/8A 10 48 51 53 65 69 72 52 55 57 70 75 77 Fitting type not typically
STEEL FITTINGS
G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77 specified on Caterpillar
WITH STEEL
G 1/2A 14 66 70 73 90 95 99 89 94 98 120 127 133 applications.
MATING
COMPONENTS; G 1/2A 16 66 70 73 90 95 99 89 94 98 120 127 133 Refer to the specific
UN-LUBRICATED
G 3/4A 20 92 97 101 125 132 137 170 179 187 230 243 254 procedure
THREADS
G 1A 25 -- -- -- -- -- -- 236 248 260 320 336 353 in this Service Manual.
G 1-1/4A 30 -- -- -- -- -- -- 398 418 438 540 567 594
G 1-1/2A 38 -- -- -- -- -- -- 516 542 568 700 735 770
BSPP Connecting
Material Thread Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
G 1/4A 6 20 21 21 27 28 28 22 22 23 30 30 31
G 1/4A 8 20 21 21 27 28 28 22 22 23 30 30 31
ALUMINUM/ G 3/8A 10 31 33 34 42 45 46 34 36 37 46 49 50 Fitting type not typically
BRASS FITTINGS
G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50 specified on Caterpillar
OR ALUMINUM/
G 1/2A 14 43 45 47 58 61 64 58 61 64 79 83 87 applications.
BRASS
MATING G 1/2A 16 43 45 47 58 61 64 58 61 64 79 83 87 Refer to the
COMPONENTS;
G 3/4A 20 60 63 66 81 85 89 111 117 122 150 159 165 specific procedure in
UN-LUBRICATED
G 1A 25 -- -- -- -- -- -- 153 161 169 207 218 229 this Service Manual.
THREADS
G 1-1/4A 30 -- -- -- -- -- -- 259 272 285 351 369 386
G 1-1/2A 38 -- -- -- -- -- -- 335 352 368 454 477 499
2-72 31211015 6036, 6042, 8042, 10042, 10054

6036, 6042, 8042, 10042, 10054 31211015 2-73

2.9.13 Assembly Instructions for Flange

Connections (FL61 and FL62)
1. Ensure sealing surfaces are free of rust, splits, scratches,
dirt, foreign matter, or burrs.
2. Pre-lubricate the O-ring with hydraulic oil.
3. Position flange and clamp halves.
4. Place lock washers on bolt and bolt through clamp
halves.
5. Tighten all bolts by hand.
6. Torque bolts in diagonal sequence in two or more
increments to the torque listed.
2-74 31211015 6036, 6042, 8042, 10042, 10054

a. Flange Code (FL61 & FL62) - Inch Fasteners
MAE9480
STEEL 4-BOLT FLANGE SAE J518
(INCH FASTENERS)
Fastener Torque for Fastener Torque for
Inch Bolt Flanges Equipped with Flanges Equipped with
Flange Flange
A* Thread GRADE 5 Screws GRADE 8 Screws
Type SAE Size
Size
Dash [Ft-Lb] [Nm] [Ft-Lb] [Nm]
Size
(in) (mm) (in) (mm) (UNF) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.50 38.10 5/16-18 18 19 19 24 25 26 24 25 26 32 34 35
12 0.75 19 1.88 47.75 3/8-16 32 33 35 43 45 47 44 46 49 60 63 66
16 1.00 25 2.06 52.32 3/8-16 32 33 35 43 45 47 44 46 49 60 63 66
20 1.25 32 2.31 58.67 7/16-14 52 54 57 70 74 77 68 71 75 92 97 101
CODE 61 24 1.50 38 2.75 69.85 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
SPLIT
32 2.00 51 3.06 77.72 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
FLANGE
(FL61) 40 2.50 64 3.50 88.90 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
48 3.00 76 4.19 106.43 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
56 3.50 89 4.75 120.65 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
64 4.00 102 5.13 130.30 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
80 5.00 127 6.00 152.40 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
Inch Bolt Fastener Torque for Flanges Fastener Torque for Flanges
Flange Flange Equipped with GRADE 5 Screws Equipped with GRADE 8 Screws
A* Thread
Type SAE Size
Size
Size
(in) (mm) (in) (mm) (UNF) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.59 40.39 5/16-18 -- -- -- -- -- -- 24 25 26 32 34 35
12 0.75 19 2.00 50.80 3/8-16 -- -- -- -- -- -- 44 46 49 60 63 66
CODE 62 16 1.00 25 2.25 57.15 7/16-14 -- -- -- -- -- -- 68 71 75 92 97 101
SPLIT
20 1.25 32 2.62 66.55 1/2-13 -- -- -- -- -- -- 111 116 122 150 158 165
FLANGE
(FL62) 20 1.25 32 2.62 66.55 -- -- -- -- -- -- -- -- -- -- -- -- --
24 1.50 38 3.12 79.25 5/8-11 -- -- -- -- -- -- 218 228 239 295 310 325
32 2.00 51 3.81 96.77 3/4-10 -- -- -- -- -- -- 332 348 365 450 473 495
NOTE: * A dimension for reference only.
6036, 6042, 8042, 10042, 10054 31211015 2-75

b. Flange Code (FL61 & FL62) - Metric Fasteners
MAE9480
TYPE/FITTING STEEL 4-BOLT FLANGE SAE J518

IDENTIFICATION (INCH FASTENERS)
Inch Fastener Torque for Fastener Torque for
Bolt Flanges Equipped with Flanges Equipped with
Flange Flange Size A* Thread
Type SAE CLASS 8.8 Screws CLASS 10.9 Screws
Size
Size (in) (mm) (in) (mm) (Metric) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.50 38.10
12 0.75 19 1.88 47.75 M8 x 1.25 18 19 19 24 25 26 18 19 19 24 25 26
16 1.00 25 2.06 52.32 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
20 1.25 32 2.31 58.67 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
CODE 61 24 1.50 38 2.75 69.85 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
SPLIT
32 2.00 51 3.06 77.72 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
FLANGE
(FL61) 40 2.50 64 3.50 88.90 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
48 3.00 76 4.19 106.43 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
56 3.50 89 4.75 120.65 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
64 4.00 102 5.13 130.30 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
80 5.00 127 6.00 152.40 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
Inch Fastener Torque for Fastener Torque for
Bolt Flanges Equipped with Flanges Equipped with
Flange Flange Size A* Thread
Type SAE GRADE 5 Screws GRADE 8 Screws
Size
Size (in) (mm) (in) (mm) (Metric) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.59 40.39 M8 x 1.25 -- -- -- -- -- -- 24 25 26 32 34 35
12 0.75 19 2.00 50.80 M10 x 1.5 -- -- -- -- -- -- 52 54 57 70 74 77
CODE 62 16 1.00 25 2.25 57.15 M12 x 1.75 -- -- -- -- -- -- 96 101 105 130 137 143
SPLIT
20 1.25 32 2.62 66.55 M12 x 1.75 -- -- -- -- -- -- 96 101 105 130 137 143
FLANGE
(FL62) 20 1.25 32 2.62 66.55 M14 x 2 -- -- -- -- -- -- 133 139 146 180 189 198
24 1.50 38 3.12 79.25 M16 x 2 -- -- -- -- -- -- 218 228 239 295 310 325
32 2.00 51 3.81 96.77 M20 x 2.5 -- -- -- -- -- -- 406 426 446 550 578 605
NOTE: * A dimension for reference only.
2-76 31211015 6036, 6042, 8042, 10042, 10054

2.9.14 Double Wrench Method

To prevent undesired hose or connector rotation, two
wrenches must be used; one torque wrench and one
back- up wrench. If two wrenches are not used,
inadvertent component rotation may occur which
absorbs torque and causes improper joint load and leads
to leaks. For hose connections, the ‘layline’ printed on the
hose is a good indicator of proper hose installation. A
twisted lay-line usually indicates the hose is twisted.
Double Wrench Method to Prevent Hose Twist
MAE9490
6036, 6042, 8042, 10042, 10054 31211015 2-77

2.9.15 FFWR and TFFT Methods 2.9.16 Adjustable Stud End Assembly
1. FFWR (Flats from Wrench Resistance Method) For Adjustable Stud End Connections; the following
a. Tighten the swivel nut to the mating fitting until no assembly steps are to be performed:
lateral movement of the swivel nut can be detected; a. Lubricate the o-ring with a light coat of hydraulic oil.
finger tight condition.
b. Position #1 – The o-ring should be located in the
b. Mark a dot on one of the swivel hex nut flats and groove adjacent to the face of the back-up washer.
another dot in line on the connecting tube adapter. The washer and o-ring should be positioned at the
c. Use the double wrench method per Appendix A, extreme top end of the groove as shown.
turn the swivel nut to tighten. The nut is to be c. Position #2 – Position the locknut to just touch the
rotated clockwise the number of hex flats. back-up washer as shown. The locknut in this
d. After the connection has been properly tightened, position will eliminate potential back up washer.
mark a straight line across the connecting parts, not
covering the dots, to indicate the connection has 2.9.17 O-ring Installation (Replacement)
been properly tightened.
Care must be taken when installing o-rings over threads
during replacement or installation. O-rings could become
FFWR Method
nicked or torn. A damaged o-ring could lead to leakage
problems.
1. Inspect o-ring for tears or nicks. If any are found replace
o-ring.
2. Ensure proper o-ring to be installed. Many o-rings look
the same but are of different material, different
hardness, or are slightly different diameters or widths.
3. Use a thread protector when replacing o-rings on
MAE9500
fittings.
4. In ORB; ensure o-ring is properly seated in groove. On
2. TFFT (Turns from Finger Tight Method)
straight threads, ensure o-ring is seated all the way past
a. Tighten the swivel nut to the mating fitting until no the threads prior to installation.
lateral movement of the swivel nut can be detected;
finger tight condition. 5. Inspect o-ring for any visible nicks or tears. Replace if
found.
b. Mark a dot on one of the swivel hex nut flats and
another dot in line on the connecting tube adapter.
c. Use the double wrench method per Appendix A,
turn the swivel nut to tighten. The nut is to be
rotated clockwise the number of turns.
d. After the connection has been properly tightened,
mark a straight line across the connecting parts, not
covering the dots, to indicate the connection has
been properly tightened.
2-78 31211015 6036, 6042, 8042, 10042, 10054

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) . . . . . . . 3-38
3.7.9 Retract Chain Removal and Replacement (6036, 6042, 8042 & 10042) . . . . . . . . 3-39
3.7.10 Extend Chains Removal and Replacement (10054) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
3.7.11 Retract Chain Removal and Replacement (10054) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
6036, 6042, 8042, 10042, 10054 31211015 3-1

Boom
3.8 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

3.8.1 Wear Pad Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3.8.2 Wear Pad Installation and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3.9 Quick Coupler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
3.9.1 Quick Coupler Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
3.9.2 Quick Coupler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
3.10 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
3.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
3-2 31211015 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)
FIRST BOOM
BOOM EXTEND SECOND BOOM SECTION
CHAINS BOOM RETRACT
THIRD BOOM SECTION
CHAIN
SECTION
BOOM PROXIMITY
SENSOR
EXTEND/RETRACT
CYLINDER
COMPENSATION
CYLINDER
TILT CYLINDER
LIFT/LOWER
CYLINDER
QUICK COUPLER
FOUR SECTION BOOM (10054)
FOURTH BOOM SECOND & THIRD THIRD BOOM

SECTION EXTEND BOOM SECTION SECTION
EXTEND CHAINS SECOND BOOM FIRST BOOM
CHAIN SECTION
SECTION
FOURTH BOOM
SECTION RETRACT SECOND & THIRD
FOURTH BOOM CHAIN BOOM SECTION
SECTION RETRACT CHAIN
BOOM PROXIMITY
BOOM PROXIMITY SENSOR
SENSOR
EXTEND/RETRACT
CYLINDER
COMPENSATION
CYLINDER
TILT CYLINDER
LIFT/LOWER
CYLINDER
MH4351
QUICK COUPLER
6036, 6042, 8042, 10042, 10054 31211015 3-3

Boom
3.2 SAFETY INFORMATION
WARNING WARNING
NEVER weld or drill the boom unless approved in writing
DO NOT service the machine without following all safety
by the manufacturer. The structural integrity of the boom
precautions as outlined in Section 1, “Safety Practices”, of
will be impaired if subjected to any repair involving
this manual.
welding or drilling.
3.3 BOOM SYSTEM - THREE SECTION (6036, 3.4.1 Boom Removal

6042, 8042 & 10042)
1. Remove any attachment from quick coupler assembly.
3.3.1 Boom System Operation Note: If replacing the third section boom, remove the quick
coupler from the third section. Refer to Section 3.9, “Quick
The three section boom assembly consists of first, second Coupler”.
and third boom section assemblies with double top boom
extend chains and a single retract chain. Boom extension and 2. Park the machine on a hard, level surface, level the
retraction is accomplished via hydraulic power and chain machine, fully retract the boom, lower the boom, place
movement. the transmission in (N) NEUTRAL, engage the park brake
and shut the engine OFF.
As the Extend/Retract hydraulic cylinder, which is anchored
at the rear of the second boom section and the rear of the 3. Place a Do Not Operate Tag on both the ignition key
first boom section, begins to extend, it forces the second switch and the steering wheel, stating that the machine
boom section out of the first boom section. should not be operated.
The second and third boom sections are connected by 4. Open the engine rear and side engine doors. Allow the
extend and retract chains. These chains are routed around system fluids to cool.
sheaves on the second boom section. As the second boom 5. Move the attachment tilt joystick in both directions to
section is forced out, the extend chain pulls the third boom relieve any trapped pressure in the attachment tilt
section out of the second boom section. system. If the machine is equipped with auxiliary
As hydraulic pressure is applied to the retract port on the controls, move the auxiliary hydraulic joystick in both
Extend/Retract cylinder, the second boom section is pulled directions to relieve any trapped pressure in the
back into the first boom section, and retract chain pulls the auxiliary hydraulic system.
third boom section back into the second section. 6. Properly disconnect the battery. Refer Section 9.8,
This mechanical linkage formed by the chains and “Battery”, for procedure.
supporting hardware extends and retracts the second and 7. Label, disconnect and cap the hydraulic hoses at the
third boom sections at the same rate. rear of the boom. Cap all fittings to keep dirt and debris
The first boom section does not extend or retract, but lifts from entering the hydraulic system.
and lowers via action of the lift/lower cylinder. 8. Label and disconnect the boom proximity sensor at the
rear of the boom.
3.4 BOOM ASSEMBLY MAINTENANCE 9. Remove the pin from the rod end of the compensation
cylinder being careful not to drop the cylinder. Lower
These instructions must be completed in sequence. The third the cylinder onto the frame rails.
boom section must be removed before removing the second
boom section. The third and second boom section must be 10. Remove the pin from the rod end of the lift/lower
removed at one time before removing the first boom section. cylinders. Lower the cylinders onto the frame rails.
Before beginning, conduct a visual inspection of the 11. Confirm that the boom assembly is balanced with the
machine and work area, and review the task about to be sling and remove the boom assembly
undertaken. Read, understand and follow these instructions. pivot pin.
12. Lift the boom assembly from the machine and lower
onto suitable supports.
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Boom
3.4.2 Third Boom Section Removal

1 2
Note: If replacing the third section boom, remove the quick
coupler from the third section. Refer to Section 3.9, “Quick
Coupler”.
2. Park the machine on a hard, level surface, level the
machine, fully retract the boom, lower the boom, place
the transmission in (N) NEUTRAL, engage the park brake
3. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the machine
should not be operated.
4. Open the engine rear and side engine doors. Allow the MH2841
system fluids to cool.
11. Remove the stack clamps (1) and hose clamp support
5. Move the attachment tilt joystick in both directions to bracket (2) to the left side of the third boom section.
relieve any trapped pressure in the attachment tilt
system. If the machine is equipped with auxiliary
controls, move the auxiliary hydraulic joystick in both
directions to relieve any trapped pressure in the
auxiliary hydraulic system.
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.
3
7. If the machine is equipped with auxiliary hydraulics,
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 MH0871
capscrews securing the left side wear pad and hose
clamp support bracket to the top of the third boom 12. Pull the free ends of the hydraulic hoses (3) from the
section. 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 31211015 3-5

Boom
4 6
7
MH0912
14. At the rear of the boom, measure the amount of threads MH2551
protruding beyond each locknut (4) and record the

Note: Record the location of the shoulder bolt (6) to ensure
measurement for reassembly. Remove the two locknuts
correct installation.
and flat washers holding both extend chain clevis’ to
the anchor plate on the first boom section. 16. At the rear of the boom, locate the retract chain (7) 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 boom
5 section, the quick coupler assembly and the Attachment Tilt
cylinder should be removed at this time. Refer to Section Note:,
“The following procedure covers all styles of quick couplers.”
If the third boom section is not to be replaced, the quick coupler
assembly and Attachment Tilt cylinder can remain in place.
17. Using a sling or suitable support, pull the third boom
MH0921
section straight out of the second boom section.
Reposition the slings as needed so the third boom
15. At the front of the second boom section, pull both section balances when removed from the second boom
extend chains (5) out from between the second and section. Set the boom section down on a hard, level
third boom sections. The extend chains can remain surface. Support the boom as needed to prevent it from
anchored between the yoke plates on the first boom tipping over.
section. Loop both chains over the top of the chain 18. At the rear of the third boom section, remove the
sheave and lay the chains on top of the boom. 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 3.8,
“Boom Wear Pads”.
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Boom
3.4.3 Second Boom Section Removal 7. Remove hose reel side plate, lower left side wear pad
and shims. Label and tag each set of wear pads being
1. At the front of the first boom section, remove the top,
removed.
bottom and side wear pads to the inside of the boom.
Label and tag each set of wear pads being removed. 8. Pull the hose reel, with hoses, out the back of the
second boom section. Allow the hose reel assembly to
2. Remove the capscrews and lockwashers holding the
slide down the hoses and rest it on the floor.
center wear pad spacer mount to the front of the first
boom section. Label and tag each set of wear pads 9. Label and remove the hoses from the hose reel. The
being removed. center bolt can remain in place to hold the hose reel and
side plates together.
8
10
MH1451
MH1021 10. Label, disconnect and cap the hydraulic hoses from the
bottom tube assemblies at the mounting plate (10).
3. At the rear of the second boom section, remove the
capscrew and lockwasher holding the retract chain 11. Pull the hose ends out from between the second and
sheave pin (8) to the mounting plate inside the boom. first boom sections and out the rear of the boom.
4. Remove the retract chain sheave pin from the mount 12. Using a suitable sling or support, secure the front of the
and the retract chain sheave. Remove the retract chain Extend/Retract cylinder.
sheave from the second boom section.
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
MH1051
9
13. Remove the retaining ring from one side of the
Extend/Retract cylinder rod end mounting pin (11).
MH1501
14. Using a sling or suitable support, pull the second boom
section straight out of the first boom section.
6. At the rear of the second boom section, remove the Reposition the slings as needed so the second boom
hose reel assembly (9), lower wear pad and spacer. section balances when removed from the first boom
Reassemble the capscrews, lockwashers and flat section. Set the second boom section down on blocks
washers to hold the lower wear pad in place for second on a hard, level surface.
boom section removal.
6036, 6042, 8042, 10042, 10054 31211015 3-7
Boom
15. Remove the remaining wear pads. Label and tag each
set of wear pads being removed.
16. Inspect all wear pads for wear. Refer to Section 3.8, 14
MH1131
4. Label, disconnect and cap the hydraulic hoses from the

12 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 bulkhead
fittings on the mounting plate. Cap the fittings to keep
dirt and debris from entering the hydraulic system.
MH1091
17. Remove the extend chain sheave (12).

16
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 15
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
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 measurement for
reassembly of the chain. Remove the locknut and flat
washer.
3. Remove the retract chain by pulling it out through the
17
rear of the boom. Place the retract chain on a clean
surface.
MH1201
3-8 31211015 6036, 6042, 8042, 10042, 10054

Boom
8. Label, disconnect and cap the hydraulic hoses attached 15. Lower the base end of the Extend/Retract cylinder and
to both compensation cylinders (17). Cap all fittings to remove the rod end of the cylinder from the retainer at
keep dirt and debris from entering the hydraulic system. the front of the boom. Place the Extend/Retract cylinder
9. Support the compensation cylinder on the right side of on a clean, flat surface.
the machine. Remove the rod end pins securing the 16. At the front of the first boom section, remove rubber
cylinder in position. Move the cylinder to a clean, flat bumper to the Extend/Retract cylinder retainer. Inspect
surface. Repeat this procedure for the left side the rubber bumper. If it is in good condition, the rubber
compensation cylinder. bumper can be reused. If the bumper is 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 18. Inspect all wear pads for wear. Refer to Section 3.8,
3.4.5 First Boom Section Installation

1. On the rear of the boom, assemble the extend and
MH1221
retract bulkhead fittings to the mounting plate on the
10. Remove the boom proximity sensor (18) from the right right side. Insert the fittings from the bottom up and
side boom pivot mounting plate. secure in place with the bulkhead fitting nuts on the top
11. Securely block up or support the right Lift/Lower side. Tighten securely. Repeat this procedure for the
cylinder. Remove the rod end pin. Repeat this procedure attachment tilt fittings on the left side.
for the left Lift/Lower cylinder. 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.
3. Using a sling, position the extend/retract cylinder to its
MH1241 original orientation under the boom.
12. Remove the boom pivot pins (19) to the frame. While 4. Coat the base end of the cylinder with anti-seize
removing the pins, note the location and quantity of compound. Insert the base end cylinder pin through
shims between the outer boom and frame. 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 retaining
boom section away from the machine. Set the boom ring on each side of the pin.
section down on a hard, level surface. Support the 5. Lift the rod end of the Extend/Retract cylinder enough
boom as required to allow removal of the Extend/ to insert the threaded stud on the rubber bumper into
Retract cylinder from the underside of the boom. the hole in the Extend/Retract cylinder retainer. Secure
14. Use a hoist and slings to support the Extend/Retract the rubber bumper in place with a locknut. Tighten
cylinder. At the base end of the cylinder, remove a securely. Lower the rod end of the Extend/Retract
retaining ring from one side of the cylinder base end cylinder, and allow it to rest on the rubber bumper.
pin.
6036, 6042, 8042, 10042, 10054 31211015 3-9

Boom
6. Using a suitable hoist and slings, lift the boom assembly 11. Use a hoist or suitable support to position the right side
and position the boom on the frame. Align the compensation cylinder to its original orientation onto
mounting plates on the frame between the mounting the lower cylinder mount. Coat the entire
hubs on each side of the boom assembly. Lower the Compensation cylinder pin with anti-seize compound.
boom assembly until the holes in the boom assembly Insert the pin through the rod end of the cylinder and
and the mounting plates align. the self-aligning bearing. Secure with lockbolt. Repeat
7. On the end of the boom pivot pin, closest to the procedure for left side Compensation cylinder.
capscrew hole, mark the capscrew mounting hole 12. Install the boom proximity sensor on the right side
location. Coat the entire pin with anti-seize 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 mounting B
holes in the boom mounting hub.
A
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 (B) between the sensor and the boom is
0.12 in (3 mm). Torque the inside jam nut to
MH1381 36 lb-in (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 (A) between
the boom mounting hub and the self aligning bearing 16
in the frame. If an additional shim is required to
maintain the maximum gap, the extra shim MUST be 15
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 (16) to the inside
bulkhead fitting and the Extend/Retract cylinder.
15. Install the Extend and Retract tube clamp halves (15).
16. Uncap and connect the hydraulic hoses and attach to
their appropriate cylinder locations.
3-10 31211015 6036, 6042, 8042, 10042, 10054

Boom
17. Install the Extend and Retract and Auxiliary (if 3.4.6 Second Boom Section Installation
equipped) tube assemblies to their appropriate
bulkhead fittings. Secure with tube clamps.
21
18. Uncap and connect the previously labeled attachment
tilt and auxiliary (if equipped) hydraulic hoses to their
appropriate bulkhead fittings.
8
MH1481
1. At the rear of the second boom section, assemble the

retract chain sheave (21) to the mounting ears on the
right side of the boom. Place the sheave between the
ears and insert the sheave pin (8) from the left side.
20
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
MH1461 pin and to distribute grease evenly.
19. Inside the rear of the boom, slide the threaded clevis
end (20) 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 clevis until the
threads are flush with the top of the nut.
21. Install the bottom wear pads to the first boom section 9
with the previously used hardware.
MH1501
3. Install the hose reel assembly (9), 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.
6. Before installing the second boom section into the first
boom section, place a string (heavy enough to pull the
attachment tilt and auxiliary hydraulic hoses) down the
inside of the boom. Allow the string to hang out the rear
of the boom. Pull the other end out the opening on the
left side of the boom where the hoses will exit the
boom. Position the strings all the way to the left side of
the first boom section.
6036, 6042, 8042, 10042, 10054 31211015 3-11

Boom
7. Using a suitable sling, carefully slide the second boom 3.4.7 Third Boom Section Installation
section into the first boom section. Leave enough room
at the front of the boom to install the center wear pad.
0
6.0 )
8. Install the center wear pad mount and wear pad to the 19 8 cm
bottom front of the first boom section. (49
9. Install the side and top wear pads to the front of the first
boom section.
MH1401
1. Stretch the attachment tilt and auxiliary (if equipped)

hoses out straight on a flat surface. Measure from the
male end of each hose back 196 in (498 cm) and apply
12 tape around each hose at that point. The tape is for
proper tensioning of the 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
MH1091 place with hose clamps. DO NOT tighten the hose
clamps at this time.
10. Install the double extend chain sheave (12) to the front
of the second boom section.
11. With the sling still in place, install the rod end of the 2
Extend/Retract cylinder, pin and retaining ring.
12. Install the front, bottom wear pads in the second boom
section.
MH1631
3. Install the hose clamp support bracket (2) 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 (1).
Hold the hoses in this position, and tighten the hose
clamps.
3-12 31211015 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.
5
9
MH1651
MH1691
6. Lay the two extend chains (5) on the top of the third
boom section with the threaded clevis ends toward the 12. Assemble the hoses to the hose reel (9) at the rear of the
rear of the boom. Coat the threads on each clevis with boom.
multi-purpose grease and insert the clevis’ through the
Note: Keep the hoses in the same order as they come from the
holes in the anchor plate. Install a washer and locknut
hose clamps. DO NOT allow the hoses to cross.
onto each clevis. Tighten the locknut enough so the
threads are even with the top of the locknut. 13. Tie the strings (positioned inside the first boom section)
7. At the rear of the third boom section, place the male to the male end of the hydraulic hoses coming off the
ends of the hydraulic hoses in the third boom section to bottom of the hose reel assembly.
prevent damage while installing the third boom section 14. Working from the front of the boom, pull each hose
into the second boom section. through the boom assembly through the opening at
8. Grease the sections of the boom in areas where the the bottom of the first boom section.
wear pads will slide. 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.
10
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 (10).
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 31211015 3-13
Boom
18. Insert the shoulder bolt from the top down and secure 3.4.8 Boom Installation
in place with a locknut.
23
22 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 to
relieve any trapped pressure in the attachment tilt
SH1871
system. If the machine is equipped with auxiliary
19. Assemble the two extend chains to the mount if the controls, move the auxiliary hydraulic joystick in both
yoke plates (22) were removed from the extend chains. directions to relieve any trapped pressure in the
Secure in place with a locknut. Tighten the locknut auxiliary hydraulic system.
securely; but the yoke plates must pivot freely. 4. Refer to Section 2.7, “Thread Locking Compound”, for all
20. Align the holes in the yoke plates with the hole in the thread locking requirements.
mount on the first boom section. Coat the shoulder 5. With the sling still in place, install the rod end of the
bolt (23) with anti-seize compound and insert the Compensation cylinder, pin and bolt. Torque lock bolt to
shoulder bolt through the yoke plates and the mount 100 - 110 lb-ft (135 - 149 Nm).
on the boom. Secure in place with a locknut. Tighten
6. With the sling still in place, install the rod end of each
the locknut securely; but the yoke plates must pivot
lift/lower cylinder, pin and bolt. Torque lock bolt to
freely.
200 - 215 lb-ft (271 - 291 Nm).
21. Install the quick coupler and attachment tilt cylinder to
7. Uncap and connect the hydraulic hoses at the rear of
the front of the boom. Refer to Section 3.9.2, “Quick
the boom.
Coupler Installation”.
8. Connect the boom proximity sensor at the rear of the
22. If necessary, install the auxiliary hydraulic fittings to the
boom.
front of the boom.
9. Recheck wear pad gaps to ensure they meet the
23. Uncap and connect the previously labeled hoses to the
minimum gap requirement. Shim as necessary.
attachment tilt cylinder.
10. Ensure that the boom chains are properly adjusted.
24. Properly connect the battery. Refer Section 9.8,
Refer to Section 3.7.6, “Boom Chain Tension Adjustment
“Battery”, for procedure.
(6036, 6042, 8042 & 10042)”.
25. Remove the Do Not Operate Tags from both the ignition
key switch and the steering wheel.
26. Start the engine and operate all boom functions several
times. Check the chain tension again and adjust as
necessary. Check for leaks, and check the hydraulic fluid
level in the tank; add fluid if required. 13. Start the engine and operate all boom functions several
times. Check for leaks, and check the hydraulic fluid at
27. Clean up all debris, hydraulic fluid, etc., in, on, near and
the reservoir; add fluid if required.
around the machine.
28. Install the rear cover to the boom.
29. Close and secure the engine rear and side engine doors.
3-14 31211015 6036, 6042, 8042, 10042, 10054

Boom
3.5 BOOM SYSTEM - FOUR SECTION (10054) 3.6.1 Fourth Boom Section Removal
3.5.1 Boom System Operation Note: If replacing the fourth section boom, remove the quick
The four section boom consists of the fourth, third, second coupler from the fourth section. Refer to Section 3.9, “Quick
and first boom assemblies with double intermediate boom Coupler”.
extend chains, a single inner boom extend chain, a single
inner boom retract chain and a single intermediate boom
retract chain.
the transmission lever in (N) NEUTRAL, engage the park
As the Extend/Retract hydraulic cylinder, which is anchored brake and shut the engine OFF.
at the front of the second boom section, and the rear of the
first boom section begins to extend, it forces the second
boom section out of the first boom section.
The fourth, third, second and first boom sections are
4. Open the engine rear and side engine doors. Allow the
connected by extend and retract chains. These chains are
routed around sheaves on the third and second boom
sections. As the second and third boom sections are forced 5. Move the attachment tilt joystick in both directions to
out, the extend chain pulls the fourth boom section out of relieve any trapped pressure in the attachment tilt
the third. 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 third boom section is pulled
auxiliary hydraulic system.
back into the fourth boom section, and the retract chain pulls
the third and fourth boom sections back into the second 6. Label, disconnect and cap the hoses attached to the
boom section. attachment tilt cylinder. Cap all fittings to keep dirt and
This mechanical linkage formed by the chains and
supporting hardware, extends and retracts the second, third 7. If the machine is equipped with auxiliary hydraulics,
and fourth boom sections at the same rate. label, cap and remove the hoses from the bulkhead
fittings.
The first boom section does not extend or retract, but lifts
If replacing the fourth boom section with a new boom
and lowers via action of the Lift/Lower cylinders.
section: Remove the female coupler, male nipple and
bulkhead fittings from the bulkhead plate inside the
3.6 BOOM ASSEMBLY MAINTENANCE boom head.
These instructions must be completed in sequence. The 8. Remove the rear cover from the boom.
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 1
machine and work area, and review the task about to be
undertaken. Read, understand and follow these instructions.
WARNING MH1451
NEVER weld or drill the boom unless approved in writing 9. At the front of the first boom section, label and remove
by the manufacturer. The structural integrity of the boom the hydraulic hoses from the bottom tube assemblies at
will be impaired if subjected to any repair involving the mounting plate (1). Cap the hose ends.
welding or drilling.
6036, 6042, 8042, 10042, 10054 31211015 3-15

Boom
MH1691
MH1791
10. Label and remove the hydraulic hoses from the hose 16. At the front of the boom, disconnect the fourth boom
reel (2). section extend chain clevis (1) from the anchor plates
on the third boom section. Pull the extend chain clevis
from between the plates and lay over the front of the
3
fourth boom section.
17. Remove the extend chain sheave (6).
18. Remove the top and side wear pads on the inside of the
4 third boom section. Label and tag each set of wear pads
being removed.
MH1781
2
11. At the rear of the boom, locate the fourth boom section
extend chain locknut (3). 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
section extend chain locknuts (4). Measure the amount MH1501
of threads protruding beyond each locknut and record 19. At the rear of the boom, remove the hose reel
the measurements for reassembly. assembly (2). This requires removal of the bottom and
14. Loosen, but DO NOT remove the locknuts. 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 31211015 6036, 6042, 8042, 10042, 10054

Boom
10
7
MH1861
23. Remove the two capscrews and lockwashers holding

the hose carrier support (10) and the lower wear pad to
the third boom section.
24. Pull the hose carrier support with hose carrier attached
MH2841 toward the rear of the boom. Reinstall the capscrews
and lockwashers to hold the wear pad in place.
20. Inside the third boom section, remove the hose clamps
DO NOT fully tighten the capscrews.
and hose clamp support bracket (7).
25. Remove the hose carrier support from the hose carrier.
21. Return to the cab, start the engine and fully retract the
boom slowly. Shut the engine OFF. Note: If replacing the third boom section with a new boom
section, the quick coupler assembly and the Attachment Tilt
Note: Record the location of the shoulder bolt to ensure correct
cylinder should be removed at this time. Refer to Section 3.9,
installation.
“Quick Coupler”.
8
26. Using a sling or suitable support, pull the fourth boom
section straight out of the third boom section.
Reposition the slings as needed so the fourth boom
section balances when removed from the third boom
section. Set the boom section down on a hard, level
surface. Support the boom as needed to prevent it from
tipping over.
9 11
MH4071
22. At the rear of the boom, remove the shoulder bolt (8) to
the fourth boom section retract chain (9). Let the chain MH1871
hang out the rear of the boom.

27. At the rear of the boom section, remove the extend
chain clevis (11) from the extend chain clevis anchor.
28. At the rear of the fourth boom section, remove the
remaining wear pads, shims and hardware. Label and
6036, 6042, 8042, 10042, 10054 31211015 3-17

Boom
12
14
MH1901
MH1961
30. Inside the boom section, remove the hardware securing
the hose carrier (12) to the bottom of the boom. 35. Remove the hose carrier assembly (11) from the boom
by carefully pulling both the upper and lowers portions
31. On each side of the boom, remove the hardware
through the rear of the boom at the same 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 wear
pads being removed.
13
15
MH1911
32. Loosen, but DO NOT remove the hardware holding the

front of the hose carrier guide and the top wear
pad (13) 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 (15) holding the yoke plates

to the mount at the front of the first boom section.
3. Remove the extend chain sheave pin and sheave on the
third boom section.
3-18 31211015 6036, 6042, 8042, 10042, 10054

Boom
3.6.3 Second Boom Section Removal

1. At the front of the first boom section, remove the top,
16 side and bottom wear pads. Label and tag each set of
wear pads being removed.
17
MH2011
4. Remove the locknuts (16) holding the threaded clevis of

the extend chains to the anchor bracket on the rear of
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 (17) from the inside of
7. Remove the shoulder bolt. Let the retract chain hang the second boom section.
out the rear of the boom. 3. Using a suitable sling or support, secure the front of the
8. Using a sling or suitable support, pull the third boom Extend/Retract cylinder.
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.
18
MH2171
5. On the left side of the first boom section, remove the

boom extend interlock proximity sensor (18) 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 section down on a hard,
level surface. Support the boom as needed to prevent it
from tipping over.
6036, 6042, 8042, 10042, 10054 31211015 3-19

Boom
7. Remove the remaining wear pads, shims and hardware. 5. Remove the retract chain by pulling it out the rear of the
Label and tag each set of wear pads being removed. boom.
“Boom Wear Pads”. 21
MH1131
6. Label, disconnect and cap the attachment tilt and

auxiliary (if equipped) hydraulic hoses on the mounting
plate (21).
7. Label, disconnect and cap the attachment tilt and
auxiliary (if equipped) hydraulic tubes from the
bulkhead fittings.
19 8. Label, disconnect and cap the Extend/Retract hydraulic
MH2141 hoses from the bulkhead fittings.
9. At the underside of the second boom section, remove
the locknut (19) from the retract chain clevis. Pull the
retract chain out of the boom through the rear of the
boom. 22
23
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 and
MH1151
9. Label, disconnect and cap the Extend/Retract hydraulic

tubes (22) from the bulkhead fittings. Remove the tube
clamps (23).
24
20
MH1111
4. At the underside of the boom, remove the retract chain

locknut (20). Measure the amount of threads protruding MH1201
beyond the locknut and record the measurement for
reassembly of the chain. 10. Label, disconnect and cap the hydraulic hoses attached
to the compensation cylinders (24).
3-20 31211015 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. Remove good condition, the rubber bumper can be reused. If
the locknut from the base end of compensation the bumper is showing signs of cracking or
cylinder. Lift the compensation cylinder away from the deterioration, it should be replaced.
machine. Repeat procedure for the right compensation 20. Remove the Extend/Retract cylinder from the boom.
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.
25
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 bumper into
12. On the right side boom pivot mounting plate, remove the hole in the Extend/Retract cylinder retainer. Secure
the boom proximity sensor (25). the rubber bumper in place with a new locknut. Tighten
13. With the boom securely supported, block the Lift/Lower securely. Lower the rod end of the Extend/Retract
cylinders. Remove the lockbolts from the rod end of the cylinder, and allow it to rest on the rubber bumper.
cylinders and lower the cylinders onto the machine. 4. Using a suitable hoist and slings, lift the boom assembly
and position the boom on the frame. Align the
mounting plates on the frame between the mounting
26 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.
6. Insert the pivot pin from the outside of the boom
MH1241
assembly, making sure the marks for the capscrew
mounting hole stay in line with the capscrew mounting
14. Remove the boom pivot pins (26) and lockbolts. holes in the boom mounting hub.
15. Using a sling or suitable support, carefully lift the first
boom section away from the machine. Set the boom
section down on a hard, level surface. Support the
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 31211015 3-21

Boom
A B
27
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 until
MH1381 the gap (7) between the sensor and the boom is
7. Shim the boom as required using the shims (27) to 0.12 in (3 mm). Torque the inside jam nut to
maintain a 0.10 in (2,5 mm) maximum gap (A) between 36 lb-in (4,1 Nm), to hold the sensor in position.
the boom mounting hub and the self aligning bearing
in the frame. If an additional shim is required to
maintain the maximum gap, the extra shim MUST be
inserted on the right side of the boom. 22
8. Align the rod end of the right Lift/Lower cylinder with
the self-aligning bearing on the boom assembly. Coat 23
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.
9. Use a hoist or suitable support to position the right side
compensation cylinder to its original orientation onto
the lower cylinder mount. Coat the entire
Compensation cylinder pin with anti-seize compound. MH1151
Insert the pin through the rod end of the cylinder and 12. Install the Extend and Retract tubes (22) to the inside
the self-aligning bearing. Secure with lockbolt. Repeat bulkhead fitting and the Extend/Retract cylinder.
procedure for left side Compensation cylinder.
13. Install the Extend and Retract tube clamp halves (23).
10. Install the boom proximity sensor on the right side
mounting plate. With the boom properly shimmed, 14. Uncap and connect the previously labeled hydraulic
position the boom assembly all the way to the right hoses and attach to their appropriate cylinder locations.
side. 15. Install the extend and retract and auxiliary
(if equipped) tube assemblies to their appropriate
bulkhead fittings. secure with tube clamps.
16. Uncap and connect the previously labeled attachment
tilt and auxiliary (if equipped) hydraulic hoses to their
appropriate bulkhead fittings.
3-22 31211015 6036, 6042, 8042, 10042, 10054

Boom
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.
28
MH1461 MH1501
17. Inside the rear of the boom, slide the threaded clevis 3. Install the hose reel assembly (2), left side and bottom
end (28) of the retract chain down the right side of the wear pads to the rear of the second boom section.
boom. Guide the threaded part of the clevis out 4. Install the boom side and top wear pads of the second
through the hole in the tab on the bottom of the boom. boom section.
Pull threaded part of clevis all the way through tab.
18. Coat the entire threaded portion of the clevis with wear pads will slide.
multi-purpose grease. Install a flat washer and locknut
onto the clevis. Thread the nut onto the clevis until the 6. Before installing the second boom section into the first
threads are flush with the top of the nut. boom section, place a string (heavy enough to pull the
attachment tilt and auxiliary hydraulic hoses) down the
19. Install the bottom wear pads to the first boom section inside of the boom. Allow the string to hang out the rear
with the previously used hardware. of the boom. Pull the other end out the opening on the
left side of the boom where the hoses will exit the
3.6.6 Second Boom Section Installation 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 enough room
at the front of the boom to install the center wear pad.
17
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 29
and insert the sheave pin (17) from the left side. Align MH2211
the hole in the pin retainer plate with the threaded hole
in the left ear. Secure the pin. 8. Install the center wear pad mount (29) and wear pad to
the bottom front of the first boom section.
6036, 6042, 8042, 10042, 10054 31211015 3-23

Boom
9. Install the side and top wear pads to the front of the first 3.6.7 Third Boom Installation
boom section.
1. Install the bottom, side and top wear pads to the rear of
10. Install the double extend chain sheave to the front of the third boom section.
the second boom section.
17
11. With the sling still in place, install the rod end of the
Extend/Retract cylinder, pin and retaining ring.
12. Install the front, bottom wear pads in the second boom
section.
30
MH2021
2. At the rear of the third boom section, assemble the

retract chain sheave (30) to the mounting ears on the
left side of the boom. Place the sheave between the ears
25
and insert the sheave pin (17) from the right side. Line
up the hole in the pin retainer plate with the threaded
MH2171
hole in the right ear. Secure the pin.
13. On the left side of the first boom section, reassemble 3. Apply grease to the grease fitting in the pin. Spin the
the boom extend interlock sensor (25) with mounting sheave by hand to ensure the sheave spins freely on the
bracket. Secure in place with the previously used pin and to distribute grease evenly.
hardware. Tighten securely.
4. Install the bottom front wear pads.
14. Secure the boom extend interlock sensor wire to the
attachment tilt tubes under the boom with new tie
wraps. 31
MH2301
5. Lay the two extend chains (31) on the top of the third
boom section with the threaded clevis ends toward the
rear of the boom. Coat the threads on each clevis with
multi-purpose grease and insert the clevis’ through the
holes in the anchor plate. Install a washer and locknut
onto each clevis. Tighten the locknut enough so the
threads are even with the top of the locknut.
3-24 31211015 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
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 to
MH2381
the sheave. Turn the sheave by hand to distribute the
grease evenly. 1. Lay the hose carrier assembly out flat on a level surface.
15 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.
32
MH1991
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 (15) 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 sheave MH2441
on the right side of the boom. Stretch the chain forward 4. Lay the fourth boom section extend chain (32) on the
and place the clevis between the two anchor plates. top of the fourth boom section with the threaded clevis
Align the hole in the clevis with the hole location end toward the rear of the boom. Coat the threads on
recorded in the removal procedure. Insert the shoulder the clevis with multi-purpose grease and insert the
bolt and locknut, tighten securely. 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 31211015 3-25

Boom
33
MH2411
5. Fold the hose carrier assembly in half, ensure the female

ends (33) of the hoses are on the bottom, and carefully
slide the folded hose carrier into the fourth boom
section.
6. Line up the lower mounting holes in the hose carrier
assembly with the holes in the bottom of the fourth
boom section. Secure with the previously used MH2471
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 with carrier) one at a time over the top of the angled
the angled guides toward the front. Slide the hose guide (34) on the front side of the hose guide. Push the
guide into the fourth boom section, and place the front hoses into the hose channel on the left side of the
notches onto the rear wear pad mounting capscrew. Be fourth boom section and down to the front of the boom
sure the notch in the side of the hose guide is under the section. Repeat this procedure for the two right side
flat washer on each side of the boom. hoses into the hose channel on the right side of the
8. Rotate the back of the hose guide up toward the top of boom.
the fourth boom section as far as it will go. Tighten the 10. Insert a capscrew through the hole in the fourth boom
rear wear pad mounting capscrews enough to hold the section. Secure the hose guide in place with a flat
hose guide. washer and locknut. Torque to 28 - 34 lb-ft (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
3-26 31211015 6036, 6042, 8042, 10042, 10054

Boom
10
MH1861
15. Reassemble the hose carrier support to the hose carrier

on the right side. Install the hose carrier support (10)
and lower wear pad with the previously used hardware.
16. Place the retract chain up around the retract chain
sheave on the left side of the boom. Stretch the chain
forward and place the clevis between the two anchor
MH2521
plates. Line up the hole in the clevis with the anchor
plate hole location recorded during removal. 22. Place the extend chain clevis between the mounting
17. Insert the shoulder bolt and secure in place with a plates at the front of the second boom section. Coat the
locknut. Tighten the locknut. shoulder bolt (5) with anti-seize compound and insert
through the plates and clevis. Secure the shoulder bolt
18. Install the side and top wear pads.
in place with a locknut. Tighten securely, but the chain
19. Place the fourth boom section extend chain sheave (6) clevis should pivot freely.
between the mounts at the front of the third boom
section. Insert the sheave pin through the mounts and Note: Keep the four hoses in line as they come out of the hose
the sheave. Secure in place with the previously used carrier assembly at the rear of the boom. DO NOT allow the
hardware. hoses to cross.
20. After the sheave is assembled, apply a good grade of 23. Install the hose clamp support bracket and top left side
multi-purpose grease to the grease fitting at the end of wear pad.
the pin. Turn the sheave by hand to distribute grease 24. Position the hydraulic hoses with the edge of the tape at
evenly. the hose clamps. Hold the hoses in this position, and
21. Place the fourth boom section extend chain up and tighten the hose clamps.
around the sheave at the front of the third boom
section.
MH1691
25. Assemble the hoses to the hose reel (2) at the rear of the
boom.
6036, 6042, 8042, 10042, 10054 31211015 3-27

Boom
26. Tie the strings (positioned inside the first boom section 3.7 BOOM EXTEND AND RETRACT
during installation) to the male end of the hydraulic
CHAINS
hoses coming off the bottom of the hose reel assembly.
27. Working from the front of the boom, pull each hose
through the boom assembly through the opening at 3.7.1 Boom Chain Inspection
the bottom of the first boom section.
28. Remove the strings from the hoses. WARNING
Worn pins, stretched or cracked links or corrosive
environments can cause chain failure. A chain failure
could result in uncontrolled boom movement, loss of
load or machine instability.
1 Under normal operating conditions the boom extend chains
will need to be inspected every 250 hours of operation. The
retract chains need to be exposed and inspected every 1000
hours of operation. Environmental conditions and dynamic
impulse/shock loads can drastically affect normal operating
MH1451
conditions and require more frequent inspection intervals.
29. At the front of the first boom section, assemble the hose Environments in which material handling machines operate
assemblies and tube assemblies to the mounting can vary widely from outdoor moisture to temperature to
mildly corrosive or highly corrosive industrial atmospheres,
plate (1).
in addition to abrasive exposures such as sand and grit.
Note: Where the hose assemblies come out of the outer boom, Some effects can be as follows:
lubricate the radius in the first boom section with soap and • Moisture - Corrosive rusting reduces chain strength
water to allow proper tensioning of hoses. by pitting and cracking.
30. Install the quick coupler and attachment tilt cylinder to • Temperature - Low temperature reduces chain
the front of the boom. Refer to Section 3.9.2, “Quick strength by embrittlement. Going in and out of
Coupler Installation”. cold storage results in moisture from condensation.
31. Uncap and connect the previously labeled hoses to the • Chemical Solutions or Vapors - Corrosive attack on
attachment tilt cylinder. the chain components and/or the mechanical
connections between the chain components.
Cracking can be (and often is) microscopic. Going
“Battery”, for procedure. from microscopic cracking to complete failure can
33. Remove the Do Not Operate Tags from both the ignition be either abrupt or may require an extended period
key switch and the steering wheel. of time.
34. Start the engine and operate all boom functions several • Abrasives - Accelerated wearing and scoring of the
times. Check the chain tension again and adjust as articulating members of the chain (pins an d
necessary. Check for leaks, and check the hydraulic fluid plates), with a corresponding reduction in chain
level in the tank; add fluid if required. strength. Due to the inaccessibility of the bearing
surfaces (pin surfaces and plate apertures), wear
35. Clean up all debris, hydraulic fluid, etc., in, on, near and and scoring are not readily noticeable to the naked
around the machine. eye.
36. Install the rear cover to the boom.
3-28 31211015 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.
• Attempting to “inch” loads which are beyond the MZ1463
rated capacity of the machine.

Check the chain for wear on the link plate edges caused
The above load cycles and environmental conditions make it by running back and forth over the sheave. The
impossible to predict chain life. It is therefore necessary to maximum reduction of material should not exceed 5%.
conduct frequent inspections until replacement life can be Measure and compare to a normal link plate height by
predicted. measuring a portion of chain that does not run over the
The boom chain’s normal life expectancy can be expressed sheave. If the measured plate height (1) is 5% less than
the normal plate height (2), discard and replace the
as a maximum percent of elongation. This is generally 3%.
As the chain flexes back and forth over the sheave, the chain.
bearing joints (pins and inside link plates) gradually incur Elongation
wear due to articulation.
It is important to measure the chain in the section that
3.7.2 Inspection Guidelines moves over the sheaves because it receives the most
frequent articulation. Measuring the chain near its clevis
1. Park the machine on a firm, level surface, raise the boom terminals could give an inaccurate reading. The ends of
to a horizontal (level) position, place the transmission in the chains, near the clevis terminal, will not have flexed
(N) NEUTRAL, engage the park brake switch. as frequently, if at all, as the middle of the chains.
2. Fully extend the boom until the extend chain is taut. It is best to measure in 12 pin increments from pin
Shut the engine off. center to pin center. For example, if the links are one
inch from pin center to pin center, the distance should
3. The extend chains will be visible for inspection with the be 12 in (305 mm). If the links are 3/4 in (19,0 mm) apart,
machine in this state. the distance after 12 pins should be 9 in (228,6 mm).
4. While doing the chain inspection, check all chain clevis
4
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 31211015 3-29

Boom
Distorted or Battered Link Plates Cracked Plates

Inspect the chains very carefully, front and back as well
85 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 cause result of repeated cyclic
tight joints and prevent flexing. loading beyond the MZ1467
Turning or Protruding Pins chain’s endurance limit.
Highly loaded chain, operating with inadequate • Stress Corrosion

lubrication can generate abnormal frictional forces Cracking - The outside
between pin and link plates. When chain is allowed to link plates are
operate in this condition, a pin or series of pins, can particularly 10 MZ1468
begin to twist out of a chain, resulting in failure. susceptible to stress

corrosion cracking (10).
• Corrosion Fatigue Cracking - Corrosion fatigue
cracks are very similar to fatigue cracks in
7
6 appearance. Corrosion fatigue is the combined
8 action of an aggressive environment and cyclic
stress.
MZ1465
Other Modes of Failure
Examine the pin head rivets to determine if the “VEE” • Ultimate Strength Failure -
flats are still in correct alignment (6). Chain with These types of failures are
rotated/displaced heads (7) or abnormal pin caused by overloads far in 1
protrusion (8) should be replaced immediately. excess of the design load. MZ1469
DO NOT attempt to repair the chain by welding or Either fractured plates (1) or 2
driving the pin(s) back into the chain. Once the press fit enlarged holes (2) can occur. If
integrity between outside plates and pins has been either of these failures occurs,
MZ1470
altered, it cannot be restored. the chain should be replaced
immediately.
Any wear pattern on the pin heads or the sides of the
link plates indicates misalignment in the system. This • Tight Joints -
condition damages the chain as well as increases All joints in
frictional loading and should be corrected. 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.
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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 and
1. Park the machine on a firm, level surface. Place the Lubricant Capacities”, for proper lubricant.
transmission in (N) NEUTRAL, engage the park brake The lubricant must penetrate the chain joint to prevent
switch and raise the boom to a horizontal (level) wear. Applying lubricant to the external surfaces will
position. prevent rust, but the chains should be articulated to make
2. Fully extend the boom and shut the engine OFF. 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 clear the space
While doing the chain inspection, check all chain clevis ends between the plates so that lubricant can penetrate to the
for distortion or cracking and sheaves for bearing wear or working surfaces.
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 or directly poured on, but the chain should be well flooded
stretched, the chain must be replaced. It is recommended with lubricant and the boom should be extended and
that when any chain is replaced, that all the chains and retracted to be sure that the lubricant penetrates to the
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 for
d. Retract Chains this wiping operation.
Regular application of lubricant is necessary to make sure
The retract chains are only partially visible through the rear
that all working surfaces are adequately lubricated. In
of the boom with all the sections retracted. It is possible to extremely dusty conditions, it may be necessary to lubricate
see a section of the retract chain as the boom is slowly the chains more often. Refer to Section 2.5, “Service and
extended. If there is ANY question that one or all the retract Maintenance Schedules”, and Section 2.6, “Lubrication
chains are damaged, the boom should be removed and Schedules”, for detailed information.
disassembled with the retract chains being inspected and
Lubrication of chains on machines working consistently in
replaced if necessary.
extreme hot or cold conditions requires special
Note: DO NOT attempt to repair a chain. Replace a stretched consideration. It is important that a reputable lubrication
or damaged chain with a new part. Always replace both the specialist or a JLG distributor be consulted for guidance.
chain and the clevis. It is recommended that when any chain is
replaced, that all chains and clevis’ be replaced at the same
time.
6036, 6042, 8042, 10042, 10054 31211015 3-31

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 head
(6036, 6042, 8042 & 10042)
before doing the tension check. Note: Always perform Section 3.7.5, “Boom Chain Tension
2. Park the machine on level ground. Place the Check” before adjusting the boom chain tension.
transmission 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 double boom extend 3

chains between the bottom of the extend chains and
the top of the second boom section at their closest
point. Acceptable boom chain sag is between
MH1752
1.5 in (38 mm) and 2.5 in (64 mm) on the 6036, 6042,
8942, 10042 & 10054. For the 10054, also measure the If the chain sag measurement (1) is less than
sag of the single extend chain between the bottom of 1.5 in (38 mm), tighten the two extend chain
the extend chain and the top of the third boom section adjustment locknuts (3). If the chain sag measurement
at it’s closest point. Acceptable boom chain sag is is more than 2.5 in (64 mm), loosen the two extend
between 2.85 in (72 mm) and 3.85 in (98 mm). chain adjustment locknuts.
If the measurement is either less than, or greater 2. Tighten or loosen the two extend chain adjustment
than the range given, the boom chains need to be locknuts located at the rear of the boom. Be sure that
adjusted. Continue with Section 3.7.6, “Boom Chain each extend chain maintains the same tension.
Tension Adjustment (6036, 6042, 8042 & 10042)” or Equal chain tension can be checked by the position of
Section 3.7.7, “Boom Chain Tension Adjustment the yoke (4) on the outer boom. The front of the yoke
(10054)”, to adjust the chain system. should be parallel with the front edge of the outer
boom.
5. Start the engine, retract the boom completely and turn
the engine OFF.
3-32 31211015 6036, 6042, 8042, 10042, 10054

Boom
a. Component/Assembly Verification
(6036, 6042 & 8042)
9
8
7
OH1091
OA0513
3. If there is no adjustment left on the extend chains, The third (7) to second (8) boom section separation should
tighten the retract chain locknut (5) at the front on the be checked when assembling new boom sections or chains,
underside of the outer boom. or when the rear retract chain clevis has been moved forward
on the anchor plate.
4. Recheck chain tension. Refer to Section 3.7.5, “Boom
Chain Tension Check”. Measure the separation (9) between the third and second
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 tensioned. A
6 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”.
3. To increase the separation distance: Loosen the
MA9451 retract chain locknut (5) on the bottom of the boom
one or two turns and tighten the two extend chain
5. Further chain adjustment can be achieved by loosening locknuts equally the same number of turns. A minimum
all three chain locknuts and moving the rear retract of one full thread on the clevis must protrude beyond
chain clevis (6) from the original mounting hole in the the collar of the locknut.
anchor plate to the next hole.
4. To decrease the separation distance: Loosen the
This is only acceptable when boom chain sag cannot be
extend chain locknuts at the rear of boom equally one
acquired and the chain elongation measurement is still
or two turns and tighten the retract chain locknut (5)
less than 12.36 in (313 mm). Follow the instructions in
the same number of turns. A minimum of one full
Section 3.7.6, a. “Component/Assembly Verification
thread on the clevis must protrude beyond the collar of
(6036, 6042 & 8042)”.
the locknut.
5. Install the rear boom cover.
Chain Tension Check”.
6. If the third to second boom separation distance cannot
be achieved, contact your local JLG service distributor.
6036, 6042, 8042, 10042, 10054 31211015 3-33

Boom
b. Component/Assembly Verification (10042) 3.7.7 Boom Chain Tension Adjustment (10054)

9
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
8
7
OH1091
The third (7) to second (8) boom section separation should

be checked when assembling new boom sections or chains,
or when the rear retract chain clevis has been moved forward
Measure the separation (9) between the third and second
boom section top plates. The distance should be at least
18.38 in (467 mm) and not greater than 22.38 in (568 mm)
with the boom fully retracted and the chains properly
OA0493
tensioned. A distance of less than 18.38 in (467 mm) could
result in interference and cause damage to boom
components. 11

22.38 in (568 mm):
1. Verify that the retract chain clevis (6) is not mounted in
the last hole in the anchor plate.
retract chain locknut (5) on the bottom of the boom
locknuts equally the same number of turns. A minimum
of one full thread on the clevis must protrude beyond
MH1781
the collar of the locknut.
4. To decrease the separation distance: Loosen the 1. Adjust the two third boom section extend chains.
extend chain locknuts at the rear of boom equally one If the chain sag measurement (10) is less than
or two turns and tighten the retract chain locknut (5) 1.5 in (38 mm), tighten the two extend chain adjustment
the same number of turns. A minimum of one full locknuts (11).
If the chain sag measurement (10) is more than
the locknut.
2.5 in (63,5 mm), loosen the two extend chain
5. Install the rear boom cover. adjustment locknuts (11).
If the third to second boom separation distance cannot be
achieved, contact your local JLG service distributor.
3-34 31211015 6036, 6042, 8042, 10042, 10054

Boom
14
12 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.
OH0552 acquired and the chain elongation measurement is still
less than 12.36 in (313 mm). Follow the instructions in
2. Tighten or loosen the two extend chain adjustment Section 3.7.7, b. “Component/Assembly Verification
locknuts (11) located at the rear of the boom. Be sure (10054)”.
that each extend chain maintains the same tension. 6. Recheck chain tension. Refer to Section 3.7.5, “Boom
Equal chain tension can be checked by the position of Chain Tension Check”.
the yoke (12) on the first boom section. The front of the
yoke should be parallel with the front edge of the outer b. Component/Assembly Verification (10054)
boom. The third to second boom section separation should be
checked when assembling new boom sections or chains, or
when the rear retract chain clevis has been moved forward
17
13
16
15
OA0513
OH2862
3. If there is no adjustment left on the extend chains,
tighten the retract chain locknut (13) at the front on the Measure the separation between the third (15) and
underside of the boom. second (16) section boom top plates. The distance (17)
should be at least 8.5 in (216 mm) and not greater than 11
4. Recheck chain tension. Refer to Section 3.7.5, “Boom in (279 mm) with the boom fully retracted and the chains
Chain Tension Check”. properly tensioned. A distance of less than 8.5 in (216 mm)
could result in interference and cause damage to boom
components.
6036, 6042, 8042, 10042, 10054 31211015 3-35

Boom
If the distance is less than 8.5 in (216 mm) or greater than c. Inner Boom Chain Tension Adjustment (10054)
11 in (279 mm):
Note: Always perform the Section 3.7.5, “Boom Chain Tension
1. Verify that the retract chain clevis is not mounted in the Check” before adjusting the fourth boom section extend chain
last hole in the anchor plate. tension.
2. Make sure that the chain system is properly tensioned. 19
18
MH1781
3. To increase the separation distance: Loosen the OA0493
retract chain locknut (13) on the bottom of the boom

locknuts (18) equally the same number of turns. A 1
minimum of one full thread on the clevis must protrude
beyond the collar of the locknut.
extend chain locknuts (18) at the rear of boom equally
one or two turns and tighten the retract chain locknut
(13) the same number of turns. A minimum of one full
the locknut.
Note: If the third to second boom section separation distance
cannot be achieved, contact your local authorized service
distributor. MH1781
1. Adjust the fourth boom section extend chain:

If the chain sag measurement (19) is less than
2.85 in (72 mm), tighten the extend chain adjustment
locknut (1).
If the chain sag measurement (19) is more than
3.85 in (98 mm), loosen the extend chain adjustment
locknut (1).
3-36 31211015 6036, 6042, 8042, 10042, 10054

Boom
d. Component/Assembly Verification (10054)

The fourth to third boom section separation should be
checked when assembling new boom sections or chains, or
when the rear retract chain clevis has been moved forward
2 6
OH0661 4 5
OH2871
2. If there is no adjustment left on the extend chains,
tighten the retract chain locknut (2) on the bottom of Measure the separation between the third (4) and
the second boom section several turns. 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
13.75 in (349 mm) could result in interference and cause
damage to boom components.
3 14.25 in (362 mm):
1. Verify that the retract chain clevis is not mounted in the
last hole in the anchor plate.
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 minimum of
one full thread on the clevis must protrude beyond the
collar of the locknut.
MH4071
4. Further chain adjustment can be achieved by loosening extend chain locknut at the rear of boom one or two
both chain locknuts and moving the rear retract chain turns and tighten the retract chain locknut on the
clevis (3) from the original mounting hole in the anchor bottom of the second boom section the same number
plate to the next hole. of turns. A minimum of one full thread on the clevis
must protrude beyond the collar of the locknut.
acquired and the chain elongation measurement is still Note: If the fourth to third boom section separation distance
less than 12.36 in (313 mm). Follow the instructions in cannot be achieved, contact your local authorized service
Section 3.7.7, d. “Component/Assembly Verification distributor.
(10054)”.
6036, 6042, 8042, 10042, 10054 31211015 3-37

Boom
3.7.8 Extend Chains Removal and

Replacement
(6036, 6042, 8042 & 10042)
1. Park the machine on level ground. Place the 9
switch, level the boom and shut the engine OFF.
3. Properly disconnect the battery. Refer Section 9.8,
MH6510
4. Remove the boom rear cover. 8. At the rear of the boom, attach one end of a wire to the
threaded clevis (9) on the right side extend chain using
a threaded eye or a flat washer tack welded to a
capscrew. The outside diameter of the eye or flat washer
must be smaller than the diameter of the threads on the
clevis.
9. Have an assistant pull the chain from the front of the
7 boom while guiding the wires into the boom from the
rear. Remove the wire from the clevis, but not from
inside the boom.
10. Inspect wear and condition of the booms, chains, clevis’,
MH1752 chain sheaves, Extend/Retract cylinder, chain rods,
5. At the rear of the boom, locate the extend chain clevis anchors and all mounting hardware. Replace any
locknuts (7). Record the amount of threads extending worn or damaged parts. DO NOT attempt to make any
beyond both the locknuts. These measurements will be repairs to the chain.
the starting point for adjustment of the extend chains Note: Chains and clevis’ are wear items and experience the
after installation. same stress. DO NOT attempt to repair a chain. Replace a
6. Remove and replace the extend chains one at a time. stretched or damaged chain with a new part. Always replace
Remove the right side locknut and flat washer, holding both the chain and the clevis’.
the clevis to the anchor plate. 11. Coat the threads of the threaded clevis with
8 multi-purpose grease.
12. Lay the new extend chain on top of the first boom
section with the threaded clevis toward the front of the
boom.
13. Attach the wire to the threaded clevis of the new extend
chain using a threaded eye or a flat washer tack welded
SH1811 to a capscrew. The outside diameter of the eye or flat
washer must be smaller than the diameter of the
7. At the front of the boom, remove the capscrew (8) and threads on the clevis.
locknut holding the right side extend chain clevis to the
yoke plates. Replace the capscrew if damaged or worn.
3-38 31211015 6036, 6042, 8042, 10042, 10054

Boom
3.7.9 Retract Chain Removal and Replacement

(6036, 6042, 8042 & 10042)
1. Park the machine on level ground. Place the
10 2. Place a Do Not Operate Tag on both the ignition key
11
4. Remove the boom rear cover.
12
SH1852
14. Pull the extend chain forward and place over the right 13
side of the chain sheave (10). Guide the wire and the
threaded clevis under the chain sheave, and between
the top of the third boom section (11) and the second
boom section (12).
15. Have an assistant guide the extend chain into the front
of the boom, while pulling on the wire from the rear of
the boom. Guide the threaded clevis into the hole in the
anchor plate.
16. Assemble the flat washer and locknut to the threaded OA0513
clevis. Thread the locknut until the threads are flush 5. At the front underside of the boom, record the amount
with the top of the nut. of threads extending beyond the locknut (13). This
17. Pull the anchor clevis up around the double chain measurement will be the starting point for adjustment
sheave and position the clevis between the yoke plates. of the boom retract chain.
18. Coat the capscrew with anti-seize compound. Insert the 6. At the front underside of the boom, loosen the locknut
capscrew through the yoke plates and clevis and secure far enough that it can be removed by hand.
in place with a locknut. Tighten securely; but the chain
must pivot freely.
19. Remove the wire from the clevis.
20. Repeat this procedure for the left side extend chain.
21. At the rear of the boom, tighten the two locknuts on the
14
extend chain clevis’ until the amount of threads
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.
24. Properly connect the battery. Refer Section 9.8, MA9441
“Battery”, for procedure. 7. Attach a wire or string (14) to the threaded clevis with a
25. Remove the Do Not Operate Tags from both the ignition threaded eye or a flat washer tack welded to a
key switch and the steering wheel. capscrew. The outside diameter of the eye or flat
threads on the clevis. The wire or string will be used to
6036, 6042, 8042, 10042, 10054 31211015 3-39
Boom
pull the chain back through the boom during 14. From the rear of the boom, have an assistant push the
reassembly. threaded clevis end of the chain under the chain sheave
8. Remove the locknut and flat washer holding the retract and down between the second and first boom sections.
chain threaded clevis to the mounting tab. Pull the front clevis using the string or wire. Keep the
chain to the right side of the boom, push the threaded
Note: Record the location of the shoulder bolt to ensure correct clevis down to the tab at the front underside of the first
installation. boom section.
15 15. Have an assistant guide the threaded end of the clevis
through the hole in the tab.
16. Remove the string or wire from the end of the clevis.
17. Reassemble the flat washer and locknut onto the
threaded clevis. Tighten the locknut until the threaded
end of the clevis is flush with the top of the locknut.
18. At the rear of the boom, place the retract chain up and
over the chain sheave. Place the clevis between 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
MH2551 recorded during removal.
9. At the rear of the boom, locate the two retract chain 20. If installing a new chain, line up the hole in the clevis
anchor plates holding the retract chain to the third with the second hole from the rear of the anchor plates.
boom section just in front of the retract chain sheave. Insert the shoulder bolt, saved during removal of the
Remove the locknut and shoulder bolt (15) holding the old chain.
retract chain clevis to the anchor plates. The two anchor 21. Secure the shoulder bolt in place with a locknut.
plates can remain in place on the third boom section. Tighten the locknut securely.
10. From the rear of the boom, pull the retract chain out of 22. Tighten the locknut on the retract chain clevis until the
the rear of the boom. amount of threads protruding beyond the locknut is the
11. Inspect wear and condition of the booms, chains, clevis’, same as the measurement recorded during removal of
chain sheaves, Extend/Retract cylinder, chain rods, clevis the retract chain.
anchors and all mounting hardware. Replace a worn or 23. Check and adjust retract chain tension. Refer to Section
damaged chain. DO NOT attempt to make any repairs 3.7.5, “Boom Chain Tension Check”.
to the chain.
Note: Chains and clevis’ are wear items and experience the 25. Properly connect the battery. Refer Section 9.8,
same stress. DO NOT attempt to repair a chain. Replace a “Battery”, for procedure.
stretched or damaged chain with a new part. Always replace
both the chain and the clevis’. 26. Remove the Do Not Operate Tags from both the ignition
12. Remove the string from the old chain and attach it to
the new clevis.
13. Coat the threads of the threaded clevis with
multi-purpose grease.
3-40 31211015 6036, 6042, 8042, 10042, 10054

Boom
3.7.10 Extend Chains Removal and 8. Inspect the capscrews for signs of wear or damage.
Replacement (10054) Replace with new capscrews if damaged or worn.
9. At the front of the second boom section, remove the
a. Second and Third Boom Section Extend Chains capscrew and lockwasher holding the extend chain
Removal and Replacement sheave pin to the sheave mount bracket. Remove the
1. Park the machine on level ground. Place the pin from the mount bracket and the extend chain
transmission in (N) NEUTRAL, engage the parking brake sheave. Remove the extend chain sheave from the
switch, level the boom and shut the engine OFF. mount.
should not be operated. 18
16
MH6510
10. At the rear of the boom, attach one end of a wire to the
threaded clevis (18) on the right side extend chain with
a threaded eye or a flat washer tack welded to a
capscrew. The outside diameter of the eye or flat
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
MH1781
inside the boom.
12. Coat the threads of the threaded clevis with multi-
5. At the rear of the boom, locate the extend chain
purpose grease.
locknuts (16). Record the amount of threads extending
beyond the locknuts. This measurement will be the 13. Lay the new extend chain on top of the first boom
starting point for adjustment of the extend chains after section with the threaded clevis toward the front of the
installation. boom.
6. Remove and replace the boom extend chains one at a 14. Attach the wire to the threaded clevis of the new extend
time. Remove the right side locknut and flat washer chain using a threaded eye or a flat washer tack welded
holding the right side chain clevis to the anchor plate. to a capscrew. The outside diameter of the eye or flat
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.
6036, 6042, 8042, 10042, 10054 31211015 3-41

Boom
24. At the rear of the boom, tighten the two locknuts on the
chain clevis’ until the amount of threads protruding
beyond each locknut is the same as the measurement
recorded during removal of the extend chains.
25. Check and adjust the retract chain tension. Refer to
19
b. Fourth Boom Section Extend Chains Removal and

Replacement
MH2601 1. Park the machine on level ground. Place the

15. Pull the extend chain forward and place in between the switch, level the boom and shut the engine OFF.
chain sheave mounts. Guide the wire (19) and the
threaded clevis into the boom by placing the threaded 2. Place a Do Not Operate Tag on both the ignition key
clevis between the top of the third boom section and switch and the steering wheel, stating that the machine
the second boom section. should not be operated.
16. Have an assistant guide extend chain into the front of 3. Properly disconnect the battery. Refer Section 9.8,
the boom while pulling the wire and threaded clevis “Battery”, for procedure.
toward the rear of the boom. Guide the threaded clevis 4. Remove the boom rear cover.
into the hole in the anchor plate.
1
17. Place the flat washer onto the threaded end of the
threaded clevis and assemble the locknut. Thread
locknut onto the threaded clevis until the threads are
flush with the top of the nut.
19. Repeat this procedure for the left side extend chain.
20. After both of the chains are replaced inside the boom,
assemble the double sheave to the mount at the front
of the second boom section.
21. Place the double extend chain sheave between the
mounts and under the extend chains at the front of the
second boom section. Insert the sheave pin through the MH1781
mounts and the double sheave. Line up the mounting
hole in the sheave pin with the threaded hole in the 5. At the rear of the boom, locate the extend chain
sheave mount and secure in place with the capscrew locknut (1). Record the amount of threads extending
and the lockwasher. Tighten securely. beyond the locknut. This measurement will be the
starting point for adjustment of the extend chain after
22. Pull the anchor clevis’ up around the double chain installation.
sheave and position the clevis’ one at a time between
the yoke plates. 6. Remove the locknut and flat washer holding the extend
chain clevis to the anchor plate on the boom.
23. Coat the capscrews with anti-seize compound. Insert the
capscrews through the yoke plates and clevis’ and
secure in place with locknuts. Tighten each locknut
securely, but the chain clevis’ must pivot freely.
3-42 31211015 6036, 6042, 8042, 10042, 10054

Boom
13. Lay the new extend chain on top of the fourth boom
section with the threaded clevis toward the front of the
2
boom.
14. Attach the wire to the threaded clevis of the new extend
chain with a threaded eye or a flat washer tack welded
to a capscrew. The outside diameter of the eye or flat
3
MH1791
7. At the front of the boom, disconnect the extend chain 5

clevis from the anchor plates on the second boom
section. Remove the locknut holding the shoulder
bolt (2) to the anchor plates. Pull the extend chain clevis
from between the plates and lay over the front of the
fourth boom section (3).
6
8. Remove the locknut and capscrew holding the extend
chain sheave to the front of the third boom section. MH5731
9. Inspect the sheave pin for corrosion or damage. If the

15. Pull the extend chain forward and place in between the
pin is damaged, it should be replaced. Minor corrosion
chain sheave mounts. Guide the wire and the threaded
can be repaired with fine emery cloth. Save the chain
clevis into the boom by placing the threaded clevis
sheave, pin and capscrew.
between the third boom section (5) and the top of the
fourth boom section (6).
16. Have an assistant guide the extend chain into the front
4 of the boom while pulling the wire and threaded clevis
into the hole in the anchor plate.
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 are
flush with the top of the nut.
MH6510
19. After the chain is replaced inside the boom, assemble
10. At the rear of the boom, attach one end of a wire to the the sheave to the mount at the front of the third boom
threaded clevis (4) on the extend chain with a threaded section.
eye or a flat washer tack welded to a capscrew. The 20. Place the extend chain sheave between the mounts at
outside diameter of the eye or flat washer must be the front of the third boom section. Insert the sheave
smaller than the diameter of the threads on the clevis. pin through the mounts and the sheave. Secure in place
11. Have an assistant pull the chain from the front of the with the capscrew, saved, and a locknut. Tighten
boom while guiding the wire into the boom from the securely.
inside the boom.
12. Coat the threads of the threaded clevis with
multi-purpose grease.
6036, 6042, 8042, 10042, 10054 31211015 3-43

Boom
21. After the sheave is assembled, apply a good grade of

multi-purpose grease to the grease fitting at the end of
the pin. Turn the sheave by hand to distribute the
grease evenly.
22. Pull the extend chain up and around the sheave at the
front of the third boom section. 7
23. Place the extend chain clevis between the mounting
plates at the front of the third boom section. Coat the
saved 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.
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 OA0513
measurement recorded during removal of the extend
chain. 5. At the front underside of the boom, locate the retract
chain locknut (7). Record the amount of threads
25. Check and adjust the extend chain tension. Refer to extending beyond the locknut. This measurement will
Section 3.7.5, “Boom Chain Tension Check”. be the starting point for adjustment of the retract chain
26. Install the boom rear cover. after installation.
27. Properly connect the battery. Refer Section 9.8, 6. At the front underside of the fourth boom section,
“Battery”, for procedure. remove the locknut and flat washer holding the retract
28. Remove the Do Not Operate Tags from both the ignition chain threaded clevis to the mounting tab.
key switch and the steering wheel. 7. Attach a wire or string to the threaded clevis with a
threaded eye or a flat washer tack welded to a
3.7.11 Retract Chain Removal and Replacement capscrew. The outside diameter of the eye or flat
(10054) washer must be smaller than the diameter of the
threads on the clevis. The wire or string will be used to
c. Third Boom Section Retract Chain Removal and pull the chain back through the boom during
Replacement reassembly.
1. Park the machine on level ground. Place the Note: Record the location of the shoulder bolt to ensure correct
transmission in (N) NEUTRAL, engage the parking brake installation.
2. Place a Do Not Operate Tag on both the ignition key 8
MH2551
8. At the rear of the boom, locate the two retract chain

anchor plates. Remove the locknut and shoulder bolt (8)
holding the retract chain clevis to the anchor plates. The
two anchor plates can remain in place on the third
boom section.
3-44 31211015 6036, 6042, 8042, 10042, 10054

Boom
9. From the rear of the boom, pull the boom retract chain 20. Remove the Do Not Operate Tags from both the ignition
out of the rear of the boom. key switch and the steering wheel.
10. Disconnect the string or wire from the retract chain
clevis, and allow it to hang out the rear of the boom. d. Fourth Boom Section Retract Chain Removal and
Replacement
11. Coat the threads of the threaded clevis with multi-
purpose grease. 1. Park the machine on level ground. Place the
12. At the rear of the boom, attach the string or wire to the
new retract chain threaded clevis end with a threaded
eye or a flat washer tack welded to a capscrew. The 2. Place a Do Not Operate Tag on both the ignition key
outside diameter of the eye or flat washer must be switch and the steering wheel, stating that the machine
smaller than the diameter of the threads on the clevis. should not be operated.
13. From the rear of the boom, have an assistant push the 3. Properly disconnect the battery. Refer Section 9.8,
threaded clevis end of the new retract chain under the “Battery”, for procedure.
chain sheave and down between the second and first 4. Remove the boom rear cover.
boom sections, while pulling the retract chain through
5. Start the engine and extend the boom until the retract
the boom using the previously attached string or wire.
chain adjustment nut on the bottom of the second
Keep the retract chain to the right side of the boom,
boom section is visible. Shut the engine OFF.
push and pull the threaded clevis down to the tab at the
front underside of the boom. 6. At the front underside of the boom, locate the retract
chain locknut. Record the amount of threads extending
beyond the locknut. This measurement will be the
starting point for adjustment of the retract chain after
installation.
10
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
OH0661
over the chain sheave. Place the clevis between the two
anchor plates. Line up the hole in the clevis with the 7. Loosen the locknut (10) on the retract chain clevis.
anchor plate hole position recorded during removal. DO NOT remove the locknut at this time, but loosen the
nut as far as possible to gain as much slack as possible in
16. Insert the shoulder bolt through the plates and clevis
the retract chain.
and secure in place with a locknut. Tighten the locknut
securely. 8. Return to the operator cab, start the engine and slowly
retract the boom all the way back, and then extend the
17. Check and adjust the retract chain tension. Refer to
boom approximately 1 in (25 mm) or just until all the
tension on the retract chain is relieved. Shut the engine
18. Install the boom rear cover. OFF.
6036, 6042, 8042, 10042, 10054 31211015 3-45

Boom
Note: Record the location of the shoulder bolt to ensure correct 13. Attach a wire to the end of the retract chain clevis (12)
installation. with a threaded eye or a flat washer tack welded to a
capscrew. The outside diameter of the eye or flat
11
threads on the clevis. The wire must be long enough to
pull the clevis and chain through the boom. The wire
must be heavy enough to pull the weight of the entire
chain back through the boom during the reassembly.
14. From the rear of the boom, using the wire attached to
the rear anchor clevis, pull the retract chain through the
middle of the two center hoses on the chain reel and
over the top of the chain reel and out of the rear of the
boom.
15. Remove the wire still attached from the clevis on the old
chain.
MH2671 16. Install the wire still attached, to the new chain clevis.
9. At the rear of the boom, locate the two retract chain 17. Coat the threads of the threaded clevis on the new chain
anchor plates (11). The two anchor plates can remain in with multi-purpose grease.
place on the fourth boom section.
13
10. Pull the retract chain clevis toward the rear of the boom, 14
through the middle of the two center hoses on the
chain reel and over the top of the chain reel. Let 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 15 MH6021
expose the other end for removal.

18. From the front of the boom, have an assistant pull on
11. Have an assistant start the engine and slowly extend the the tow wire while guiding the chain clevis between the
boom. Guide the retract chain with the wire attached two center hoses of the hose reel and under the chain
into the back of the boom. Extend the boom until the sheave (13), on the left side of the boom and down the
retract chain adjustment nut on the lower left side of boom between the third (14) and second (15) boom
the second boom section can be accessed and sections. Keep the retract chain lined up squarely with
removed. Turn the engine OFF. the chain sheave and help feed the retract chain in while
12. Remove the locknut and flat washer holding the pulling on the wire from the front of the boom.
threaded clevis on the retract chain to the tab in the
12
16
MH6510 MH5991
19. Guide the threaded end of the clevis through the hole in
the tab (16) on the second boom section.
3-46 31211015 6036, 6042, 8042, 10042, 10054

Boom
20. Remove the wire from the end of the clevis. 27. Pull the extend chain up and around the sheave at the
21. Place the flat washer onto the threaded clevis. Assemble front of the third boom section.
a locknut onto the threaded clevis. Turn the locknut 28. Place the extend chain clevis between the mounting
only 2 or 3 turns onto the clevis to allow assembly of the plates at the front of the third boom section. Coat the
other end of the retract chain. shoulder bolt with anti-seize compound and insert
22. At the front of the boom, disconnect the extend chain through the plates and clevis. Secure the shoulder bolt
clevis from the anchor plates on the second boom in place with a locknut. Tighten securely, but the chain
section. Remove the locknut holding the shoulder bolt clevis should pivot freely.
to the anchor plates. Pull the extend chain clevis from 29. Return to the operator compartment and start the
between the plates and lay over the front of the fourth engine. Slowly extend the boom to gain access to the
boom section. retract chain adjustment nut on the lower left side of
23. Return to the operator compartment and start the the second boom section. Shut the engine OFF.
engine and slowly retract the boom. To avoid having the 30. Tighten the adjustment nut until the threads of the
retract chain becoming entangled, keep tension on the threaded clevis are flush with the top edge of the nut.
chain coming out the back of the boom. Retract the This will be a starting point for adjustment of the fourth
boom as far as possible with the Extend/Retract boom section retract chain.
cylinder. Turn the engine OFF. 31. Check and adjust the retract chain tension. Refer to
24. The fourth boom section will not retract completely and Section 3.7.5, “Boom Chain Tension Check”.
must be manually pushed in. To avoid having the retract 32. Install the boom rear cover.
chain becoming entangled, keep tension on the chain
coming out the back of the boom while the fourth 33. Properly connect the battery. Refer Section 9.8,
boom section is pushed in. “Battery”, for procedure.
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 boom.
25. Remove the wire from the anchor clevis at the rear of
the boom. Place the retract chain up and over the chain
sheave in front of the hose reel assembly. Place the
clevis between the two anchor plates. Line up the hole
in the clevis with the anchor plate hole position
recorded during removal.
17
MH2671
26. Insert the shoulder bolt (17) through the plates and
clevis and secure in place with a locknut. Tighten the
locknut securely.
6036, 6042, 8042, 10042, 10054 31211015 3-47

Boom
3.8 BOOM WEAR PADS The following wear pad procedure must be followed to
insure the proper wear pad installation:
The wear pads on this machine are flat rectangular wear pads
• Maintain a total boom section clearance (2) of
with metal inserts. 0.070 - 0.130 in (1,78 - 3,30 mm) both the horizontal and
vertical directions
3.8.1 Wear Pad Inspection
1 5
1
4
MZ7680 3
1. Park the machine on level ground. Place the

2. Inspect all wear pads for wear. If the angle indicators (1)
on the ends of the wear pads are not visible, or show MAQ0420
uneven wear, they should be replaced. Always replace • A spacer (3) must be used before any shim (4) is used.
pads as a set.
• A shim (4) must be inserted between the spacer (3) and
wear pad support plate, block or boom section (5).
• The number of shims can vary at each shim point.
• The bottom wear pads must be shimmed equally on
each side.
A
2
MD1130
• The length of the wear pad bolt depends on the

number of shims, spacers and washers being used.
MZ7661
• The bolt length can be ±0.004 in (±1,0 mm) (A) from the
3. Measure all side and top wear pads for proper clearance. face of the insert.
0.070 - 0.130 in (1,78 - 3,30 mm) between the wear pad • The bolt length should be determined by measuring
and the next boom section (2) is acceptable. the distance from the face of the insert to the face of the
4. Shim each wear pad to within the above measurement boom (B) including any spacer, shim(s) and washer(s).
if required. • One or two hardened washers are to be used on each
wear pad bolt except where noted otherwise.
3.8.2 Wear Pad Installation and Lubrication DO NOT use more than two hardened washers.
• Use only one hardened washer if mounting bolts are
The boom has been factory lubricated for proper wear pad recessed.
break-in and will normally require minor future lubrication.
• Torque wear pad bolts as required.
However, after replacing any wear pad(s), or prolonged
periods of inoperation, lubrication of the boom wear • Lubricate the face and pockets of each wear pad after
surfaces with Schaffer 200S Silver Streak grease is being installed.
recommended to keep the boom wear surfaces lubricated Boom Section Wear Pad Pathway Lubrication:
properly. • Clean and lightly grease all wear pad pathways with
Lubrication of the boom wear surfaces is also recommended Mystik Tetrimoly grease.
when the machine is stored, to help prevent rusting. • Clean and lightly grease the hose carrier guide bar
pathways with Mystik Tetrimoly grease.
3-48 31211015 6036, 6042, 8042, 10042, 10054

Boom
3.9 QUICK COUPLER 4. Align the quick coupler with the rod end tilt cylinder
and insert the tilt cylinder pin (7). Secure with the
Note: The following procedure covers all styles of quick previously removed bolt and nut (6).
couplers. 5. Install any attachment. Refer to Operation & Safety
Manual for detailed installation instructions.
3.9.1 Quick Coupler Removal
1. Remove any attachment. Refer to Operation & Safety 3.10 FORKS
Manual for detailed removal instructions.
Forks should be cleaned and inspected prior to being
2. Lower boom, tilt forward to access coupler pin, set park
attached to carriage. If the following criteria is not met, forks
brake and turn off engine.
must be removed from service immediately.
Daily Inspection
8 12
9
15
8 14 13
16
7
11
10
20
6
6
MAQ1580
3. Remove the lock bolt and nut (6) securing the tilt 19 17
cylinder rod end pin (7) to the quick coupler assembly.
Remove the rod end pin (7). 18 MH6460
4. Support the quick coupler assembly. Remove the bolt

and nut (8) securing the quick coupler to the boom 6. Inspect forks (10) for cracks, paying special attention to
head. Remove the pin (9) from the quick coupler heel (11) and mounting tubes (12).
assembly. 7. Inspect forks for broken or bent tips (13) and twisted
5. Inspect the above pins for nicks or surface corrosion. blades (14) and shanks (15).
Use fine emery cloth to fix minor nicks or corrosion. If Yearly Inspection
damaged or if it cannot be repaired the pin must be
1. Straightness of the upper face of blade (14) and the
replaced.
front face of shank (15) should not exceed 0.5 percent of
the length of blade or height of shank.
3.9.2 Quick Coupler Installation
2. Angle (16) between upper face of blade and front face
1. Refer to Section 2.7, “Thread Locking Compound” for all of shank should not exceed 93 degrees.
thread locking requirements.
3. Thickness of blade (19) and shank (20) should not be
2. Assemble the quick coupler to the boom head. Line up reduced to 90 percent of original thickness.
the quick coupler between the mounts on the boom
head. The quick coupler should be centered in the 4. Ensure fork length (18) is adequate for intended loads.
boom head. 5. Fork markings should be legible, re-stamp if required.
3. Coat the quick coupler head pin (9) with an anti-seize 6. Compare fork tips (17) when mounted on a carriage.
compound. Insert the quick coupler head pin through Maximum difference in height of fork tips is 3 percent of
the quick coupler and boom head. Secure with the the length of the blade (19).
previously removed bolt and nut (8).
6036, 6042, 8042, 10042, 10054 31211015 3-49

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 retract 1. Broken hydraulic hose(s) or 1. Locate break, replace hose(s) or
tube(s) and/or connections tube(s), tighten connections.
leaking.
2. Extend/retract hydraulic system 2. Refer to Section 8.5.2, “Pressure

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

Section 8.9.1, “General Cylinder
Instructions”.
4. Broken chains or anchors 4. Replace chains as needed
2. Boom shifts to right or left when 1. Boom side wear pads improperly 1. Shim wear pads to correct gap.
extending. shimmed or worn. Replace wear pads as needed.
Refer to Section 3.8, “Boom Wear
Pads”.
3. Excessive pivot pin noise and/or 1. Insufficient lubrication. 1. Lubricate at regular intervals.
wear. Refer to Section 2.6, “Lubrication
Schedules”. Replace worn pins as
needed.
2. Worn bearing(s). 2. Replace bearing(s) and lubricate

at regular intervals Refer to
Section 2.6, “Lubrication
Schedules”.
4. Excessive Compensation 1. Insufficient lubrication. 1. Lubricate at regular intervals.

cylinder pivot pin noise and/or Refer to Section 2.6, “Lubrication
wear. Schedules”.Replace worn pins as
needed.
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) or
and/or connection leaks. tube(s), tighten connections.
2. Lift/lower hydraulic system not 2. Refer to Section 8.5.2, “Pressure

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

8.9, “Hydraulic Cylinders”.
4. Seized boom pivot pin bearing. 4. Replace bearing.
3-50 31211015 6036, 6042, 8042, 10042, 10054

Boom

6. Drooping chain, or jerky boom 1. Chain(s) tension not properly 1. Adjust chain(s).
extend or retract functions. adjusted.
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 3.8, “Boom Wear Pads”.
4. Contaminated, corroded or rusted 4. Remove contamination and/or

wear pad sliding surfaces. corrosion from wear pad sliding
surfaces and lubricate. If the
surfaces cannot be reconditioned,
replace the boom section(s).
5. Extend/Retract hydraulic system 5. Refer to Section 8.5.2, “Pressure

not operating properly. Specifications”.
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) or
and/or connection leaks. tube(s), tighten connections.
2. Lift/Lower hydraulic system not 2. Refer to Section 8.5.2, “Pressure

3. Faulty Lift cylinder. 3. Repair cylinder. Refer to

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 2.5, “Service and
Maintenance Schedules”. Replace
worn pins as needed. Refer to
Instructions”.
2. Worn self-aligning bushing(s). 2. Replace bushing(s) and lubricate

at regular intervals. Refer to
Section 2.6, “Lubrication
Schedules”.
6036, 6042, 8042, 10042, 10054 31211015 3-51

Boom

9. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and correct
as needed. Refer to Section 3.8,
2. Rapid cycle times with heavy 2. Reduce cycle times.

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

wear pad sliding surfaces. corrosion from wear pad sliding
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 8.5.2, “Pressure
operate. operating properly. Specifications”.
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 to

lubricated. Section 2.5, “Service and
Maintenance Schedules”.
3. Chain sheave(s) not rotating 3. Lubricate chain sheave. Refer to

freely. Section 2.5, “Service and
Maintenance Schedules”. Repair
or replace chain sheave(s) as
needed.
4. Improper chain lubrication. 4. Lubricate at regular intervals.

Refer to Section 2.5, “Service and
Maintenance Schedules”. Replace
chains as needed.
3-52 31211015 6036, 6042, 8042, 10042, 10054

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 Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.2 Steering Column and Steering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.3 Service Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.4 Throttle Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.5 Joystick Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.6 Auxiliary/Frame Level Lever Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.3.7 Windshield Wiper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.3.8 Heater System (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.3.9 Heater and A/C System (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
6036, 6042, 8042, 10042, 10054 31211015 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
HEATER AND A/C BOOM CONTROL/

STEERING WHEEL CONTROLS (OPTIONAL) TILT JOYSTICK
INSTRUMENT PANEL
AUXILIARY HYDRAULIC
CONTROL LEVER
TRANSMISSION
CONTROL LEVER
PARK BRAKE FRAME LEVEL

SWITCH CONTROL LEVER
IGNITION
SWITCH
SERVICE BRAKE PEDAL
MZ8440
ACCELERATOR PEDAL
4-2 31211015 6036, 6042, 8042, 10042, 10054

Cab and Covers

WARNING 1

precautions as outlined in Section 1, “Safety Practices”, 3
section of this manual.
4.2 OPERATOR CAB
4.2.1 Cab Safety
2
WARNING 4 MAE4620
The protection offered by this ROPS/FOPS will be 5. Carefully pry horn button (1) out of steering wheel (2).
impaired if subjected to any modification or structural
6. Remove horn wire (3) from back of horn button.
damage, at which time replacement is necessary. ROPS/
FOPS must be properly installed using fasteners of 7. Mark steering wheel and shaft to ensure proper
correct size and grade, and torqued to their specified installation. Remove nut (4) securing the steering
value. wheel (2) to splined steering column shaft.
8. Use a steering wheel puller to remove steering wheel (2)
from splined shaft.
WARNING
b. Steering Wheel Installation
DO NOT weld, grind, drill, repair or modify the cab in any
way. Any modification or damage to cab structural 1. Install steering wheel (2) onto splined steering column
components requires cab replacement. Refer to shaft.
Section 2.5 in the Operation & Safety Manual. 2. Secure steering wheel with nut (4). Torque as required.
To help ensure optimum safety, protection and 3. Connect the previously remove horn connectors (3).
performance, replace the cab if it is damaged. Refer to the
appropriate parts manual for ordering information. 4. Press the horn button (1) onto steering wheel.
4.2.2 Serial Number Decal “Battery”, for procedure.
The cab serial number decal is located on the left side of the 6. Close and secure engine covers.
cab, behind the seat. Information specified on the serial 7. Remove Do Not Operate Tag from ignition key switch
number plate includes the cab model number, the cab serial and steering wheel.
number and other data. Write this information down in a
convenient location to use in cab correspondence. 4.3.2 Steering Column and Steering Valve
4.3 CAB COMPONENTS a. Steering Valve Removal

1. Park the machine on a firm, level surface, level the
4.3.1 Steering Wheel machine, fully retract the boom, lower the boom, place
the transmission in (N) NEUTRAL, engage the parking
a. Steering Wheel Removal brake and turn the engine OFF.
1. Park machine on a firm, level surface, level machine, 2. Place a Do Not Operate Tag on both the ignition key
fully retract boom, lower boom, place transmission in switch and the steering wheel, stating that the machine
(N) NEUTRAL, engage park brake and shut engine OFF. should not be operated.
2. Place a Do Not Operate Tag on both ignition key switch 3. Open the engine rear and side engine doors. Allow the
and steering wheel. system fluids to cool.
3. Open engine covers. Allow system fluids to cool.
6036, 6042, 8042, 10042, 10054 31211015 4-3
Cab and Covers
4. Properly disconnect the battery. Refer Section 9.8, b. Steering Valve Installation
1. Install the steering column and steering valve, by
5. Remove the lower dash panel. inserting them through the lower dash panel opening.
2 Position steering valve in the cab to its original
orientation. Secure the steering valve and column with
the previously used hardware.
Torque to 13 lb-ft (18 Nm).
6
9 Note: ALWAYS use new o-rings when servicing the machine.
2. Install new o-rings into the fittings. Lubricate the o-rings
with clean hydraulic oil.
5
3. Uncap and connect the previously labeled load 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
7
four hoses to the steering valve.
6. Connect the horn button wire to the cab wiring harness.
8
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).
MZ8450
6. Remove the steering wheel (2), disconnect the “Battery”, for procedure.
instrument panel harness connector (5), disconnect and 9. Remove the Do Not Operate Tags from both the ignition
remove the travel select lever (6). key switch and the steering wheel.
7. Label, disconnect and cap the four hoses (7) from the 10. Start the engine and check the operation of steering
side of the steering valve (8). Cap the fittings on the system. Check for hydraulic fluid leaks. Check the
steering valve. Label, disconnect and plug the load sense hydraulic fluid level in the tank and add fluid as
hose at the front of the steering valve. Cap the fitting on required.
the steering valve.
11. Install the left, right and lower dash panels.
8. Disconnect the horn button wire from the cab wiring
harness.
9. Support the bottom of the steering valve, and remove c. Steering Test
the four capscrews and lockwashers. Remove the
steering valve (8) through the lower dash panel Conduct a pressure check of the steering hydraulic circuits at
opening. Remove the steering column (9). the main control valve. Refer to Section 8.5.1, “Pressure
Checks and Adjustments”.
Note: DO NOT disassemble the steering valve. The steering
valve is not serviceable and must be replaced in its entirety, if
defective.
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4.3.3 Service Brake Pedal SN 0160074878 to Present, including 0160074813

0160074818 and 0160074882
a. Brake Valve Removal
Refer to Section 8.8.2, “Service Brake Valve”, for removal
information.
10
b. Brake Valve Installation
Refer to Section 8.8.2, “Service Brake Valve”, for installation
information.
c. Service Brake Pedal Removal

brake and turn the engine OFF.
switch and steering wheel, stating that the machine
should not be operated. MAE4430
6. Prior to SN 0160074878, excluding 0160074813
0160074818 and 0160074882: Remove the two
4. Properly disconnect the battery. Refer Section 9.8, capscrews, four flat washers, two pivots and two
“Battery”, for procedure. nuts (10) securing the service brake pedal to the cab.
5. Remove the lower dash panel. 7. SN 0160074878 to Present, including 0160074813
Prior to SN 0160074878, excluding 0160074813 0160074818 and 0160074882: Remove four bolts (10)
0160074818 and 0160074882 securing the service brake pedal to the cab.
8. 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.
3. Install the service brake pedal with the previously used
hardware.
4. Be sure the brake pedal has the correct range of motion.
10 Secure pivot pin with bolt and lockwasher.
5. Adjust the service brake switch as needed.
6. Install the lower dash panel.
10
MZ8460 key switch and the steering wheel.
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4.3.4 Throttle Pedal 4.3.5 Joystick Assembly

These removal and installation instructions apply to the
a. Throttle Pedal Removal
hydraulic joystick.
machine, fully retract the boom, lower the boom, place a. Joystick Assembly Removal
2. Place a Do Not Operate Tag on both the ignition key the transmission in (N) NEUTRAL, engage the parking
switch and steering wheel, stating that the machine brake and turn the engine OFF.
3. Properly disconnect the battery. Refer Section 9.8, switch and steering wheel, stating that the machine
“Battery”, for procedure. should not be operated.
4. Remove the console panel in the cab.
15
13 16 14
12
17
11 MZ8470
4. Remove the bolts (11) securing the throttle pedal to the

cab floor (12).
5. Disconnect the electrical harness connector (13) from
the back side of the throttle pedal.
6. Remove the throttle pedal assembly from the cab.
b. Throttle Pedal Installation

1. Position the throttle pedal in its mounting location
within the cab. MZ8490
2. Reconnect the wire harness plug to the backside of the

Note: Label all hydraulic hoses to ensure correct installation.
throttle pedal.
3. Secure the throttle pedal in place with previously used 5. Label, disconnect and cap the hydraulic hoses (14)
hardware. attached to joystick (15).
4. Properly connect the battery. Refer Section 9.8, 6. Disconnect the tilt function electrical connector.
“Battery”, for procedure. 7. Lift the joystick’s rubber sleeve (16), remove the
5. Remove the Do Not Operate Tags from both the ignition bolts (17) securing the boom joystick to the cab.
key switch and the steering wheel. 8. Remove the joystick assembly.
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b. Joystick Assembly Installation

1. Secure the joystick to the cab with the previously used
hardware. 18
2. Connect the tilt function electrical connector.
3. Uncap and connect the previously removed hydraulic
hoses to the joystick.
5. Test the joystick function:
• 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.
• Move the joystick handle to the right, activating the 19
boom extend function. The boom should EXTEND.
• Move the joystick handle to the left, activating the
boom retract function. The boom should RETRACT.
• Move the joystick switch rearward, activating the MZ8480
attachment tilt function. The boom should TILT UP.
Note: Record the location, and label all cables to ensure correct
• Move joystick switch forward, activating attachment tilt
function. The boom should TILT DOWN. installation.
6. Install console panel in the cab. 5. Remove the knob on each control lever (18).
7. Remove the Do Not Operate Tags from both the ignition 6. Loosen and remove the three bolts (19) securing the
key switch and the steering wheel. control levers.
4.3.6 Auxiliary/Frame Level Lever Assemblies

These removal and installation instructions apply to the
frame level and auxiliary hydraulic joysticks.
a. Lever Assembly Removal 20

21
switch and steering wheel, stating that the machine 22
MZ8500
“Battery”, for procedure. 7. Remove the clip and pin (20) from the main control
4. Remove the console panel in the cab. valve control spool.
8. Remove the bolts securing each cable bracket (21) to
the main control valve.
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b. Cable Removal 6. Test the lever(s) function:

26 27
25 Frame Level Lever:
28
25 28 • Move rear lever to right, activating frame level function.
The machine should move RIGHT.
• Move rear lever to left, activating frame level function.
The machine should move LEFT.
Auxiliary Lever:
22 • Move the front leverto the right, the auxiliary
attachment should LOWER/OPEN.
23 • Move the front lever to the left, the auxiliary attachment
24 MZ8510
should RAISE/CLOSE.
1. Disconnect control cable (22) at the lever control:
7. Install console panel in the cab.
a. Remove the bolt (23) securing the control cable.
b. Push the control lever to expose the cable nut. Use a key switch and the steering wheel.
wrench on the flats to loosen the cable nut (24).
c. Remove the cable. 4.3.7 Windshield Wiper Assembly
2. Mark the location of the adjusting nuts (25) on the main Refer to Section 9.10, “Window Wiper/Washer Windshield
control valve end of the control cable. Wiper Motor”, for removal and installation information.
3. Loosen lock nut (26) and remove clevis (27).
4. Remove adjusting nuts (26) and washers (28). 4.3.8 Heater System (if equipped)
Note: If machine is equipped with air conditioning, DO NOT
c. Cable Installation loosen or disconnect any air conditioning hoses until the air
1. Install one adjusting nut (25), and washer (28) on the conditioning system has been properly drained by the local JLG
control cable (22). dealer or certified air conditioning service center.
2. Install cable bracket (21) onto the control cable (22). a. Cab Heater Assembly Removal
3. Install washer (28), nut (25), lock nut (26) and clevis (27)
onto the control cable (22).
DO NOT tighten the adjusting nuts at this time.
4. Connect control cable (22) at the lever control: and shut the engine OFF.
a. Push the control lever and install the control cable. 2. Place a Do Not Operate Tag on both the ignition key
b. Use a wrench on the flats to hold the slider head, switch and the steering wheel, stating that the machine
and tighten the cable nut (24). should not be operated.
c. Install the bolt (23) securing the control cable. 3. Open the engine rear and side engine doors. Allow the
d. Lever Assembly Installation
1. Secure the lever assembly(s) to the cab with the “Battery”, for procedure.
previously used hardware. 5. Place a suitable container beneath the radiator drain
2. Secure the control cable(s) bracket to the main control plug or petcock. Slowly turn the radiator cap to the first
valve with the previously removed hardware. stop, and allow any pressure to escape. Remove the
3. Center the control levers and tighten the adjusting radiator cap.
nuts (25) as required. 6. Place a funnel at the base of the radiator to channel the
4. Install the previously removed knobs on each lever drained coolant into the container. Loosen the drain
assembly. plug or petcock and allow the coolant to drain.
5. Properly connect the battery. Refer Section 9.8, 7. Transfer the coolant to a container with a cover, and
“Battery”, for procedure. label as “Used Antifreeze”. Dispose of the used coolant
at an approved recycling facility.
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8. Close the radiator drain plug or petcock. 14. Remove the left and right front air vents (36) to access
and remove the duct mounting nuts.
31 31 15. Remove heater ducts (37) from heater assembly.
31
32 16. Remove brackets (38 & 39) securing heater assembly to
29 cab.
29
29
30
MAQ1800
29
9. Loosen and remove the four bolts (29) securing the
heater cover (30). Remove the heater cover.
10. Loosen and remove the five bolts (31) securing the
heater hood (32). Remove the heater hood.
34
35
44
43
MAE19990
33 17. Label and disconnect heater (43) electrical connections.

18. Label and remove hoses (44) connected to heater.
MAQ1810
19. Remove the heater assembly (34).
11. Disconnect the wiring harness connection (33) from the
heater assembly (34). b. Cab Heater Assembly Installation
12. Remove the two clamps (35) securing the heater hoses 1. Install heater assembly (34) and secure with previously
to the side of the cab. removed brackets (38 & 39).
13. Label, disconnect and cap the heater hoses. Pull the 2. Install heater ducts (37) to heater assembly.
hoses away from the heater tubes.
3. Install the heater assembly (34) to the roof mount (36)
36 and secure with the previously removed bolts (33).
37 4. Install the two clamps (35) securing the heater hoses to
37
the side of the cab.
5. Connect the wiring harness connection (33) to the
blower.
6. Install the heater access panel and secure with the
36 previously used hardware.
7. Install brackets (38 & 39) securing heater assembly to
38 MZ8530 cab.
39
8. Install heater ducts (37) to the heater assembly.
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9. Fill the cooling system completely with coolant, 10. Disconnect the wiring harness connections from the
allowing time for the coolant to fill the engine block. blower.
The cooling system capacity is listed in Section 2.3, “Fluid
Specifications”.
key switch and the steering wheel. 42
12. Start engine, run it briefly at low idle and check machine
for any visual sign of fluid leakage. 40
Note: STOP engine immediately if any leakage is noted, and 41
make any necessary repairs before continuing.
13. Wait for the engine to cool and check the coolant level.
Add coolant as required to bring the coolant to the
proper level. MZ8520
14. Check the operation of cab heater. 11. Label, disconnect and cap the seat heater hoses (40).
15. Shut the engine OFF. Pull the hoses away from the heater tubes.
12. Remove the four capscrews, nuts and lockwashers (41).
c. Under Seat Heater Assembly Removal 13. Remove the seat heater assembly (32).
machine, fully retract the boom, lower the boom, place d. Under Seat Heater Assembly Installation
the transmission in (N) NEUTRAL, engage the park brake 1. Slide the seat heater assembly (42) into the seat riser,
and shut the engine OFF. and secure with the four capscrews, lockwashers and
2. Place a Do Not Operate Tag on both the ignition key nuts (41).
switch and the steering wheel, stating that the machine 2. Connect the wiring harness connections to the seat
should not be operated. heater assembly (32).
3. Open the engine rear and side engine doors. Allow the 3. Uncap and connect the previously labeled hoses (40) to
system fluids to cool. the heater tubes.
4. Properly disconnect the battery. Refer Section 9.8, 4. Install the heater access panel and secure with the
“Battery”, for procedure. previously used hardware.
5. Place a suitable container beneath the radiator drain 5. Fill the cooling system completely with coolant,
plug or petcock. Slowly turn the radiator cap to the first allowing time for the coolant to fill the engine block.
stop, and allow any pressure to escape. Remove the The cooling system capacity is listed in Section 2.3, “Fluid
radiator cap. Specifications”.
6. Place a funnel at the base of the radiator to channel the 6. Remove the Do Not Operate Tags from both the ignition
drained coolant into the container. Loosen the drain key switch and the steering wheel.
plug or petcock and allow the coolant to drain.
7. Transfer the coolant to a container with a cover, and for any visual sign of fluid leakage.
label as “Used Antifreeze”. Dispose of the used coolant
at an approved recycling facility. Note: STOP engine immediately if any leakage is noted, and
8. Close the radiator drain plug or petcock.
9. Remove the heater access panel. 8. Wait for the engine to cool and check the coolant level.
Add coolant as required to bring the coolant to the
proper level.
9. Check the operation of cab heater.
10. Shut the engine OFF.
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4.3.9 Heater and A/C System (if equipped) 12. Remove bolts securing the condenser assembly (42) to
cab roof. Remove condenser assembly from rear of the
a. Removal cab roof.
1. Park machine on a firm, level surface, level machine, 13. Label and disconnect all electrical connections attached
fully retract boom, lower boom, place transmission in to the heater and air conditioning assembly (43).
(N) NEUTRAL, engage park brake and shut engine OFF. 14. Label and remove hoses (44) connected to the heater
2. Place a Do Not Operate Tag on both ignition key switch and air conditioning assembly (43).
and steering wheel. 15. Label and disconnect air conditioning hoses attached to
3. Open engine covers. Allow system fluids to cool. heater assembly.
4. Properly disconnect the battery. Refer Section 9.8, 16. Remove bolts securing heater assembly to cab. Remove
“Battery”, for procedure. heater assembly.
5. Place a suitable container beneath radiator. Slowly turn 17. Label and disconnect air conditioning hoses attached to
surge tank cap and allow any pressure to escape. compressor (45).
Remove surge tank cap. 18. Remove hardware securing compressor to engine.
6. Place a funnel at base of radiator to channel drained Remove compressor (45).
coolant into container. Remove drain plug and allow
coolant to drain. b. Installation
7. Transfer coolant to a container with a cover, and label as 1. Install cab condenser assembly (42) to cab roof. Secure
“Used Coolant”. Dispose of used coolant at an approved with previously removed hardware.
recycling facility. 2. Connect previously labeled electrical connections to
8. Tighten radiator drain plug. the condenser assembly (42).
9. Drain the refrigerant from the air conditioning system. 3. Connect previously labeled hoses (24) to condenser
assembly (42).
Note: The local JLG dealer or certified air conditioning service
center or personnel to perform the refrigerant removal from the 4. Position heater and air conditioning assembly (43) to
system. original orientation to cab. Secure with previously
removed hardware.
5. Connect previously labeled electrical connections to
heater and air conditioning assembly.
6. Connect previously labeled heater hoses to appropriate
locations.
42 7. Connect previously labeled air conditioning hoses to
appropriate locations.
41
8. Connect previously labeled air conditioning hoses
45 attached to compressor (45).
9. Install compressor (45) to engine.
10. Fill cooling system completely with coolant, allowing
time for the coolant to fill the engine block. The cooling
system capacity is listed in Section 2.3, “Fluid and
Lubricant Capacities”.
11. Fill air conditioning system completely with refrigerant.
Refer Section 2.3, “Fluid and Lubricant Capacities”, for
44 43 refrigerant type and capacity.
MAE4600
Note: Ensure that the petcock is closed for vehicle equipped
with a cab heater, when one liter of coolant is drained from
10. Label and disconnect hoses (41) attached to the
system and all air is purged.
condenser assembly (42).
11. Label and disconnect all electrical connections attached
to the condenser assembly (42).
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Note: The local JLG dealer or certified air conditioning service

center or personnel to perform the refrigerant installation to
the system.
for any visual sign of fluid leakage.
Note: STOP engine immediately if any leakage is noted, and
14. Wait for engine to cool and check coolant level. Add
coolant as required to bring coolant to proper level.
15. Wait for engine to cool and check coolant level. Add
coolant as required to bring coolant to proper level.
16. Check the operation of cab heater and A/C.
18. Close and secure the engine cover.
19. Remove Do Not Operate Tag from ignition key switch
and steering wheel.
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4.4 CAB REMOVAL 10. Remove the heater access panel. If equipped, Label,
disconnect and cap the cab heater hoses. Refer to
Section 4.3.8, “Heater System (if equipped)”.
WARNING 11. Remove the console panel in the cab.
The protection offered by this ROPS/FOPS will be 12. Label and disconnect the electrical connections. Push
impaired if subjected to any modification or structural the connectors through the opening at the bottom of
damage, at which time replacement is necessary. the cab.
ROPS/FOPS must be properly installed using fasteners of 13. Remove the frame level and auxiliary lever assemblies
correct size and grade, and torqued to their specified from the main control valve. Refer to Section 4.3.6,
value. “Auxiliary/Frame Level Lever Assemblies”.
Note: To help ensure safety and optimum performance, 14. Label, disconnect and cap all hydraulic hoses. Refer to
replace the cab if it is damaged. Refer to the appropriate parts Section 4.3.5, “Joystick Assembly”. Cap all fittings to
manual for ordering information. keep dirt and debris from entering the hydraulic system.
Push the hoses through the opening at the bottom of
Inspect the cab, its welds and mounts. If modification, the cab.
damage, a cracked weld and/or fatigued metal is discovered,
15. If necessary, remove mirrors and other cab components
replace the cab. Contact the local JLG dealer with any
that may become damaged during cab removal.
questions about the suitability or condition of a cab.
1
Note: Remove and label cab components as needed before
removing the cab from the machine. Label, disconnect and cap
hydraulic hoses. Transfer cab parts to the replacement cab after
the replacement cab is securely mounted on the machine.
1. Park the machine on a firm, level surface. Allow 2
sufficient overhead and side clearance for cab removal.
Level the machine, fully retract the boom, lower the
boom, place the transmission in (N) NEUTRAL, engage
the park brake and shut the engine OFF.
2. Block all four wheels to help prevent the machine from
moving. Assure that there is sufficient overhead and 2
side clearance for cab removal.
4. Properly disconnect the battery. Refer Section 9.8, MZ8550
16. Attach a clevis to each of the cab lifting brackets (1).
5. Place a suitable container beneath the radiator drain Route a sling with a minimum lifting capacity of
plug or petcock. Slowly turn the radiator cap to the first 1000 lb (453 kg) to a hoist or overhead crane. Center the
stop and allow any pressure to escape. Remove the sling to ensure even lifting.
radiator cap.
17. Remove the two upper cab-to-frame capscrews and
6. Place a funnel at the base of the radiator to channel the two flat washers (2).
drained coolant into the container. Loosen the drain
plug or petcock and allow the coolant to drain. 18. Remove the two lower cab-to-frame capscrews and two
flat washers (2).
7. Transfer the coolant to a container with a cover, and
label as “Used Antifreeze”. Dispose of the used coolant 19. Carefully begin to lift the cab. Stop and check that all
at an approved recycling facility. wiring, hydraulic hoses and fasteners are disconnected
and removed.
8. Close the radiator drain plug or petcock.
9. Remove the transmission covers.
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20. When all wiring, hydraulic hoses and fasteners are 11. Install the console panel.
disconnected or removed, carefully and slowly lift the 12. Install the transmission covers.
cab and remove it from the frame. Readjust the position
of the sling as needed to help balance the cab during 13. Fill the cooling system completely with coolant, allowing
removal. time for the coolant to fill the engine block. The cooling
system capacity is listed in Section 2.3, “Fluid
21. When the cab is completely clear of the machine, Specifications”.
carefully lower it to the ground. Block up or support the
cab so that it does not move or fall. Assure that no 14. Properly connect the battery. ReferSection 9.8,
personnel enter the cab while it is being removed from “Battery”, for procedure.
the machine. 15. Carefully examine all cab components, fasteners, etc.,
22. Inspect the condition of the fittings, clamps, hydraulic one last time before engine start-up. Rectify any faulty
hoses, etc. Replace parts as indicated by their condition. conditions.
23. Inspect and replace other machine parts that are 16. Start the engine and check the operation of all controls.
exposed with the cab removed. Repair or replace as Check for hydraulic fluid leaks. Check the hydraulic fluid
required. level in the tank and add fluid as required.
Note: When the engine is initially started, run it briefly at low
4.5 CAB INSTALLATION idle and check the machine for any visual sign of fluid leakage.
STOP the engine immediately if any leakage is noted, and make
1. Block all four wheels to help prevent the machine from any necessary repairs before continuing.
moving. Assure that there is sufficient overhead and
side clearance for cab installation. 17. Wait for the engine to cool and check the coolant level.
Add coolant to the overflow bottle as required to bring
2. Attach a clevis to each of the cab lifting brackets. Route the coolant to the proper level.
a sling with a minimum lifting capacity of
1000 lb (453 kg) to carry the weight of the cab through 18. Install the mirrors and all other cab components as
the clevis’ to a hoist or over head crane. Make sure the needed, if removed.
sling is centered between the clevis’ to ensure even 19. Unblock the wheels.
lifting. 20. Close and secure the engine rear and side engine doors.
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).
6. Push the hoses through the opening at the bottom of
the cab. Uncap and connect the previously labeled
hydraulic hoses. Refer to Section 4.3.5, “Joystick
Assembly”.
7. Install the frame level and auxiliary lever assemblies
from the main control valve. Refer to Section 4.3.6,
“Auxiliary/Frame Level Lever Assemblies”.
8. Route the wiring harness connectors through the
opening at the bottom of the cab. Connect the
previously labeled connectors.
9. If equipped, install the cab heater hoses. Refer to
Section 4.3.8, “Heater System (if equipped)”.
10. Install the heater access panel.
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Section 5
Axles, Drive Shafts, Wheels and Tires
Contents

5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.1.1 6036 & 6042 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.1.2 8042. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.1.3 10042 & 10054 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.2 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3 Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3.1 Axle Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3.2 Axle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3.3 Axle Internal Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3.4 Axle Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.3.5 Axle Replacement (6036 & 6042) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.3.6 Axle Replacement (8042, 10042 & 10054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.4 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.5 Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.5.1 Drive Shaft Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.5.2 Drive Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.5.3 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.6 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.6.1 Removing Wheel and Tire Assembly from Machine. . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.6.2 Installing Wheel and Tire Assembly onto Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.7 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.7.1 Brake Disc Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.8 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
6036, 6042, 8042, 10042, 10054 31211015 5-1

5.1 AXLE, DRIVE SHAFT AND WHEEL

of the major assemblies of the axles, drive shafts, wheels and
tires. The following illustration identifies the components
that are referred to throughout this section.
5.1.1 6036 & 6042
ENGINE-TO-TRANSMISSION
DRIVE SHAFT
REAR AXLE
ASSEMBLY
REAR STEERING
CYLINDER
FRONT STEERING
CYLINDER
REAR DRIVE SHAFT
REAR AXLE
WHEEL HUBS
FRONT DRIVE SHAFT
FRONT AXLE
ASSEMBLY
MAQ1780
FRONT AXLE
WHEEL HUBS
5-2 31211015 6036, 6042, 8042, 10042, 10054

5.1.2 8042
DRIVE SHAFT
REAR AXLE
ASSEMBLY
REAR STEERING
CYLINDER
FRONT STEERING
CYLINDER REAR DRIVE SHAFT
REAR AXLE
WHEEL HUBS
FRONT DRIVE SHAFT
FRONT AXLE
ASSEMBLY
MAQ1770
FRONT AXLE
WHEEL HUBS
6036, 6042, 8042, 10042, 10054 31211015 5-3

5.1.3 10042 & 10054
DRIVE SHAFT
REAR AXLE
ASSEMBLY
REAR STEERING
CYLINDER
FRONT STEERING REAR DRIVE SHAFT

REAR AXLE
CYLINDER
WHEEL HUBS
FRONT DRIVE SHAFT
FRONT AXLE
ASSEMBLY
MAQ1790
FRONT AXLE
WHEEL HUBS
5-4 31211015 6036, 6042, 8042, 10042, 10054

5.2 GENERAL INFORMATION 5.3.3 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 appropriate Axle Repair
Manual.
this manual.
Machine Manufacturer Axle PN
Note: To help ensure optimum performance, the drive shaft Model
assemblies are specially balanced as a unit at the factory. When
212/A02 Front
servicing any flange yoke, slip yoke or drive shaft tube, order a 6036,6042 31200162
complete assembly if components are bent or damaged. Refer 212/A03 Rear
to the appropriate parts manual for ordering information.
Before performing any inspection, maintenance or service Machine Manufacturer Axle PN
operation, thoroughly clean the unit. The axles and drive Model
shafts should be checked and repaired only by experienced
8042 MS-T 3055 II All 31200695
service technicians who are aware of all safety instructions
and particular component features. 10042,10054 MS-T 3060 II Front 31200694
Use suitable products to thoroughly clean all disassembled 10042,10054 MS-T 3055 II Rear 31200695
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.
5.3 AXLE ASSEMBLIES
5.3.1 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.
5.3.2 Axle Specifications

General axle specifications are found in Section 2.3, “Fluid
Specifications”.
6036, 6042, 8042, 10042, 10054 31211015 5-5

5.3.4 Axle Maintenance Note: Clear the work area of all debris, unnecessary personnel,
etc. Allow sufficient space to raise the machine and to remove
CLEANING: Clean parts with machined or ground surfaces
the axle.
(such as gears, bearings and shafts) with emulsion cleaners
or petroleum-based cleaners. DO NOT steam clean internal 1. Park the machine on a firm, level surface, level the
components and the interior of the planetary hub and axle machine, fully retract the boom, lower the boom, place
housing. Water can cause corrosion of critical parts. Rust the transmission in (N) NEUTRAL, engage the parking
contamination in the lubricant can cause gear and bearing brake, straighten all wheels and shut the engine OFF.
failure. Remove old 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 after switch and steering wheel, stating that the machine
cleaning. DO NOT dry bearings by spinning them with should not be operated.
compressed air; this can damage mating surfaces due to lack 3. Open the engine rear and side engine doors. Allow the
of lubrication. After drying, lightly coat components with oil system fluids to cool.
or a rust-preventive chemical to help protect them from
corrosion. If storing components for a prolonged period, wrap 4. Properly disconnect the battery. Refer Section 9.8,
them in wax paper. “Battery”, for procedure.
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 tube (breather), drain the axle
and inspect internal parts for water damage and
MAQ0950
contamination. Before assembling and refilling the unit with
the specified lubricant(s), clean, examine and replace 1
damaged parts as necessary. 5. If the axle will be disassembled after removal, place a
Note: Use a suitable puller for bearing removal. Clean, inspect suitable receptacle under the axle drain plug (1).
and lubricate all bearings just prior to reassembly. If Remove the drain plug and allow the axle oil to drain
replacement of a damaged bearing cup or cone is necessary, into the receptacle. Transfer the used axle oil into a
replace the cup and cone as a set. suitable covered container, and label the container as
“Used Oil”. Dispose of used oil at an approved recycling
5.3.5 Axle Replacement (6036 & 6042) facility.
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.
Cleanliness is extremely important. Before attempting to 2
remove the axle, thoroughly clean the machine. Avoid
spraying water or cleaning solution on the stabilizer
solenoids and other electrical components. If using a steam MA9091
cleaner, seal all openings before steam cleaning. 6. Front Axle: Remove the front access panel (2) to gain
access to the front axle hose connections and mounting
bolts.
5-6 31211015 6036, 6042, 8042, 10042, 10054

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

11 1
suitable supports under both sides of the frame and 3 10 2
lower the machine onto the supports. Ensure that the
machine will remain in place during axle removal. 9 3
10. Support the axle that is being removed with a suitable 8 4

jack, hoist or overhead crane and sling. DO NOT raise 7 5
6
the axle or the machine. MT0822
11. Remove both wheel and tire assemblies from the axle Note: If new frame level (front) or stabilizer (rear) cylinder
that is being removed. Refer to Section 5.6.1, “Removing bearings (3) have been installed in the axles or machine frame,
Wheel and Tire Assembly from Machine”. the fracture in the bearing race must be positioned at the
Note: The wheel and tire assemblies must be re-installed later 9 o’clock position as shown above.
with the directional tread pattern “arrows” facing in the 5. Move the cylinder into position on the axle cylinder
direction of forward travel. anchor. Insert a cylinder-mount pin through the
12. Remove the drive shaft assembly. Refer to Section 5.5.2, cylinder and cylinder anchor. Secure the cylinder-
“Drive Shaft Removal”. mount pin with one capscrew and new locknut.
13. Remove the capscrew and locknut securing the lower 6. Apply multi-purpose grease through the self-tapping
position cylinder-mount pin to the cylinder. Tap the lube fitting to lubricate the self-align bearing and the
cylinder mount pin out, and move the cylinder to cylinder-mount pin.
prevent it from interfering with axle removal. 7. Install the drive shaft assemblies. Refer to Section 5.5.3,
14. Remove the capscrews securing the axle supports to “Drive Shaft Installation”.
the machine frame. 8. If reinstalling an axle previously removed from the
15. Remove the axles from the machine using the jack, hoist machine, position the driveshaft yoke on the axle
or overhead crane and sling supporting the axle. according to the alignment marks made earlier. If
DO NOT raise or otherwise disturb the machine while installing a new axle, note the position of the driveshaft
removing the axle. Balance the axle and prevent it from yoke at the transmission. Align the driveshaft yoke on
tipping, turning or falling while removing it from the axle in the same plane as the yoke on the
beneath the machine. Place the axle on a suitable transmission.
support or holding stand. 9. Install the wheel and tire assemblies. Refer to
Section 5.6.2, “Installing Wheel and Tire Assembly onto
b. Axle Installation Machine”.
1. Before proceeding, ensure that the machine will remain 10. Carefully remove the jack, hoist or overhead crane and
in place during axle installation. Block the front and rear sling supporting the axle.
of both tires on the axle that is already installed on the 11. Carefully raise the machine using a suitable jack or hoist.
machine. Remove the supports from beneath the frame and
2. If applicable, raise the machine using a suitable jack or lower the machine to the ground.
hoist. Place suitable supports beneath the frame and 12. Remove the blocks from the front and rear of both tires
lower the machine onto the supports, allowing enough on the other axle.
room for axle installation. Ensure that the machine will
remain in place during axle installation. Note: ALWAYS use new o-rings when servicing the machine.
6036, 6042, 8042, 10042, 10054 31211015 5-7

13. Install new o-rings into the fittings. Lubricate the

o-rings with clean hydraulic oil.
14. Uncap and connect the steering and brake lines at their
axle fittings.
4
15. Check the hydraulic reservoir oil level.
18. Start the engine. Turn the steering wheel several times 4
lock to lock, operate the frame tilt function several times
in both directions and check the function of the brakes. 5
Check for hydraulic leaks, and tighten or repair as
necessary.
19. Front Axle: Install the front access panel.
MH3281
Note: The service brake circuit will need to be bled after axle Note: Steps 5 thru 7 apply to 10054 Only.
installation. Refer to Section 8.8.4, “Brake Bleeding”. 5. Label and disconnect the wiring harness connectors at
both outrigger cylinder pressure switches (4). Remove
5.3.6 Axle Replacement the wire ties securing the wiring harness to the
(8042, 10042 & 10054) outrigger cylinders.
6. Tie a length of string to each pressure switch wiring
a. Outrigger Removal (10042 & 10054 only)
connector, and pull harness out through openings (5) at
On Models 10042 and 10054 equipped with outriggers, it is rear of outrigger housing.
necessary to remove the outrigger assembly before 7. Untie strings from wiring connectors and tape, or
removing the front axle. otherwise secure ends of strings to outrigger housing.
1. Park the machine on a firm, level surface, level the These strings will be used to pull harness through
machine, fully retract the boom, lower the boom, place housing during installation.
brake, straighten all wheels and shut the engine OFF.
5-8 31211015 6036, 6042, 8042, 10042, 10054

b. Outrigger Installation
7 1. Using a suitable jack, hoist or overhead crane and sling,
remove the outrigger assembly from its supports.
Balance the assembly and prevent it from tipping,
turning or falling while positioning it on the machine.
DO NOT raise or otherwise disturb the machine while
installing the outrigger assembly. Keep the assembly
supported and balanced during the installation
procedure.
2. Place the same number and thickness of shims (8) on
the pivot pin, as recorded during removal.
8
9 6 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.
Note: ALWAYS use new o-rings when servicing the machine.
5. Install new o-rings into the fittings. Lubricate the o-rings
with clean hydraulic oil.
6. Uncap and connect the previously labeled hydraulic
hoses (6) to their appropriate locations.
MH6260
7. Tie the strings left in the outrigger housing during
8. Label, disconnect and cap the outrigger hydraulic removal to each pressure switch wiring connector, and
hoses (6). Cap all fittings to keep dirt and debris from pull the harness through the outrigger housing.
entering the hydraulic system. 8. Connect the wiring connectors to the outrigger cylinder
9. Support the outrigger assembly using a suitable jack, pressure switches. Secure the harnesses to the cylinders
hoist or overhead crane. with wire ties.
10. Remove the capscrews, hex nuts, flat washers and 9. Check the hydraulic reservoir oil level.
mount plates (7). 10. Properly connect the battery. Refer Section 9.8,
Note: Record the number and thickness of shims to ensure “Battery”, for procedure.
correct installation. 11. Remove the Do Not Operate Tags from both the ignition
11. Remove the outrigger assembly using a suitable jack,
hoist or overhead crane. Remove the shims (8) from the 12. Start the engine. Turn the steering wheel several times
pivot pin. lock to lock, operate the frame tilt function several times
in both directions and check the function of the brakes.
12. Move the outrigger assembly away from the machine
Check for hydraulic leaks, and tighten or repair as
and carefully lower it to the ground. Block up or support
necessary.
the assembly so that it does not move or fall.
13. Inspect the pivot bearing (9). Replace the bearing if
worn or damaged.
6036, 6042, 8042, 10042, 10054 31211015 5-9

c. 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.
Cleanliness is extremely important. Before attempting to
remove the axle, thoroughly clean the machine. Avoid
spraying water or cleaning solution on the stabilizer 2
solenoids and other electrical components. If using a steam
cleaner, seal all openings before steam cleaning.
MA9091
Note: Clear the work area of all debris, unnecessary personnel,
etc. Allow sufficient space to raise the machine and to remove 8. Front Axle: Remove the front access panel (2) to gain
the axle. access to the front axle hose connections and mounting
1. Park the machine on a firm, level surface, level the bolts.
machine, fully retract the boom, lower the boom, place 9. Label, disconnect and cap the steering and brake lines
the transmission in (N) NEUTRAL, engage the parking at the axle. Cap all fittings to prevent dirt and debris
brake, straighten all wheels and shut the engine OFF. from entering the hydraulic system. Wipe up any spilled
2. Place a Do Not Operate Tag on both the ignition key oil.
switch and steering wheel, stating that the machine 10. Block the front and rear of both tires on the axle that is
should not be operated. not being removed. Ensure that the machine will remain
3. Open the engine rear and side engine doors. Allow the in place during axle removal before proceeding.
system fluids to cool. 11. Raise the machine using a suitable jack or hoist. Place
4. Properly disconnect the battery. Refer Section 9.8, suitable supports under both sides of the frame and
“Battery”, for procedure. lower the machine onto the supports. Ensure that the
machine will remain in place during axle removal.
5. Remove the fender assembly (if equipped).
12. Support the axle that is being removed with a suitable
6. Models 10042 and 10054, Front Axle Only: Remove jack, hoist or overhead crane and sling. DO NOT raise
outrigger assembly. Refer to Section 5.3.6, a. “Outrigger the axle or the machine.
Removal (10042 & 10054 only)”.
13. Remove both wheel and tire assemblies from the axle
that is being removed. Refer to Section 5.6.1, “Removing
Wheel and Tire Assembly from Machine”.
Note: The wheel and tire assemblies must be re-installed later
with the directional tread pattern “arrows” facing in the
direction of forward travel.
14. Remove the drive shaft assembly. Refer to Section 5.5.2,
“Drive Shaft Removal”.
MAQ0960
7. If axle will be disassembled after removal, place a

suitable receptacle under axle drain plug (1). Remove
drain plug and allow axle oil to drain into receptacle.
Transfer used axle oil into a suitable covered container,
and label container as “Used Oil”. Dispose of used oil at
an approved recycling facility.
5-10 31211015 6036, 6042, 8042, 10042, 10054

room for axle installation. Ensure that the machine will

remain in place during axle installation.
3. Using a suitable jack, hoist or overhead crane and sling,
remove the axle from its support or holding stand.
Balance the axle and prevent it from tipping, turning or
falling while positioning it beneath the machine.
DO NOT raise or otherwise disturb the machine while
installing the axle. Keep the axle supported and
balanced on the jack, hoist or overhead crane and sling
throughout the installation procedure.
4. Position the axle under the frame, and align the pivot
10
pin bearings with the holes in the frame.
5. Coat the axle pivot pin (11) with a light film of clean
engine or hydraulic oil; DO NOT use an anti-seize
10 12 compound.
6. Install the axle pivot pin (11) and shims (12). Add or
11 remove shims until a maximum gap of 0.6 in (1.5 mm) is
obtained. Balance the number and thickness of shims
equally of both sides. Secure the pivot pin with one
capscrew and a new locknut.
12
11 1
6
11 12 MAQ0981 10 2
15. Remove the capscrew and locknut securing the lower 9 3
position cylinder-mount pin (10) to the cylinder. Tap the
8 4
cylinder mount pin out, and move the cylinder to
prevent it from interfering with axle removal. 7 5
6 MT0822
16. Remove the capscrew and locknut securing the axle
pivot pin (11) to the frame. Note: If new frame level (front) or stabilizer (rear) cylinder
bearings (13) have been installed in the axles or machine
Note: Record the number and location of shims (12) to ensure
frame, the fracture in the bearing race must be positioned at
correct installation.
the 9 o’clock position as shown below.
17. Remove the pivot pin and shims.
7. Move the cylinder into position on the axle cylinder
18. Remove the axles from the machine using the jack, hoist anchor. Insert a cylinder-mount pin (10) through the
or overhead crane and sling supporting the axle. cylinder and cylinder anchor. Secure the
DO NOT raise or otherwise disturb the machine while cylinder-mount pin with one capscrew and new
removing the axle. Balance the axle and prevent it from locknut.
tipping, turning or falling while removing it from
8. Apply multi-purpose grease through the self-tapping
beneath the machine. Place the axle on a suitable
lube fitting to lubricate the self-align bearing and the
support or holding stand.
cylinder-mount pin.
d. Axle Installation 9. Install the drive shaft assemblies. Refer to Section 5.5.3,
“Drive Shaft Installation”.
1. Before proceeding, ensure that the machine will remain
in place during axle installation. Block the front and rear 10. If reinstalling an axle previously removed from the
of both tires on the axle that is already installed on the machine, position the driveshaft yoke on the axle
machine. according to the alignment marks made earlier. If
installing a new axle, note the position of the driveshaft
2. If applicable, raise the machine using a suitable jack or yoke at the transmission. Align the driveshaft yoke on
hoist. Place suitable supports beneath the frame and the axle in the same plane as the yoke on the
lower the machine onto the supports, allowing enough transmission.
6036, 6042, 8042, 10042, 10054 31211015 5-11

11. Install the wheel and tire assemblies. Refer to 18. Check the hydraulic reservoir oil level.
Section 5.6.2, “Installing Wheel and Tire Assembly onto 19. Properly connect the battery. Refer Section 9.8,
Machine”. “Battery”, for procedure.
12. Carefully remove the jack, hoist or overhead crane and 20. Remove the Do Not Operate Tags from both the ignition
sling supporting the axle. key switch and the steering wheel.
13. Carefully raise the machine using a suitable jack or hoist. 21. Start the engine. Turn the steering wheel several times
Remove the supports from beneath the frame and lock to lock, operate the frame tilt function several times
lower the machine to the ground. in both directions and check the function of the brakes.
14. Remove the blocks from the front and rear of both tires Check for hydraulic leaks, and tighten or repair as
on the other axle. necessary.
Note: ALWAYS use new o-rings when servicing the machine. 22. Install the fender assembly (if equipped).
15. Install new o-rings into the fittings. Lubricate the 23. Close and secure the engine rear and side engine doors.
o-rings with clean hydraulic oil. Note: The service brake circuit will need to be bled after axle
16. Uncap and connect the steering and brake lines at their installation. Refer to Section 8.8.4, “Brake Bleeding”.
axle fittings.
17. Models 10042 and 10054, Front Axle Only: Install
outrigger assembly. Refer to Section 5.3.6, b. “Outrigger
Installation”.
5.4 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 2.3, “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. Refer to Section 2.3, “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.
Refer to Section 2.3, “Fluid
Specifications”.
8. Axle housing damaged. 8. Replace damaged parts.
5-12 31211015 6036, 6042, 8042, 10042, 10054


2. Intermittent noise when 1. Universal joint(s) worn or 1. Repair or replace universal joints
traveling. damaged. 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) worn 2. Repair or replace universal joints

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

unbalanced.
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 or tighten plugs to
axle housings). missing. 96 lb-ft (130 Nm).
2. Hose fittings loose. 2. Tighten fittings.
3. Axle shaft seal damaged or 3. Replace seal and/or joint coupling

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

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

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 housing(s) 7. Replace housing(s) as needed.

damaged.
6036, 6042, 8042, 10042, 10054 31211015 5-13


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 housing 2. Replace o-ring.

(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 damaged. 3. Replace piston rod seal.
4. Cylinder tube damaged. 4. Replace cylinder tube.
7. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level. Refer to
Section 2.3, “Fluid Specifications”.
2. Axle and/or wheel end housings 2. Drain axle and fill to correct level.
filled with incorrect oil or oil Refer toSection 2.3, “Fluid
contaminated or oil level low. 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 8.5.2, “Pressure
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 8.5.2, “Pressure
2. Steering cylinder leaking 2. Repair or replace steering cylinder

internally. as needed.
10. Excessive noise when brakes are 1. Brake discs worn. 1. Check brake discs for wear. Refer
engaged. to Section 5.7.1, “Brake Disc
Inspection”.
2. Brake discs damaged. 2. Replace brake discs.
5-14 31211015 6036, 6042, 8042, 10042, 10054


11. Brakes will not engage. 1. Brake (hydraulic) system not 1. Refer to Section 8.5.2, “Pressure
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. Refer
machine or braking power to Section 5.7.1, “Brake Disc
reduced. Inspection”.
2. Brake (hydraulic) system not 2. Refer to Section 8.5.2, “Pressure

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

damaged (leaking).
6036, 6042, 8042, 10042, 10054 31211015 5-15

5.5 DRIVE SHAFTS

TO ENGINE
5.5.1 Drive Shaft Inspection and Maintenance 1

2
5
Inspect areas where the drive shaft flange yokes and slip
yokes mount to the drive shafts. Verify all straps and bolts are
tight by attempting to turn each drive shaft in both
TO AXLE
directions. Look for excessive looseness, missing parts, cracks TO
TO TRANSMISSION
or other damage. Worn or damaged drive shafts and cross TRANSMISSION
and bearing assemblies may cause an excessive amount of
vibration or noise.
2 4
Verify the mating surfaces between the driveshaft yoke, 3
universal joint and are clean and smooth. 1
Refer to Section 2.6, “Lubrication Schedules” for information TO
1
TRANSMISSION 2
regarding the lubrication of the grease fittings on the drive
shafts. 3 MAQ4600
TO AXLE 4
Note: To ensure optimum performance, the driveshaft
assemblies are specially balanced as a unit at the factory. When 7. Remove the four bolts (1) and two straps (2) securing
servicing any flange yoke, slip yoke or driveshaft tube, order a the universal joint to the transmission output shaft
complete assembly if components are bent or damaged. Refer flange.
to the appropriate parts manual for ordering information. 8. Remove the four bolts (3) and two straps (4) securing
the universal joint to the axle. Discard bolts.
Note: Any bolt removed from the drive shaft assembly MUST
be replaced. DO NOT re-torque. 9. Remove the front drive shaft assembly.
Note: Refer to Section 2.7, “Thread Locking Compound”, for all 10. Repeat the above procedure for the rear drive shaft.
thread locking requirements. 11. Remove the four bolts (1) and two straps (2) securing
the universal joint to the transmission output shaft
5.5.2 Drive Shaft Removal flange.
1. Park the machine on a firm, level surface, level the 12. Remove the four bolts (5) securing the engine output
machine, fully retract the boom, lower the boom, place flange to the engine.
the transmission in (N) NEUTRAL, engage the park brake 13. Remove the engine/transmission drive shaft assembly.
5.5.3 Drive Shaft Installation
switch and steering wheel, stating that the machine 1. Raise the drive shaft assembly into position. The slip-
should not be operated. 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 marks made
during removal.
“Battery”, for procedure. Note: The yokes at both ends of the drive shaft must be in the
same plane to help prevent excessive vibration.
5. Block the wheels.
2. Install the two straps (2) and four new bolts (1) securing
6. The drive shaft assemblies are a balanced assembly.
the universal joint to the transmission. Torque bolts to
Mark the yoke and axle, transmission and the shaft and
60 lb-ft (81 Nm).
slip yoke so that these components can be returned to
their original positions when reinstalled. Yokes at both 3. Install the two straps (4) and four new bolts (3) securing
ends of the drive shaft must be in the same plane to the universal joint to the axle. Torque bolts to
help prevent excessive vibration. 60 lb-ft (81 Nm).
4. Install the four bolts (5) securing the engine output
flange to the engine. Torque bolts to 60 lb-ft (81 Nm).
5. Install four new bolts (5) securing the engine output
flange to the engine. Torque as required.
5-16 31211015 6036, 6042, 8042, 10042, 10054

5.6 WHEELS AND TIRES 1
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 that
MY4190
replacement tires have the following characteristics:
The wheel and tire assemblies must be installed with the
• Equal or greater ply/load rating and size of original. directional tread pattern “arrows” (1) facing in the direction
of forward travel.
• Tire tread contact width equal or greater than original.
• Wheel diameter, width and offset dimensions equal to 5.6.1 Removing Wheel and Tire Assembly from
the original. Machine
• Approved for the application by the tire manufacturer 1. Park the machine on a firm, level surface, fully retract
(including inflation pressure and maximum tire load). the boom, lower the boom, place the transmission in (N)
The rims installed have been designed for stability NEUTRAL, engage the park brake and shut the engine
requirements which consist of track width, tire pressure and OFF.
load capacity. Size changes such as rim width, center piece 2. Place an Do Not Operate Tag on both the ignition key
location, larger or smaller diameter, etc., without written switch and steering wheel, stating that the machine
factory recommendations, may result in unsafe condition should not be operated.
regarding stability.
3. Loosen but DO NOT remove the lug nuts on the wheel
Foam filled tires have a positive effect on the weight, stability and tire assembly to be removed.
and handling characteristics of the machine, especially
4. Place a suitable jack under the axle pad closest to the
under load. The use of hydrofill as a tire-fill substance is not
wheel being removed. Raise the machine and position a
recommended because of possible environmental impact.
suitable support beneath the axle. Allow sufficient room
Large-bore valve stems are used to help expedite tire to lower the machine onto the support and to remove
inflation and deflation. An inner tube may be used if a tire the wheel and tire assembly.
does not provide an airtight seal. Check tire inflation
5. Lower the machine onto the support.
pressures when the tires are cold. When mounting a tire on
the wheel, the tire must be mounted on the wheel respective 6. Remove lug nuts and lug washers in an alternating
of the directional tread pattern of the tire; this produces a left pattern.
or right tire and wheel assembly. 7. Remove the wheel and tire assembly from the machine.
6036, 6042, 8042, 10042, 10054 31211015 5-17

5.6.2 Installing Wheel and Tire Assembly onto 5.7 BRAKES

Machine
Note: The wheel and tire assemblies must be installed with the 5.7.1 Brake Disc Inspection
directional tread pattern “arrows” facing in the direction of
A brake lining wear measurement on service brake (multi-
forward travel.
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 from
PROPER DIRECTION
moving.
MAQ0990
1. Position wheel onto studs on wheel end of axle.

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

figure. Refer to Section 2.2.5, “Tires,” for proper torque
value.
4. Remove machine from supports.
5-18 31211015 6036, 6042, 8042, 10042, 10054

used oil at an approved recycling facility. 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 work site or on a roadway, prepare the machine
for towing as follows:
1. Remove the load from the machine.
2. Block all four wheels to help prevent the machine from
moving after the parking brake is disabled.
4. Position the towing machine in place. Attach any chains
needed to secure the disabled machine.
6036 & 6042
2 MAQ1000
3. Using a feeler gauge, check thickness of lined/inner

disc (2). If thickness is less than or equal (≤) to 3.75mm,
replace the lined/inner discs. 2
1
Note: If discs are worn beyond their tolerance, discs must be
replaced on both sides of axle at the same time.
MAQ1510
4. Repeat step 3 for other side of axle.
5. Fill the axle through the axle fill hole until the oil level is
8042, 10042 & 10054
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.
5.8 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 2
power. Towing the machine improperly can result in damage
to the machine drivetrain. 1
Note: In the event the machine is disabled and cannot be 5. Attach a remote portable hydraulic pressurizing unit to
moved under engine power, the situation must be properly the parking brake gauge port (1) on the secondary
evaluated and dealt with on an individual basis. Contact your function manifold (2) mounted on the inside wall of the
local JLG distributor for specific instructions for your particular frame on the left side next to the transmission.
situation.
6. Turn the key switch to the ON position, release the park
brake, and have an operator seated in the seat.
6036, 6042, 8042, 10042, 10054 31211015 5-19

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 31211015 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 31211015 6-1

Transmission
6.1 TRANSMISSION ASSEMBLY

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
MAQ0741
6-2 31211015 6036, 6042, 8042, 10042, 10054

Transmission
6.4 TRANSMISSION REPLACEMENT

WARNING Note: Contact your local JLG Service Department if internal
DO NOT service the machine without following all safety transmission repair is required during the warranty period.
Note: Cleanliness is of extreme importance. Before attempting
this manual.
to remove transmission, thoroughly clean exterior of
transmission to help prevent dirt from entering during
6.2 TRANSMISSION SERIAL NUMBER replacement process. Avoid spraying water or cleaning solution
onto or near transmission shift solenoids and other electrical
components.
6.4.1 Transmission Removal
WARNING
NEVER lift a transmission alone; enlist the help of at least
one assistant or use a suitable hoist or overhead crane
and sling with the minimum lifting capacity of
1000 lb (454 kg).
1
machine, fully retract the boom, raise the boom, place
OH2381
Transmission serial number plate (1) is located on pump side 2. Place a Do Not Operate Tag on both the ignition key
(front) of transmission at bottom right toward machine switch and steering wheel, stating that the machine
frame. Information on serial number plate is required in should not be operated.
correspondence regarding transmission.
3. Temporarily block up or support the boom.
6.3 TRANSMISSION SPECIFICATIONS AND 4. Open the engine rear and side engine doors. Allow the
MAINTENANCE INFORMATION
5. Drain the hydraulic oil reservoir. Refer to Section 8.6.1,
Refer to Section 2, “General Information and Specifications”, “Hydraulic Oil Reservoir Draining”.
for transmission, oil specifications and maintenance 6. Properly disconnect the battery. Refer Section 9.8,
information. “Battery”, for procedure.
Detailed transmission service instructions are provided in the 7. Remove the transmission covers.
following publications:
8. Thoroughly clean the transmission and surrounding
area, including all hoses and fittings.
Model Publication Type Publication #
6036, 6042,
8042, Service Manual 8990455
10042,10054
6036, 6042 31211016
8042, 10042, Parts Manual

31211017
10054
6036, 6042, 8042, 10042, 10054 31211015 6-3

Transmission
14. Remove the capscrew securing the black wire (4) to the
transmission housing, and disconnect the wire. DO NOT
reinstall the capscrew at this time.
15. Remove the capscrew securing the clamp (5) and wiring
harness to the transmission housing and move the
wiring harness safely out of the way. DO NOT reinstall
the capscrew at this time.
8
7
OH2381
9. Place a suitable receptacle under transmission drain

plug (1). Remove transmission drain plug, and allow
transmission oil to drain into receptacle.
10. Transfer the used transmission oil into a suitable,
covered container, and label the container as “Used Oil”. 6 MH3401
Dispose of used oil at an approved recycling facility.
16. Remove the capscrew (6) securing the lifting ring (7) to
Clean and reinstall the transmission drain plug.
the transmission housing. Once the lifting ring has been
11. Remove the engine-to- transmission and transmission- removed, reinstall the capscrew into the hole.
to-axle drive shafts. Refer to Section 5.5.2, “Drive Shaft
17. Move the lifting ring to the holes (8) used to secure the
Removal”.
black wire and clamp. Secure the lifting ring using the
12. Remove the hydraulic pump. Refer to Section 8.7.1, capscrews and tighten securely.
“Pump Replacement”.
18. Label, disconnect and cap the transmission oil cooler
2 inlet and outlet hoses on the transmission.
4
19. Connect a lifting strap or chain to the lifting eye at the
top of the transmission and to a suitable hoist or
overhead crane. Operate the hoist or crane to remove
3 slack from the chain, but DO NOT raise the transmission
at this time.
20. Place blocks under the transmission to help support it
during removal.
MH3391
5
13. Label and disconnect the transmission temperature

switch connector (2) and shift solenoid wiring harness
connectors (3).
6-4 31211015 6036, 6042, 8042, 10042, 10054

Transmission
6.4.2 Transmission Inspection and Internal

1 Repair
If replacing the entire transmission, transfer the transmission
temperature switch to the replacement transmission. The
gear shift solenoids are included with a new transmission.
6.4.3 Transmission Installation
WARNING
NEVER lift a transmission alone; enlist the help of at least
one assistant or use a suitable hoist or overhead crane
and sling with the minimum lifting capacity of
9 1000 lb (454 kg).
1. Install two rubber mounts and the rear transmission
mount (1) in the machine frame. Secure the mount with
MH6290 the previously used hardware.
2. Use a hoist or overhead crane and sling attached to the
21. Remove the capscrews and lockwashers securing the
lifting eye at the top of the transmission. Raise and
front transmission mount (9) to the transmission.
position the transmission within the chassis.
22. Remove the two capscrews, hex locknuts and rebound
3. Attach the transmission to the rear mounting bracket
washers. Remove the front transmission mount.
with the previously used hardware. Torque to
23. Remove the four capscrews and lockwashers securing 148 lb-ft (200 Nm).
the rear transmission mount (1) to the transmission.
4. Install the two front rubber mounts and the front
24. Remove the two capscrews, hex locknuts and rebound transmission mounting bracket (9) on the transmission
washers. Remove the rear transmission mount. with the previously used hardware. Torque to
25. Inspect the rubber mounts. Replace the mounts if 148 lb-ft (200 Nm).
damaged. 5. Attach the front mounting bracket to the frame with the
26. Carefully remove the transmission from the machine. previously used hardware
Avoid causing damage to the transmission or 6. Remove the hoist or overhead crane and sling.
surrounding parts.
27. Lift the transmission clear of the machine and lower it
onto suitable supports or secure it to a stand built
especially for the transmission or engine service. Secure 3
the transmission so that it will not move or fall. 4
28. Remove any external transmission components as

required, including the transmission temperature
switch, and inlet and outlet cooler hose fittings. Cover
all transmission openings.
29. Remove the transmission oil filter and dispose of
properly. Clean the filter mounting surface. Cover or cap
the oil filter mount.
MH3411
Note: The lifting ring (3) must be repositioned to allow the

covers to be installed.
6036, 6042, 8042, 10042, 10054 31211015 6-5

Transmission
7. Remove the two capscrews securing the lifting ring to 20. Remove the Do Not Operate Tags from both the ignition
the transmission housing. Save the capscrews for later key switch and the steering wheel.
use. 21. Close and secure the engine rear and side engine doors.
8. Remove the capscrew and secure the lifting ring in the
storage position (4) on the transmission housing as 6.4.4 After Transmission Service or
shown. Replacement
5
In general:
7
1. Check the transmission oil level and add oil as required.
2. Install a new transmission filter.
3. Check the torque on the drive shaft yoke cap screws.
4. When an overhauled or repaired transmission is
6
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
MH3391
9. Connect the transmission temperature switch

connector (5) and shift solenoid wiring harness 8
connectors (6).
10. Attach the black wire (7) to the transmission housing
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.
12. Uncap and connect the previously labeled transmission
oil cooler inlet and out hoses at the transmission.
13. Install the hydraulic pump. Refer to Section 8.7.1, “Pump
MH6300
Replacement”.
14. Install the engine-to-transmission and transmission-to- 8. Reassemble all components and fill the transmission
axle drive shafts. Refer to Section 5.5.3, “Drive Shaft through the dipstick tube opening (8). Check the level
Installation”. by taking intermittent dipstick readings as outlined in
15. Clean the transmission oil filter mounting surface. the appropriate Operation & Safety Manual. DO NOT
overfill. Reinstall the dipstick when finished.
16. Apply a thin film of clean oil to the new transmission
filter gasket. Install the new filter and torque to 9. Run the engine for two minutes at idle to help prime the
20-25 lb-ft (27-34 Nm). torque converter and the transmission oil lines.
17. Transmission oil may be added through the dipstick 10. Recheck the level of the fluid in the transmission with
tube. Remove the dipstick and add oil. Check the oil the engine running at idle and at the normal operating
level by taking intermittent dipstick readings as temperature 180 - 200° F (83 - 94° C).
outlined in the appropriate Operation & Safety Manual. 11. Add oil as necessary to bring the fluid level to within the
DO NOT overfill. Reinstall the dipstick when finished. “HOT” zone mark on the dipstick.
18. Install the transmission covers. 12. Recheck all drain plugs, lines, connections, etc., for leaks,
19. Properly connect the battery. Refer Section 9.8, and tighten where necessary.
6-6 31211015 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 or 1. Oil level too high or low. 1. Fill transmission to correct level.
will not shift properly. Refer to Section 2.3, “Fluid
Specifications”.
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 “.
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.
2. Low or no pump flow or 1. Low oil level. 1. Fill transmission to correct level.
pressure. Refer to Section 2.3, “Fluid
Specifications”.
2. Transmission filled with incorrect 2. Drain transmission and fill to

oil, or oil contaminated. correct level. Refer Section 2.3,
“Fluid Specifications”.
3. Pump suction pipe screen 3. Clean, repair and/or replace

clogged. suction pipe.
4. Central shaft damaged. 4. Replace central shaft.
5. Pump worn or damaged. 5. Repair or replace pump assembly.
6036, 6042, 8042, 10042, 10054 31211015 6-7

Transmission

3. Low clutch pressure. 1. Incorrect oil level. 1. Fill transmission to correct level.
Refer to Section 2.3, “Fluid
Specifications”.
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 8.5.2, “Pressure
Specifications”.
2. Low engine rpm causes converter 2. Adjust the engine rpm to

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

4. Clutch discs worn or damaged. 4. Replace clutch discs.
5. Transmission overheating. 5. Refer to Section 6.5, “Transmission

5. Transmission overheating 1. Low oil level. 1. Fill transmission to correct level.

(oil above 120° C (248° F)). Refer to Section 2.3, “Fluid
Specifications”.
2. Clogged radiator. 2. Remove debris from the radiator.

oil, or oil contaminated. correct level. Refer to Section 2.3,
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.
6-8 31211015 6036, 6042, 8042, 10042, 10054

Transmission

6. Grinding or “clunking” noise 1. Oil level too low. 1. Fill oil to correct level. Refer to
from transmission. Section 2.3, “Fluid Specifications”.

oil. correct level. Refer to Section 2.3,
3. Incorrect clutch engagement. 3. Refer to Section 9.12.2,

“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.
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 2.3, “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 missing capscrews to 85 lb-ft (115 Nm).
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 (output 8. Replace output shaft seal.

shaft seal damaged).
9. Housing damaged. 9. Replace housing as needed.
6036, 6042, 8042, 10042, 10054 31211015 6-9

Transmission
6-10 31211015 6036, 6042, 8042, 10042, 10054

Section 7
Engine
Contents

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.3.1 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.4.1 Coolant System Pressure Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.4.2 Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.4.3 Radiator/Oil Cooler and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.6.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.6.2 Fuel/Hydraulic Oil Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.6.3 After Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.6.4 Diesel Exhaust Fluid (DEF) Tank - (if equipped for ULS 85 hp or 110 hp (63 kW or 82
kW)) (Prior to S/N 0160082087) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.6.5 Diesel Exhaust Fluid (DEF) Header – (if equipped for ULS 85hp or 110hp (63kW or
82kW)) (Prior to S/N 0160082087) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.6.6 Diesel Exhaust Fluid (DEF) Pump Filter – (if equipped for ULS 85hp or 110hp (63kW or
82kW)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.6.7 Diesel Exhaust Fluid (DEF) System Cleaning – (if equipped for ULS 85hp or 110hp (63kW
or 82kW)) (Prior to S/N 0160082087) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.6.8 Cummins Diesel Exhaust Fluid (DEF) Tank - (if equipped for ULS 110 hp (82 kW)) (S/N
0160082087 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.6.9 Cummins Diesel Exhaust Fluid (DEF) Header – (if equipped for ULS 110hp (82kW)) (S/N
0160082087 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.6.10 Diesel Exhaust Fluid (DEF) Pump Filter – (if equipped for ULS 85hp or 110hp) (63kW or
82kW)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.6.11 Cummins Diesel Exhaust Fluid (DEF) System Cleaning – (if equipped for ULS 110hp
(82kW)) (S/N 0160082087 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.6.12 Diesel Exhaust Fluid (DEF) System – Engine Coolant Strainer Cleaning (S/N 0160082087
to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
7.7.1 Exhaust System - (if equipped for ULS 85 or 110 hp (63kW or 82kW) . . . . . . . . . 7-17
7.7.2 Exhaust System - ULS 74 hp (55kW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7.7.3 Exhaust System - LS 85 hp (63 kW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
7.8 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7.8.1 Air Cleaner Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7.8.2 Air Cleaner Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
6036, 6042, 8042, 10042, 10054 31211015 7-1

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7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

7.9.1 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
7.9.2 Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
7.10 Isolation Coupler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
7.10.1 Isolation Coupler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
7.10.2 Isolation Coupler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
7-2 31211015 6036, 6042, 8042, 10042, 10054

Engine
7.1 INTRODUCTION 7.2 ENGINE SERIAL NUMBER

The engine serial number is located on the turbocharger
WARNING side of the valve cover. Information contained in the serial
number is required in correspondence with the engine
DO NOT service the machine without following all safety manufacturer.
this manual. 7.3 SPECIFICATIONS AND MAINTENANCE
INFORMATION
WARNING For engine, coolant and oil specifications, and maintenance
Engine fuel lines are pressurized. DO NOT attempt information, refer to Section 2, “General Information and
repairs unless specific training has been completed. Specifications”.
Note: Detailed Cummins engine service instructions (covering
7.1.1 Disclaimer and Scope disassembly, inspection, internal repair, assembly, adjustment
and troubleshooting) are provided in appropriate Cummins
These instructions are written for worldwide use. In
engine service manual.
territories where legal requirements govern engine smoke
emission, noise, safety factors, etc., apply all instructions, Note: Refer to Section 9.20, “Engine Fault Codes”, for error
data and dimensions provided herein in such a way that after codes and troubleshooting.
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.
6036, 6042, 8042, 10042, 10054 31211015 7-3

Engine
7.3.1 Component Terminology

of the engine components. The following illustration
identities the components that are referred to throughout
this section.
IF EQUIPPED FOR ULS IF EQUIPPED FOR LS
TURBOCHARGER
TURBOCHARGER
STARTER STARTER
ALTERNATOR
ALTERNATOR
THERMOSTAT
THERMOSTAT
FUEL INJECTOR FUEL INJECTOR

PUMP PUMP
WATER PUMP
FUEL FILTER MAQ1820
MAQ1180
WATER PUMP FUEL FILTER
OIL FILTER OIL FILTER
7-4 31211015 6036, 6042, 8042, 10042, 10054

Engine
7.4 ENGINE COOLING SYSTEM

1
7.4.1 Coolant System Pressure Cap

The surge tank cap is designed to use a 17 psi (120 kPa) cap.
An incorrect or malfunctioning cap can result in the loss of
coolant and a hot-running engine.
7.4.2 Thermostat Replacement

Before considering thermostat replacement, check the
coolant level, fan belt tension and instrument cluster
temperature indicator.
• If engine seems to take a long time to warm, thermostat
may be stuck in the open position and requires
replacement.
MAQ1590
• If engine runs hot, check the temperature of the upper
radiator hose. 8. Remove four bolts securing thermostat housing (1) to
• If hose is not hot, thermostat may be stuck in the closed the engine.
position. 9. Remove thermostat housing, old gasket and
• If engine has overheated, performance may thermostat. Clean all gasket surfaces. DO NOT allow dirt
suffer, indicating other damage including a leaking or debris into the thermostat opening.
cylinder head gasket, cracked cylinder head or block,
Note: ALWAYS use correct thermostat and new gasket. NEVER
and/or other internal engine damage.
operate engine without a thermostat.
a. Thermostat Removal
1. Park machine on a firm, level surface, level machine, fully b. Thermostat Installation
retract the boom, lower boom, place transmission in (N) 1. Install engine thermostat, gasket and housing. Secure
NEUTRAL, engage parking brake, and shut engine OFF. with previously removed bolts. Torque as required.
2. Place a Do Not Operate Tag on both the ignition key 2. Properly connect the battery. Refer Section 9.8,
switch and steering wheel, stating that the machine “Battery”, for procedure.
3. Open the surge tank cap and fill the radiator completely
3. Open the engine cover. Allow the system fluids to cool. with a 50/50 mixture of ethylene glycol and water. Add
4. Properly disconnect the battery(s). Refer Section 9.8, coolant solution at a maximum rate of 1.3 gallons per
“Battery”, for procedure. minute (5 liters per minute). Replace and tighten surge
tank cap. Add coolant to surge tank until 1/4 to 1/2 full.
5. Slowly turn the surge tank cap to the first stop and allow
This overfilling will compensate for any air trapped in
any pressure to escape. Remove surge tank cap.
the cooling system.
6. Place a funnel at base of radiator to channel drained
4. Run engine to operating temperature. Visually check for
coolant into a container. Loosen drain petcock and
leaks with engine running. Check coolant level in surge
slowly allow coolant to drain. Transfer coolant into a
tank and fill, or drain, as necessary.
properly labeled container. Dispose of properly if
coolant needs to be replaced. Tighten the radiator drain 5. Close and secure the engine cover.
petcock. 6. Remove the Do Not Operate Tags from both the ignition
7. Loosen upper radiator hose clamp and remove the key switch and the steering wheel.
radiator hose from the thermostat housing.
6036, 6042, 8042, 10042, 10054 31211015 7-5

Engine
coolant needs to be replaced. Tighten the radiator drain

6
1 petcock.
8. Label and disconnect all hoses and tubes attached to
2 radiator (2), charge air cooler (3), oil cooler (4), and fuel
cooler (5). Remove surge tank (6).
3 9. Working at rear of machine, remove cap screws and lock
washers securing radiator assembly.
10. Remove radiator assembly through rear of machine.
5
b. Radiator/Oil Cooler Installation

1. Secure radiator (2), charge air cooler (3), oil cooler (4),
4
and fuel cooler (5) to machine frame with previously
used hardware. Reinstall surge tank (6).
2. Uncap and connect the all the previously labeled hoses
and tubes to their appropriate locations.
MAQ1200
3. Install the battery or batteries. Connect the battery
positive (+) and negative (-) cables to the appropriate
7.4.3 Radiator/Oil Cooler and Replacement battery terminals.
Before considering radiator or oil cooler replacement 4. Fill the radiator completely with coolant and secure cap.
for other than obvious damage, conduct a cooling Refer to Section 2.3, “Fluid Specifications”, for proper
system pressure test, check coolant specific gravity, coolant capacities.
level, fan belt tension and dash panel temperature indicator. 5. Run engine to operating temperature. Visually check for
• If engine runs hot, check temperature of upper radi- leaks with engine running. Check coolant level in
ator hose. overflow bottle and fill, or drain, as necessary.
• If hose is not hot, thermostat may be stuck in closed 6. Close and secure side and rear engine doors.
position.
• If engine has overheated, performance may 7.5 ENGINE ELECTRICAL SYSTEM
suffer, indicating other damage including a leaking
The engine electrical system, including the starter, alternator
cylinder head gasket, cracked cylinder head or
and primary wiring, is described in Section 9, “Electrical
block, and/or other internal engine damage.
System”.
a. Radiator/Oil Cooler Removal
1. Park machine on a firm, level surface, level machine, fully
retract the boom, lower boom, place transmission in (N)
NEUTRAL, engage parking brake, and shut engine OFF.
3. Open the engine cover. Allow the system fluids to cool.
4. Properly disconnect the battery(s). Refer Section 9.8,
5. Slowly turn surge tank cap (1) to first stop and allow any
pressure to escape. Remove surge tank cap.
6. Place a suitable container beneath radiator drain.
7. Place a funnel at base of radiator to channel drained
coolant into a container. Loosen drain petcock and
slowly allow coolant to drain. Transfer coolant into a
properly labeled container. Dispose of properly if
7-6 31211015 6036, 6042, 8042, 10042, 10054
Engine
7.6 FUEL SYSTEM

6 1
2 3
7.6.1 Diesel Fuel
Fuel represents a major portion of machine operating costs
and therefore must be used efficiently. ALWAYS use a
premium brand of high-quality, clean diesel fuel. Low cost,
inferior fuel can lead to poor performance and expensive
engine repair.
Refer to Section 2.3, “Fluid Specifications”, for approved fuel
specification.
7.6.2 Fuel/Hydraulic Oil Tank

Note: The fuel/hydraulic oil tank is part of a one piece unit
MAQ1210
divided into a two compartment (tank) unit. It is located on the
right side of the machine, across from the operator cab. If it is 4 5
determined that either the fuel of hydraulic oil tank must be
removed, both the fuel and hydraulic oil must be drained before 5. Remove the hydraulic oil tank top cover (1).
tank removal. Always dispose of hydraulic oil or fuel properly.
Note: If equipped, the removal of the DEF tank is required to
a. Fuel/Hydraulic OIl Tank Removal access the fuel/hydraulic oil tank mounting bolts.
1. Park the machine on a firm, level surface, level the 6. Remove the DEF tank (3). Refer to Section 7.6.4, “Diesel
machine, fully retract the boom, lower the boom, place Exhaust Fluid (DEF) Tank - (if equipped for ULS 85 hp or
the transmission in (N) NEUTRAL, engage the parking 110 hp (63 kW or 82 kW)) (Prior to S/N 0160082087)”, for
brake, and shut the engine OFF. detailed removal instructions.
2. Place a Do Not Operate Tag on both the ignition key 7. Drain the fuel tank (4). Remove the fuel tank drain plug
switch and steering wheel, stating that the machine and drain fuel into an approved and suitable container.
should not be operated. Dispose of fuel properly.
3. Open the engine cover. Allow the system fluids to cool. 8. Drain the hydraulic oil tank (5). Refer to Section 8.6.1,
4. Properly disconnect the battery. Refer Section 9.8, “Hydraulic Oil Reservoir Draining”.
“Battery”, for procedure. 9. Label, disconnect and cap the fuel and hydraulic lines
from the tank.
Note: If replacing the tank, remove all internal and external
components from the old tank, and retain for use on the 10. Label and disconnect the electrical components from
replacement tank. the fuel/hydraulic oil tank.
Note: Have a dry chemical (Class B) fire extinguisher near the 11. Temporarily install two 1/2-13 lifting eye bolts in the top
work area. of the fuel/hydraulic tank (6).
12. Position and connect a suitable chain support to tank
lifting point (6) and take up slack in the chain.
WARNING 13. While supporting the tank, remove nuts and lock
NEVER drain or store fuel in an open container due to the washers securing the tank to the machine frame.
possibility of explosion or fire. Discard the fuel in an 14. Pull tank away from the tank carriage bolts, and remove
approved manner. tank.
b. Disassembly
The fuel/hydraulic oil tank is a one-piece unit and cannot be
disassembled. The fuel level indicator and hydraulic filters can
be removed and reused on the new replacement tank. Dispose
of the old tank according to local regulations concerning
6036, 6042, 8042, 10042, 10054 31211015 7-7

Engine
hazardous materials disposal. f. Fuel/Hydraulic Oil Tank Installation

1. Attach tank to a suitable lifting device at lift point.
c. Cleaning and Drying
2. Place tank carriage bolts into slotted holes in frame.
If contaminated fuel or foreign material is in the tank, the
tank can usually be cleaned. 3. Position the tank and insert carriage bolts through tank
attachment holes. Install lock washers and finger
Note: If a leak is suspected in the fuel tank, contact your local tighten nuts onto carriage bolts. Slide the tank and
authorized Service Department. carriage bolts toward the front of machine, until
To clean the fuel tank: carriage bolts are bottomed out into the slotted frame
holes. Tighten and torque as required.
1. Have a dry chemical (Class B) fire extinguisher near the
work area. 4. Connect the previously labeled electrical components
to the tank.
2. Depending on which side of the tank is contaminated
(fuel or hydraulic oil), remove the fuel or oil tank drain 5. Uncap and connect the previously labeled hydraulic
plug, and safely drain any fuel or hydraulic oil into a hoses to their appropriate locations.
suitable container. Dispose of fuel or hydraulic oil 6. Install the previously removed DEF tank. Refer to
properly. Section 7.6.4, “Diesel Exhaust Fluid (DEF) Tank - (if
3. Clean the fuel/hydraulic oil tank with a high pressure equipped for ULS 85 hp or 110 hp (63 kW or 82 kW))
washer, or flush the tank with hot water for five minutes (Prior to S/N 0160082087)”, for detailed installation
and drain the water. Dispose of contaminated water instructions.
properly. 7. Fill the hydraulic tank, fuel tank and DEF tank according
4. For the fuel tank side, add a diesel fuel emulsifying to specifications. Refer to Section 2.4, “Fluid and
agent to the tank. Refer to manufacturer’s instructions Lubricant Capacities”.
for the correct emulsifying agent-to-water mixture ratio. 8. Fill the fuel tank.
Refill the tank with water, and agitate mixture for 10 9. Check tank for leaks.
minutes. Drain the tank completely. Dispose of
contaminated water properly. 10. Install the hydraulic oil tank cover.
5. Refill the fuel tank with water until it overflows. 11. Properly connect the battery. Refer Section 9.8,
Completely flush the tank with water. Empty the fuel “Battery”, for procedure.
tank, and allow it to dry completely. 12. Remove the Do Not Operate Tags from both the ignition
d. Assembly 13. Close and secure the engine cover.
The fuel/hydraulic oil tank is a one piece-unit and cannot be
disassembled. The fuel level indicator and hydraulic filters 7.6.3 After Fuel System Service
can be removed and reused on the new replacement tank. 1. Drain and flush the fuel tank if it was contaminated.
Dispose of the old tank according to local regulations
concerning hazardous materials disposal regulations. 2. Vent air from the fuel system in accordance with the
instructions found in the appropriate Operator & Safety
e. Inspection Manual.
3. Fill the fuel tank with fresh, clean diesel fuel as required.
Note: If a leak is suspected in the fuel tank, contact your local
authorized Service Department.
1. Inspect the tank thoroughly for any cracks, slices, leaks
or other damage.
2. With tank removed from machine, plug all openings
except one elbow fitting. Install elbow fitting, and apply
approximately 1 - 1.5 psi (7 - 10 kPa) of air pressure
through elbow. Check reservoir for leaks by applying a
soap solution to the exterior and look for bubbles to
appear at cracked or damaged area.
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7.6.4 Diesel Exhaust Fluid (DEF) Tank -

(if equipped for ULS 85 hp or 110 hp 5 6
(63 kW or 82 kW))
(Prior to S/N 0160082087)
The DEF tank is located in the front of the fuel/hydraulic oil
reservoir.
5
a. DEF Tank Removal
retract boom, lower boom, place transmission in (N)
NEUTRAL, engage parking brake, and shut engine OFF.
2. Place a Do Not Operate Tag on both ignition key switch
and steering wheel.
7 MAE16540
3. Open the engine doors. Allow the system fluids to cool.
4. Properly disconnect battery. Refer Section 9.8, “Battery”, 9. Loosen clamps, label, disconnect and plug and/or cap
for procedure. DEF tank coolant hoses (5).
10. Label, disconnect and plug and/or cap DEF tank DEF
hoses (6).
11. Remove DEF tank drain plug (7) and transfer fluid into a
suitable container. Dispose fluid at an approved
recycling facility. Reinstall drain plug (7).
1
12. Remove straps securing DEF tank to frame (4) and
remove DEF tank.
2
b. DEF Tank Inspection
1. If cleaning DEF tank, Refer to Section 7.6.7, “Diesel
Exhaust Fluid (DEF) System Cleaning – (if equipped for
3
ULS 85hp or 110hp (63kW or 82kW)) (Prior to S/N
0160082087)” for procedure.
4
2. If replacing DEF tank, remove all components and retain
MAE16520
for use on replacement tank. Refer to Section 7.6.5,
“Diesel Exhaust Fluid (DEF) Header – (if equipped for
5. Open DEF tank filler access cover (1). ULS 85hp or 110hp (63kW or 82kW)) (Prior to S/N
6. Remove DEF tank access cover at the front of the 0160082087)”.
hydraulic oil/fuel reservoir (2). 3. Dispose of damaged DEF tank according to local
7. Thoroughly clean the DEF tank and surrounding area. regulations.
8. Disconnect electrical connection on top of DEF tank (3).
c. DEF Tank Installation
1. Install all previously removed components. Refer to
Section 7.6.5, “Diesel Exhaust Fluid (DEF) Header – (if
equipped for ULS 85hp or 110hp (63kW or 82kW)) (Prior
to S/N 0160082087)”, for detailed header installation
procedure.
2. Install DEF tank and secure to frame with the previously
removed straps (4).
3. Remove plugs and/or caps from the previously labeled
DEF tank DEF hoses (6) and connect to their appropriate
locations.
6036, 6042, 8042, 10042, 10054 31211015 7-9

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4. Remove plugs and/or caps from the previously labeled 7.6.5 Diesel Exhaust Fluid (DEF) Header – (if
DEF tank coolant hoses (5) and connect to their equipped for ULS 85hp or 110hp (63kW
appropriate locations. Tighten clamps. or 82kW)) (Prior to S/N 0160082087)
5. Connect electrical connection on top of DEF tank (3). The DEF header is only required to be removed when system
6. Fill DEF tank according to specifications. Refer to maintenance is required or is exposed to contamination. The
Section 2.4, “Fluid and Lubricant Capacities”. header can be cleaned and reused when cleaning and/or
replacing the DEF Tank. Refer to Section 7.6.5, b. “DEF
7. Close DEF tank filler access cover (1).
Header Cleaning.”
8. Verify all DEF system hose connections are tight and
secure from any sharp edges, moving parts and/or a. DEF Header Removal
excessive heat. 1. Refer to Section 7.6.4, “Diesel Exhaust Fluid (DEF) Tank -
9. Install DEF tank access cover at the front of the hydraulic (if equipped for ULS 85 hp or 110 hp (63 kW or 82 kW))
oil/fuel reservoir (2). (Prior to S/N 0160082087)”, for DEF tank removal.
10. Properly connect the battery(s). Refer to Section 9.8,
“Battery”, for procedure. 8
11. Close and latch engine doors.
9
10
MAQ1600
2. Loosen and remove the six screws (8) securing the

header (9) to the DEF tank (10).
3. Remove the header (9) from the DEF tank.
Note: Verify the orientation of the header for reassembly.
b. DEF Header Cleaning

1. Refer to Diesel Exhaust Fluid (DEF) System Cleaning – (if
equipped for ULS 85hp or 110hp (63kW or 82kW)) for
detailed DEF header cleaning.
7-10 31211015 6036, 6042, 8042, 10042, 10054

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c. DEF Header Filter Replacement 5. Thoroughly clean the DEF pump and surrounding area.
11
14
13
MAE16530 12
1. Remove and discard old filter.

2. Install new filter (11) on the header assembly (9). MAE16550
d. DEF Header Installation 6. Remove the DEF pump filter cap (12), DEF seal assembly
(13) and DEF pump filter (14). Discard the filter (14).
1. Orient and secure the header (9) with the previously
removed hardware. b. DEF Pump Cleaning
Note: Verify the indent on the bottom of the header is located 1. Wipe out the inside area around the DEF pump filter
on the centering nub on the bottom of the DEF tank. housing with a mild dish washing soap and distilled
2. Refer to Section 7.6.4, “Diesel Exhaust Fluid (DEF) Tank - water.
(if equipped for ULS 85 hp or 110 hp (63 kW or 82 kW)) 2. Thoroughly rinse the DEF pump filter housing with
(Prior to S/N 0160082087)”, for DEF tank installation. distilled water.
7.6.6 Diesel Exhaust Fluid (DEF) Pump Filter –

(if equipped for ULS 85hp or 110hp
(63kW or 82kW))
The pump filter of the DEF System is only required to be
replaced when system maintenance is required or exposed
to contamination.
a. DEF Pump Filter Removal

1. Park the machine on a firm level surface, level machine,
fully retract the boom, lower boom, place transmission
in (N) NEUTRAL, engage park brake and shut engine
OFF.
switch and steering wheel.
4. Properly disconnect the battery(s). Refer to Section 9.8,
6036, 6042, 8042, 10042, 10054 31211015 7-11

Engine
c. DEF Pump Filter Installation the United States and Canada, DEF certified by the American
Petroleum Institute (API) is recommended for use.
DEF should be stored in sealed containers and at 23° to 77° F
(-5° to 25°C). Avoid storing containers in direct sunlight to
assure better shelf life.
a. DEF Tank Cleaning
1. Refer to Section 7.6.4, “Diesel Exhaust Fluid (DEF) Tank -
(if equipped for ULS 85 hp or 110 hp (63 kW or 82 kW))
(Prior to S/N 0160082087)”, for DEF tank removal.
2. Refer to Section 7.6.5, “Diesel Exhaust Fluid (DEF)
Header – (if equipped for ULS 85hp or 110hp (63kW or
82kW)) (Prior to S/N 0160082087)” for header removal.
14
3. Remove the drain plug.
4. Thoroughly clean the DEF tank with a mild dish washing
13 soap and distilled water.
5. Thoroughly flush the DEF tank with distilled water.
12
6. Install and tighten drain plug.
7. Thoroughly clean the DEF header with a mild dish
washing soap and distilled water.
MAE16550 8. Thoroughly rinse the DEF header with distilled water.
9. Refer to Section 7.6.5, “Diesel Exhaust Fluid (DEF)
1. Install new DEF pump filter (14) DEF seal assembly (13)
Header – (if equipped for ULS 85hp or 110hp (63kW or
and DEF pump filter cap (12). Tighten as required.
82kW)) (Prior to S/N 0160082087)” for filter and header
2. Properly connect the battery(s). Refer to Section 9.8, installation.
10. Refer to Section 7.6.4, “Diesel Exhaust Fluid (DEF) Tank -
3. Remove the Do Not Operate Tag from both the ignition (if equipped for ULS 85 hp or 110 hp (63 kW or 82 kW))
key switch and steering wheel. (Prior to S/N 0160082087)”, for DEF tank installation.
4. Close and latch engine doors. b. DEF Pump Cleaning
7.6.7 Diesel Exhaust Fluid (DEF) System 1. Refer to Section 7.6.6, “Diesel Exhaust Fluid (DEF) Pump
Cleaning – (if equipped for ULS 85hp or Filter – (if equipped for ULS 85hp or 110hp (63kW or
110hp (63kW or 82kW)) 82kW))” for DEF pump filter cleaning procedure.
(Prior to S/N 0160082087)
Cleaning of the DEF System is only required when the
system is exposed to contamination. If DEF quality is in
question, obtain a sample from the DEF tank and place in a
clear container. DEF should be crystal clear with a light
ammonia smell. If the DEF appears cloudy, has a colored tint
or has a strong ammonia smell, it is NOT likely to be within
specifications.
Ensure the DEF solution is the correct specification.
Cummins recommends using only DEF solutions that
maintain 32.5% (+/- 1.5%) of urea content by weight. The
urea content can be easily checked with a Refractometer
(pn 70011925). The DEF solution must meet the
requirements International Standard ISO 22241-1 for diesel
engines. There is no acceptable substitute. For engines using
Selective Catalytic Reduction (SCR) Systems, operating in
7-12 31211015 6036, 6042, 8042, 10042, 10054

Engine
7.6.8 Cummins Diesel Exhaust Fluid (DEF) Tank

- (if equipped for ULS 110 hp (82 kW))
(S/N 0160082087 to Present) 6
6
Note: Contact Cummins at 1-800-CUMMINS for all service if
the DEF tank assembly is still within warranty. Warranty may be
5
voided if service is conducted by anyone other than Cummins
service personnel.
5
Note: The following procedures are only to be performed when
warranty is expired.
The DEF tank is located in the front of the fuel/hydraulic oil
reservoir.
a. DEF Tank Removal 7
MAE23130
retract boom, lower boom, place transmission in (N) 9. Loosen clamps, label, disconnect and plug and/or cap
NEUTRAL, engage parking brake, and shut engine OFF. DEF tank coolant hoses (5).
2. Place a Do Not Operate Tag on both ignition key switch 10. Label, disconnect and plug and/or cap DEF tank DEF
and steering wheel. hoses (6).
3. Open the engine doors. Allow the system fluids to cool. 11. Remove DEF tank drain plug (7) and transfer fluid into a
4. Properly disconnect battery. Refer Section 9.8, “Battery”, suitable container. Dispose fluid at an approved
for procedure. recycling facility. Reinstall drain plug (7).
12. Remove straps securing DEF tank to frame (4) and
remove DEF tank.
b. DEF Tank Inspection

1. If cleaning DEF tank, Refer to Section 7.6.11, “Cummins
Diesel Exhaust Fluid (DEF) System Cleaning – (if
equipped for ULS 110hp (82kW)) (S/N 0160082087 to
Present)” for procedure.
1 2. If replacing DEF tank, remove all components and retain
for use on replacement tank. Refer to Section 7.6.9,
2 “Cummins Diesel Exhaust Fluid (DEF) Header – (if
equipped for ULS 110hp (82kW)) (S/N 0160082087 to
Present)”.
3
3. Dispose of damaged DEF tank according to local
4 regulations.
MAE23120
5. Open DEF tank filler access cover (1). c. DEF Tank Installation
6. Remove DEF tank access cover at the front of the 1. Install all previously removed components. Refer to
hydraulic oil/fuel reservoir (2). Section 7.6.9, “Cummins Diesel Exhaust Fluid (DEF)
Header – (if equipped for ULS 110hp (82kW)) (S/N
7. Thoroughly clean the DEF tank and surrounding area.
0160082087 to Present)”, for detailed header
8. Disconnect electrical connection on top of DEF tank (3). installation procedure.
2. Install DEF tank and secure to frame with the previously
removed straps (4).
3. Remove plugs and/or caps from the previously labeled
DEF tank DEF hoses (6) and connect to their appropriate
locations.
6036, 6042, 8042, 10042, 10054 31211015 7-13

Engine
4. Remove plugs and/or caps from the previously labeled 7.6.9 Cummins Diesel Exhaust Fluid (DEF)
DEF tank coolant hoses (5) and connect to their Header – (if equipped for ULS 110hp
appropriate locations. Tighten clamps. (82kW)) (S/N 0160082087 to Present)
5. Connect electrical connection on top of DEF tank (3). Note: Contact Cummins at 1-800-CUMMINS for all service if
6. Fill DEF tank according to specifications. Refer to the DEF tank assembly is still within warranty. Warranty may be
Section 2.4, “Fluid and Lubricant Capacities”. voided if service is conducted by anyone other than Cummins
service personnel.
7. Close DEF tank filler access cover (1).
Note: The following procedures are only to be performed when
8. Verify all DEF system hose connections are tight and
secure from any sharp edges, moving parts and/or
excessive heat. The DEF header should be removed only when system
9. Install DEF tank access cover at the front of the hydraulic maintenance is required.
oil/fuel reservoir (2). a. DEF Header Removal
10. Properly connect the battery(s). Refer to Section 9.8, 1. Refer to Section 7.6.8, “Cummins Diesel Exhaust Fluid
“Battery”, for procedure. (DEF) Tank - (if equipped for ULS 110 hp (82 kW)) (S/N
11. Close and latch engine doors. 0160082087 to Present)”, for DEF tank removal.
10
0$(
2. Loosen and remove six screws (8) securing header (9) to

DEF tank (10).
3. Remove header (9) from DEF tank.
Note: Verify the orientation of the header for reassembly.
Note: In the event of DEF system contamination, the DEF
system itself can be cleaned, but the DEF header must be
discarded and replaced. Refer to Section 7.6.11, “Cummins
Diesel Exhaust Fluid (DEF) System Cleaning – (if equipped for
ULS 110hp (82kW)) (S/N 0160082087 to Present)”for DEF
system cleaning.
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Engine
b. DEF Header Filter Replacement Cleaning of the DEF System is only required when the
system is exposed to contamination. If DEF quality is in
question, obtain a sample from the DEF tank and place in a
clear container. DEF should be crystal clear with a light
ammonia smell. If the DEF appears cloudy, has a colored tint
or has a strong ammonia smell, it is NOT likely to be within
9 specifications.
11 Ensure the DEF solution is the correct specification.
Cummins recommends using only DEF solutions that
maintain 32.5% (+/- 1.5%) of urea content by weight. The
urea content can be easily checked with a Refractometer
(pn 70011925). The DEF solution must meet the
requirements International Standard ISO 22241-1 for diesel
engines. There is no acceptable substitute. For engines using
Selective Catalytic Reduction (SCR) Systems, operating in
the United States and Canada, DEF certified by the American
Petroleum Institute (API) is recommended for use.
DEF should be stored in sealed containers and at 23° to 77° F
(-5° to 25°C). Avoid storing containers in direct sunlight to
0$( assure better shelf life.
1. Remove old filter and discard. Note: The DEF header cannot be cleaned if contaminated. It
must be replaced. Ensure a replacement header has been
2. Install new filter (11) on the header assembly (9). obtained before beginning DEF system cleaning procedures.
c. DEF Header Installation a. DEF Tank Cleaning
1. Orient and secure the header (9) with the previously 1. Refer to Section 7.6.8, “Cummins Diesel Exhaust Fluid
removed hardware. (DEF) Tank - (if equipped for ULS 110 hp (82 kW)) (S/N
0160082087 to Present)”, for DEF tank removal.
Note: Verify the indent on the bottom of the header is located
on the centering nub on the bottom of the DEF tank. 2. Refer to Section 7.6.9, “Cummins Diesel Exhaust Fluid
(DEF) Header – (if equipped for ULS 110hp (82kW)) (S/N
2. Refer to Section 7.6.8, “Cummins Diesel Exhaust Fluid 0160082087 to Present)” for header removal.
(DEF) Tank - (if equipped for ULS 110 hp (82 kW)) (S/N
3. Discard the contaminated header.
0160082087 to Present)”, for DEF tank installation.
4. Remove the drain plug.
7.6.10 Diesel Exhaust Fluid (DEF) Pump Filter – 5. Thoroughly clean the DEF tank with a mild dish washing
(if equipped for ULS 85hp or 110hp) soap and distilled water.
(63kW or 82kW))
6. Thoroughly flush the DEF tank with distilled water.
1. Refer to Section 7.6.6, “Diesel Exhaust Fluid (DEF) Pump 7. Install and tighten drain plug.
Filter – (if equipped for ULS 85hp or 110hp (63kW or
82kW))” for DEF pump filter information. 8. Refer to Section 7.6.9, “Cummins Diesel Exhaust Fluid
(DEF) Header – (if equipped for ULS 110hp (82kW)) (S/N
7.6.11 Cummins Diesel Exhaust Fluid (DEF) 0160082087 to Present)” for new filter and header
System Cleaning – (if equipped for ULS installation.
110hp (82kW)) 9. Refer to Section 7.6.8, “Cummins Diesel Exhaust Fluid
(S/N 0160082087 to Present) (DEF) Tank - (if equipped for ULS 110 hp (82 kW)) (S/N
0160082087 to Present)”, for DEF tank installation.
Note: Contact Cummins at 1-800-CUMMINS for all service if
the DEF tank assembly is still within warranty. Warranty may be b. DEF Pump Cleaning
voided if service is conducted by anyone other than Cummins
1. Refer to Section 7.6.6, “Diesel Exhaust Fluid (DEF) Pump
service personnel.
Filter – (if equipped for ULS 85hp or 110hp (63kW or
Note: The following procedures are only to be performed when 82kW))” for DEF pump filter cleaning procedure.
6036, 6042, 8042, 10042, 10054 31211015 7-15
Engine
7.6.12 Diesel Exhaust Fluid (DEF) System –

Engine Coolant Strainer Cleaning
(S/N 0160082087 to Present)
The engine coolant strainer is installed on the DEF engine
coolant supply hose and should be cleaned every 2000
hours.
1. Park machine on a firm level surface, level machine, fully
retract boom, level boom, place transmission in (N)
NEUTRAL, engage park brake and shut the engine OFF.
switch and steering wheel.
3. Open the engine rear and side doors. Allow the system
fluids to cool.
2
4. Properly disconnect the battery.
1 4
3
1
4
2
5
MAE19780
6. Clamp the DEF engine coolant supply hose (2) with

hose pliers at each end of engine coolant strainer (3).
Note: Use a suitable container to catch coolant drainage
beneath the engine compartment.
7. Loosen and remove two clamps (4) from DEF coolant
supply hose (2). Remove engine coolant strainer (3).
MAG3050
Note: Prevent dirt, debris, and/or hose particles from entering
5. Remove and retain hardware and covers (1) from top of exposed hose ends.
machine frame. 8. Loosen and separate the strainer housings. Remove the
Note: Thoroughly clean DEF engine coolant supply hose, filter screen from inside strainer.
fittings, and surrounding area. 9. Brush any debris from the screen and upstream side of
the housing.
Note: If the screen is damaged, replace engine coolant strainer.
10. Install the screen in its original location. To reassemble,
connect strainer housings and torque from 35 - 45 ft lbs
(47 - 61 Nm).
11. Install strainer, oriented as shown, with the longer end
pointing towards the DEF coolant valve (5). Secure with
the two previously removed clamps. Orient clamps as
shown.
12. Tighten and torque clamps to 40 in-lb (4,5 Nm).
13. Remove hose pliers from the DEF coolant supply hose.
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Engine
14. Clean up debris, coolant, etc., in, on, near, and around
the machine.
15. Properly connect the battery.
16. Start the engine and check strainer for leaks. Check the
coolant level in the tank and add coolant as required.
18. Reinstall covers to top of machine frame with previously 10
11
removed hardware.
19. Close and secure the engine rear and side doors. 12
12
20. Remove Do Not Operate Tag from both the ignition key
switch and steering wheel. 13
21. Return machine to service.
10
7.7 ENGINE EXHAUST SYSTEM

14
Rattles and noise vibrations in the exhaust system are usually
caused by misalignment or parts. When aligning the system,
MAQ1220
leave all cap screws and nuts slightly loose until all parts are
properly aligned, then tighten all fasteners working from the 5. Loosen three clamps (10) securing exhaust pipe to
front of the system to the rear. muffler and engine. Remove exhaust pipe (11).
Before assembling components, use exhaust system sealer 6. Label and disconnect all coolant lines and electrical
at all slip joint connections. connections (12). Note the exact routing of all coolant
When installing exhaust system components, allow and electrical lines.
sufficient clearance between the components and other 7. Loosen two bolts (13) securing muffler mounting plate
pipes, hoses and wiring that could be adversely affected by to machine frame on right side of machine. Do Not
excessive heat. Remove bolts.
8. Remove two bolts (14) securing muffler mounting plate
7.7.1 Exhaust System - (if equipped for ULS 85 or on left side of machine.
110 hp (63kW or 82kW)
9. Be sure to properly support muffler mounting plate and
a. Exhaust Removal muffler for removal.
1. Park the machine on a firm, level surface, level the 10. Drop muffler mounting plate down on left side.
machine, fully retract the boom, lower the boom, place 11. Lift right side and slip bolts up and through slots on the
the transmission in (N) NEUTRAL, engage the parking right side of frame.
brake, and shut the engine OFF.
12. Place mounting plate on level surface and replace
2. Place a Do Not Operate Tag on both the ignition key muffler, clamps and tailpipe. Note position of muffler for
switch and steering wheel, stating that the machine re-installation purposes.
3. Open the engine cover. Allow the system fluids to cool. b. Exhaust System Installation
4. Properly disconnect the battery. Refer Section 9.8, Note: Install muffler in proper direction.
“Battery”, for procedure
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.
6036, 6042, 8042, 10042, 10054 31211015 7-17

Engine
3. Lift left side of muffler mounting plate up and 14. Start engine and check for exhaust leaks at all exhaust
re-install mounting plate bolts (14). connections. Adjust or repair as needed.
4. Tighten all mounting plate bolts. 15. Close and secure the engine cover.
5. Measure distance (A) 11.77 - 12.95 in (299 - 329mm)
between the center of the locating pins on the flex pipe 7.7.2 Exhaust System - ULS 74 hp (55kW)
section of the exhaust pipe (11). Adjust if required. a. Exhaust Removal
the travel select lever in the (N) NEUTRAL position,
engage the parking brake, and shut the engine OFF.
11
A 3. Open the rear door. Allow the system fluids to cool.
12
2
1
B
9 4
8
7
MAQ1230
6. Adjust the muffler intake tube to approximately (B)

5
74.0°.
6 8
7. Install exhaust pipe (11) to muffler and engine.
8. Verify NoX sensor (12) is mounted in the vertical MAQ2120
position (‡ 10°). 5. Loosen three clamps (1) securing exhaust pipe to

9. Adjust the muffler intake tube to approximately (B) muffler and engine.
74.0°. 6. Loosen two bolts (2) securing exhaust pipe to frame.
10. Tighten all clamps (10). 7. Remove exhaust pipe (3).
11. Install all previously removed coolant lines and 8. Loosen two bolts (4) securing muffler mounting
reconnect electrical connections. Verify proper routing plate (5) to machine frame on right side of machine.
of all coolant and electrical lines. Do Not Remove bolts.
12. Properly connect the battery. Refer Section 9.8, 9. Remove two bolts (6) securing muffler mounting plate
“Battery”, for procedure. on left side of machine.
13. Remove the Do Not Operate Tags from both the ignition 10. Be sure to properly support muffler mounting plate and
key switch and the steering wheel. muffler for removal.
11. Drop muffler mounting plate down on left side.
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Engine
12. Lift right side and slip bolts up and through slots on the 6. Install exhaust pipe (3) to muffler and engine.
right side of frame. 7. Install exhaust pipe mounting bolts (2) to frame.
13. Place mounting plate (5) on level surface and replace 8. Measure distance (A) 11.77-12.95 in (299-329mm)
muffler (7), clamps (8) and tailpipe (9). Note position of between locating pins on the flex pipe section of the
muffler for re-installation purposes. exhaust pipe (3).
b. Exhaust System Installation The following steps may be required to achieve distance (C)
(Expanded web).
Note: Install muffler in proper direction.
• Loosen the turbocharger clamp to allow rotation of the
Note: Keep all clamps loosened until entire exhaust system is in top exhaust pipe (3). Do Not remove clamp.
place.
• Pull up and out on exhaust pipe (3) to allow for a
straight line and expansion of the flex pipe.
• Tighten the turbocharger clamp while holding the
exhaust pipe (3) in place.
• If the flex pipe is in a “S” shape, loosen the band clamp
(8) securing the muffler.
• Rotate the muffler inlet tube forward until the flex pipe
becomes straight.
A
• It may be necessary to pull the muffler closer to the
frame until the flex pipe becomes straight.
9. Tighten the muffler band clamp and all remaining
clamps.
2 10. Properly connect the battery. Refer Section 9.8,
3 11. Remove the Do Not Operate Tags from both the ignition
12. Start engine and check for exhaust leaks at all exhaust
connections. Adjust or repair as needed.
7 8 13. Close and secure the rear door.
4
5
6
MAQ2130
1. Install muffler (7) and tailpipe on muffler mounting

plate (5) using proper clamps (8) in proper position.
DO NOT tighten.
3. Lift left side of muffler mounting plate up and
re-install mounting plate bolts (6).
4. Tighten all mounting plate bolts.
5. Tighten band clamp (8) enough to hold the muffler in
place.
6036, 6042, 8042, 10042, 10054 31211015 7-19

Engine
7.7.3 Exhaust System - LS 85 hp (63 kW) b. Exhaust System Installation

a. Exhaust Removal Note: Install muffler in proper direction.
1. Park the machine on a firm, level surface, level the Note: Keep all clamps loosened until entire exhaust system is in
machine, fully retract the boom, lower the boom, place place.
the transmission in (N) NEUTRAL, engage the parking 1. Install muffler and tailpipe on muffler mounting
brake, and shut the engine OFF. plate (12) using proper clamps in proper position.
3. Lift left side of muffler mounting plate up and
3. Open the engine cover. Allow the system fluids to cool. re-install mounting plate bolts (14).
4. Properly disconnect the battery. Refer Section 9.8, 4. Tighten all mounting plate bolts.
11
10
13
11
10
14 10
MAQ1830
5. Loosen three clamps (10) securing exhaust pipe to

muffler and engine. Remove exhaust pipe (11).
MAQ184
6. Loosen two bolts (13) securing muffler mounting plate
to machine frame on right side of machine. Do Not 5. Measure distance (A) 8.77-9.56 in (223-243mm) of the
Remove bolts. flex pipe section of the exhaust pipe (11). Adjust if
required.
7. Remove two bolts (14) securing muffler mounting plate
on left side of machine. 6. Install exhaust pipe (11) to muffler and engine.
8. Be sure to properly support muffler mounting plate and 7. Tighten all clamps (10).
muffler for removal. 8. Properly connect the battery. Refer Section 9.8,
9. Drop muffler mounting plate down on left side. “Battery”, for procedure.
10. Lift right side and slip bolts up and through slots on the 9. Remove the Do Not Operate Tags from both the ignition
right side of frame. key switch and the steering wheel.
11. Place mounting plate on level surface and replace 10. Start engine and check for exhaust leaks at all exhaust
muffler, clamps and tailpipe. Note position of muffler for connections. Adjust or repair as needed.
re-installation purposes. 11. Close and secure the engine cover.
7-20 31211015 6036, 6042, 8042, 10042, 10054

Engine
7.8 AIR CLEANER ASSEMBLY 7.8.2 Air Cleaner Assembly Installation

Note: Refer to Section 2.7, “Thread Locking Compound” for all
CAUTION 1. Secure air cleaner assembly to air cleaner bracket with
NEVER run the engine with only the inner safety element previously used hardware (24).
installed. 2. Install the air cleaner assembly.
Note: Refer to the appropriate Operation & Safety Manual for 3. Install air cleaner hose (23) to the air cleaner assembly
your machine for the correct element change procedure. and secure with clamps.
4. Install air intake tube (22) and secure with clamp.
7.8.1 Air Cleaner Assembly Removal
5. Tighten all clamps.
retract boom, lower boom, place the transmission in (N)
NEUTRAL, engage the parking brake, and shut the
engine OFF. 7. Remove the Do Not Operate Tags from both the ignition
and steering wheel, stating that the machine should not 8. Close and secure the rear and right side doors.
be operated.
3. Open the rear and right side doors. Allow system fluids
to cool.
24
22
23
MAQ1240
5. Loosen clamp securing air intake tube (22) and remove

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

Engine
7.9 ENGINE REPLACEMENT 14. Remove the exhaust pipe and muffler system. Refer to
Section 7.7.1, “Exhaust System - (if equipped for ULS 85
or 110 hp (63kW or 82kW)”.
7.9.1 Engine Removal
Note: Engine Lift Bracket Kit PN 1001177168 is required for
proper engine removal.
Note: The radiator and oil cooler must be removed from the
machine before engine removal. Refer to Section 7.4, “Engine
Cooling System” Several additional components must be
removed before engine removal. They will be addressed in the
following procedures.
brake, and shut the engine OFF.
3
4. Properly disconnect the battery. Refer Section 9.8, 2
MAQ1250
“Battery”, for procedure. 3 1
5. Remove the engine cover. 15. At the front right engine mount (1), remove the
6. Drain and remove radiator assembly. Refer to hardware securing the mount to the frame.
Section 7.4.3, “Radiator/Oil Cooler and Replacement”. 16. Remove hardware securing rear engine mounts (2).
7. Label, disconnect and cap the heater hoses attached to 17. Remove the exhaust pipe bracket.
the engine (if equipped).
18. Install left and right engine lift brackets (3).
Note: The engine harness is routed and attached to the engine
19. Position a fork truck behind the machine, and drive
using hold-down clamps and plastic wire ties at various places
forward, placing the forks underneath the rear engine
on the engine. Before removing engine, ensure that the harness
mount and front engine lift brackets. Slightly lift the
has been completely separated (disconnected) from the engine.
engine, and slowly back engine out of the machine.
Move the harness clear of the engine, and with the help of an
Have an assistant ensure that the engine clears all frame
observer, ensure that the engine clears the harness during
components during removal.
removal.
20. Place engine on a flat, level surface.
8. Label and disconnect all electrical wire connections on
the engine. 21. If replacing engine, attach a lifting chain to the front and
rear engine lift brackets, and lift engine clear of the
9. Label, disconnect and cap the fuel inlet line at the fuel ground.
lift pump.
22. Remove the two engine lift brackets (3).
10. Label, disconnect and cap the fuel return line from the
injector pump. 23. Remove the three engine mounting brackets.
11. Remove the engine-to-transmission drive shaft. Refer to 24. Remove air intake assembly.
Section 5.5.2, “Drive Shaft Removal”.
12. Loosen the clamps on the sleeve reducer at the engine
and on the air suction pipe.
13. Remove air intake hoses and pre-cleaner. It is not
necessary to remove air cleaner assembly before engine
is removed from frame.
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Engine
7.9.2 Engine Installation 19. Check that all hydraulic system, electrical system,
cooling system, fuel system and exhaust system
Note: The engine harness is routed and attached at various
connections are correct and connected tightly.
places on the engine using hold-down clamps and plastic wire
ties. Before installing engine and with the help of an assistant, Note: Have an assistant stand by with a Class B fire
ensure that the engine clears the harness during installation. extinguisher.
1. If replacing the engine, attach a lifting strap or chain to 20. Start the engine and run to normal operating
the front and rear engine lift brackets, and lift the temperature then shut off the engine. While the engine
engine clear of the ground. is cooling, check for leaks.
2. Install the engine mounting brackets. Torque to 21. Allow the engine to cool. Check the radiator coolant
93 - 100 lb-ft (126 - 135 Nm). level, and add coolant if needed. Replace the radiator
3. Install left and right engine lift brackets (3). cap.
4. Place the engine on a flat, level surface. 22. Check for leaks from the engine, main hydraulic pump
and lines, transmission, hydraulic reservoir and fuel
5. Position a fork truck behind the engine, and drive tank. Check the levels of all fluids and lubricants. Fill as
forward, placing the forks underneath the rear engine required.
mount and front right and left engine lift brackets. Lift
the engine and slowly drive it into the back of the Note: During the full throttle check:
machine. Have an assistant ensure that the engine • DO NOT operate any hydraulic function.
clears all frame, hose and harness components during
installation. Position the engine brackets over rear and • DO NOT steer or apply any pressure to the steering
front frame mounts. wheel.
6. Secure the rear engine mounts (2) to the frame using • Place the transmission in (N) NEUTRAL.
the previously used hardware. Torque to 23. Obtain and connect an appropriate engine analyzer or
80 - 90 lb-ft (108 - 122 Nm). tachometer. Check the engine rpm at full throttle.
7. Secure front (1) engine mount to frame using previously 24. Purge the hydraulic system of air by operating all boom
used hardware. Torque to 80 - 90 lb-ft (108 - 122 Nm). functions through their entire range of motion several
8. Remove the two engine lift brackets (3). times. Check the hydraulic oil level.
9. Install exhaust pipe mount bracket. 25. Check for proper operation of all components.
10. Install the radiator overflow tube, overflow tank and 26. Turn the engine OFF.
hose support. 27. Install the side and rear engine covers.
11. Install the engine-to-transmission drive shaft. Refer to
Section 5.5.3, “Drive Shaft Installation”.
12. Uncap and connect the previously labeled fuel return
line to the injector pump.
13. Uncap and connect the previously labeled fuel inlet line
to the fuel lift pump.
14. Connect the previously labeled electrical wire
connections on the engine.
15. Uncap and connect the previously labeled heater hoses
to the engine (if equipped).
16. Install the complete radiator assembly. Refer to
Section 7.4.3, “Radiator/Oil Cooler and Replacement”.
6036, 6042, 8042, 10042, 10054 31211015 7-23

Engine
7.10 ISOLATION COUPLER 10. At this time, use a suitable cleaner/solvent and
thoroughly clean the mounting lip of the flywheel. Wipe
any debris from the inside of the bell housing. Use the
7.10.1 Isolation Coupler Removal cleaner to clean the threaded holes around the flange of
1. Park the machine on a firm, level surface, level the the bell housing.
the transmission in (N) NEUTRAL, engage the park brake, 7.10.2 Isolation Coupler Installation
1. Use cleaner to clean the backside of the coupler, where
2. Place a Do Not Operate Tag on both the ignition key it comes in contact with the flywheel.
should not be operated. Note: Refer to Section 2.7, “Thread Locking Compound” for all
Note: The new coupler is heavy and requires two people, one
on each side, to install.
2. Place the new coupler into the indentation of the
Note: Rotating the fan belt by hand gives greater access to
flywheel and use new hardware to secure the coupler to
removing the drive shaft mounting cap screws.
the flywheel. DO NOT fully tighten until all cap screws
5. Remove the cap screws and straps that secure the drive are in place.
shaft to the transmission yoke. 3. After all cap screws are in place, check to be sure the
6. Remove the cap screws and lock washers securing the coupler is resting squarely in the indentation of the
drive shaft to the coupling flange. flywheel. Torque all the cap screws to 37 lb-ft (48 Nm).
Note: It may be necessary to loosen/remove the motor mounts Note: Before assembling the drive shaft to the coupling; be
on either side of the engine to gain access to the bottom cap sure the access cover plate is placed on the engine-side of the
screws on the outer half of the coupler. Place a jack under the frame member that mounts the rear axle to the frame.
bell housing (use a wood block to support the engine) and
4. Install the access cover plate over the drive shaft and
carefully lift the engine until the bottom edge of the bell
assemble the drive shaft flange to the coupler using
housing is at the top edge of the frame member that mounts
new hardware. Torque to 48 lb-ft (65 Nm).
the rear axle to the frame. Watch the fan-to-radiator clearance
as your are lifting the engine. If necessary, turn the fan slightly 5. If engine mounts were previously removed or loosened,
by hand to gain additional clearance. 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
4
the slip joint using multi-purpose grease.
3 MH6361 “Battery”, for procedure.
7. Remove the cap screws and lock washers securing the 9. Close and secure the engine cover.
access cover plate (3). 10. Remove the Do Not Operate Tags from both the ignition
8. Remove the cap screws securing the coupler (4) to the key switch and the steering wheel.
flywheel.
Note: The coupler is heavy and requires two people, one on
each side, to remove.
9. Remove the coupler assembly.
7-24 31211015 6036, 6042, 8042, 10042, 10054

Section 8
Hydraulic Section
Contents

8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.5 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.5.1 Pressure Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.5.2 Pressure Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.5.3 Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
8.6 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
8.6.1 Hydraulic Oil Reservoir Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
8.6.2 Hydraulic Oil Reservoir Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
8.6.3 Hydraulic Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
8.6.4 Hydraulic Oil Reservoir Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
8.7 Hydraulic System Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
8.7.1 Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
8.8 Valves and Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40
8.8.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40
8.8.2 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43
8.8.3 Service Brake Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43
8.8.4 Brake Bleeding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44
8.8.5 Brake System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45
8.8.6 Steering Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45
8.8.7 Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45
8.8.8 Secondary Function Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47
8.8.9 Outrigger Valve (10042 & 10054 only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48
8.8.10 Extend Lockout Valve (10054 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49
8.9 Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
8.9.1 General Cylinder Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
8.9.2 Cylinder Pressure Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53
8.9.3 Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53
8.9.4 Cylinder Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54
6036, 6042, 8042, 10042, 10054 31211015 8-1

Hydraulic Section
8.1 HYDRAULIC COMPONENT

TERMINOLOGY
To understand the safety, operation and service information
presented in this section, it is necessary that the operator/
mechanic be familiar with the name and location of the
hydraulic components of the machine. The following
6036 & 6042 (85 HP)

LIFT/LOWER
CYLINDER(S)
COMPENSATION
CYLINDER(S)
ATTACHMENT
TILT CYLINDER
EXTEND/RETRACT
CYLINDER
HYDRAULIC FLUID
RESERVOIR
MAIN GEAR
PUMP
STEER SELECT
VALVE
MAIN CONTROL
VALVE
STABILIZER
CYLINDER
FRAME LEVEL (6042 ONLY)
CYLINDER
STEERING
SECONDARY JOYSTICK CYLINDER
FUNCTION (REAR)
VALVE
STEERING
ORBITROL
SERVICE VALVE
BRAKE VALVE
STEERING MAQ1261
CYLINDER
(FRONT)
8-2 31211015 6036, 6042, 8042, 10042, 10054

Hydraulic Section
EXTEND/RETRACT
CYLINDER
8042, 10042 & 10054
LIFT/LOWER COMPENSATION
CYLINDER(S) CYLINDER(S)
ATTACHMENT
TILT CYLINDER
MAIN PISTON
PUMP
EXTEND LOCKOUT
HYDRAULIC FLUID VALVE (10054) ONLY)
RESERVOIR
STEER SELECT
VALVE
MAIN CONTROL
VALVE
STABILIZER
FRAME LEVEL CYLINDER
CYLINDER
JOYSTICK STEERING
CYLINDER
STEERING (REAR)
ORBITROL
VALVE
SERVICE
SECONDARY BRAKE VALVE
FUNCTION
VALVE
OUTRIGGER VALVE
(10042 & 10054 ONLY)
STEERING
OUTRIGGER CYLINDER
CYLINDERS (FRONT)
(10042 & 10054 ONLY)
MAQ1271
6036, 6042, 8042, 10042, 10054 31211015 8-3

Hydraulic Section
8.2 SAFETY INFORMATION Some hydraulic functions are actuated by interfacing with
electrical system components (switches, solenoids and
sensors). When the hydraulic system is not functioning
WARNING properly, check the electrical aspect of the malfunctioning
circuit also. Refer to Section 9.5, “Electrical System
DO NOT service the machine without following all safety Schematics”.
this manual. 8.3 SPECIFICATIONS
Petroleum-based hydraulic fluids are used in this machine. Refer to Section 2.2, “Specifications”, for hydraulic system
Temperature of hydraulic fluid increases
specifications.
during operation of various hydraulic functions. A heated
petroleum-based hydraulic fluid presents a fire hazard,
especially when an ignition source is present. Hydraulic fluid
has a flash point that ranges from 300 - 600° F (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.
Whenever you disconnect a hydraulic line, coupler, fitting or
other component, slowly and cautiously loosen the part
involved. A hissing sound or slow seepage of hydraulic fluid
may occur in most cases. After the hissing sound has ceased,
continue removing the part. Any escaping oil should be
directed into an appropriate container. Cap or otherwise
block off the part to prevent further fluid seepage.
Hydraulic system maintenance will, at times, require that the
engine be operated. Always follow safety precautions.
A major cause of hydraulic component failure is
contamination. Keeping the hydraulic fluid as clean as
possible will help avoid downtime and repairs. Dirty or
contaminated hydraulic oil can damage internal
components and void the manufacturer’s warranty. When
servicing the system, cap or plug hydraulic fittings, hoses and
tube assemblies. Plug all cylinder ports, valves and the
hydraulic reservoir, and pump openings until installation
occurs. Protect threads from contamination and damage.
Manufacture’s recommended hydraulic oil cleanliness levels
are based on the three digit ISO code for 4 micron/6 micron/
14 micron particle sizes found in one ml of fluid (reference
ISO 4406: 199(E). The acceptable level is 19/17/14 or below;
anything higher requires system cleaning and filter
replacement.
Note: The human eye can only distinguish particles down to 40
microns.
Reference Section 2.5, “Service and Maintenance Schedules”,
for the appropriate maintenance intervals based on hours of
operation, but if your equipment is exposed to extremely
dirty or hostile conditions service may be required more
frequently. Always use OEM filters to assure the necessary
filtration requirements are met.
8-4 31211015 6036, 6042, 8042, 10042, 10054

Hydraulic Section
8.4 HYDRAULIC CIRCUITS 8.5 HYDRAULIC PRESSURE DIAGNOSIS

This section covers the hydraulic circuits and includes listings
for all hydraulic function pressures, where and how to check 8.5.1 Pressure Checks and Adjustments
those pressures and a hydraulic schematic. When diagnosing trouble in the hydraulic system, use the
Electrical and hydraulic functions are often related. Verify hydraulic testing information in Section 8.5.2, “Pressure
that electrical components of the circuit are functioning Specifications”.
properly whenever troubleshooting the hydraulic circuit. In general, follow the steps below whenever conducting
Always check the following before beginning to pressure checks and performing adjustments:
troubleshoot a circuit that is not functioning correctly. 1. Park the machine on a firm, level surface, engage the
1. Check hydraulic oil level in reservoir. Level should be in park brake, place the transmission in (N) NEUTRAL, level
middle of sight glass with all cylinders retracted. the boom and turn the engine OFF.
2. Check hoses, tubes, fittings and other hydraulic 2. Install a digital or a 5000 psi (345 bar) at the appropriate
components for leaks, bends, kinks, interference, etc. test port.
3. Check for air in the hydraulic system. Erratic machine 3. All hydraulic pressures are factory set and/or adjusted at
performance and/or spongy cylinder operation are an ambient temperature between 60-80°F (15,5-26,6°C).
signs of air in the hydraulic system. If air in the hydraulic 4. Start the engine. If necessary, operate machine
system is suspected, you will hear air leakage when functions several times to allow hydraulic oil to reach
hydraulic fittings are loosened and see air bubbles in operating temperature.
the hydraulic fluid.
5. Refer to Section 8.5.2, “Pressure Specifications”, for
4. Loose fittings, faulty o-rings or seals, trapped oil, leaks, testing procedures.
system opened for service, etc., can cause air in the
system. Determine what is causing air to enter the 6. Fully depress accelerator pedal if required. Place and
system and correct it. Bleed air from the system. hold joystick in position needed to operate the
particular machine function being checked. Continue
holding the joystick in position until pressure is stable
and readings are taken.
7. Check pressure gauge reading. It should read as
specified in Pressure Readings column of the charts
found in Section 8.5.2, “Pressure Specifications”. If the
reading is not as specified, turn the engine OFF and
check other components in the system. Verify that all
related hydraulic components and electrical switches,
sensors, solenoids, etc. are operating correctly.
6036, 6042, 8042, 10042, 10054 31211015 8-5

Hydraulic Section
8.5.2 Pressure Specifications
a. 6036 - 85 hp (63 kW)
C B
(PRH1) (PRH2)
SECONDARY
FUNCTION
MANIFOLD
PBG
(PARK BRAKE
MAIN CONTROL VALVE
GAUGE)
MAQ1510
MAQ1500 BVG
M A (BRAKE VALVE
(MAIN PUMP (LOAD SENSE RELIEF GAUGE)
PRESSURE) VALVE)
SERVICE BRAKE VALVE
Prior to SN 0160074878, excluding SN 0160074878 to Present, including

0160074813 0160074818 and 0160074882 0160074813 0160074818 and 0160074882
D D
(AXLE BRAKE (AXLE BRAKE
PRESSURE) PRESSURE)
MAE14330
MAQ1520
Note: Install pressure gauge at test port M on main control valve BEFORE Starting engine.
All pressures must be checked in numerical order.
Note: Only operate the functions that are specified in the particular pressure check. Operating other functions than those specified
may cause false readings.
Note: Boom level unless otherwise noted.
8-6 31211015 6036, 6042, 8042, 10042, 10054

Hydraulic Section
Test Adjustment Range/

Hydraulic Circuit Procedure Notes
Port Location Pressure
Standby Connect gauge to M port, run 325 - 375 psi
1 M NA Park Brake - ON
(low idle) engine at low idle, no function. (22,4 - 25,8 bar)
Standby Connect gauge to M port, run 525 - 575 psi
(high idle) engine at high idle, no function. (36,2 -39,6 bar)
Connect gauge to M port, run
engine at high idle, fully retract
extend/retract cylinder.
Main Pump/Load NOTE: When bottoming Lift, Tilt, 3050-3100 psi
3 Sense M Frame Level or Auxiliary at high LS (A) (210,3-213,7 Park Brake - ON
(high idle) idle, the pressure seen at the M bar)
port should be within
100 psi (6,4 bar) of the noted
extend/retract cylinder pressure.
Connect gauge to M port, run 2600-2700 psi Park Brake - ON
Steering
4 M engine at low idle, in front steer NA (179,3-186,2 Front Steering
(low idle)
mode, turn steering lock to lock. bar) Mode Selected
Secondary
Connect gauge to BVG port, run
Function Manifold 550-560psi
5 BVG engine at high idle, fully retract PRH2(B) Park Brake ON
(Service Brake) (37,9-38,6 bar)
(high idle)
Secondary
engine at high idle, stall
Function Manifold 580-590psi
6 BVG steering. Pressure should not NA Park Brake - ON
(Service Brake) (37,9-40,6 bar)
increase more than 30 psi (2,0
(high idle)
bar) from pressure 5.
Connect gauge to PBG port, run
Secondary
Function Manifold
extend/retract cylinder. 0-10 psi
7 (Park Brake PBG NA Park Brake - ON
NOTE: Range/Pressure should (0-6,8 bar)
Pressure)
repeat in all machine conditions
(high idle)
with park brake ON.
Secondary
Function Manifold
engine at high idle, fully retract 380-390 psi
8 (Park Brake PBG PRH1(C) Park Brake - OFF
extend/retract cylinder, switch (26,2-26,8 bar)
Pressure)
park brake off.
(high idle)
Steering 410-420 psi
9 PBG steering. Pressure should not PRH1(C) Park Brake - OFF
(high idle) (28,2-28,9 bar)
Block tire, connect gauge to D
Service Brake port. Start engine and run at low
10 D NA 0 psi (0 bar) Park Brake - OFF
(low idle) idle. Do Not apply brake pedal
pressure.
6036, 6042, 8042, 10042, 10054 31211015 8-7

Hydraulic Section
Test Adjustment Range/

Hydraulic Circuit Procedure Notes
Port Location Pressure
Connect gauge to D port, run
Service Brake 650 psi (44,8
11 D engine at low idle, apply NA Park Brake - OFF
(low idle) bar) Minimum
maximum brake pedal effort.
Connect gauge to D port. Verify
machine is parked on flat
ground, Run engine at low idle,
Service Brake 80 psi (5,5 bar)
12 D transmission in (N) Neutral, turn NA Park Brake - OFF
(low idle) Minimum
engine OFF, wait 3 seconds,
apply maximum brake pedal
effort.
8-8 31211015 6036, 6042, 8042, 10042, 10054

Hydraulic Section
b. 6042 - 85 hp (63 kW)

MAIN CONTROL VALVE
C B
(PRH1) (PRH2)
SECONDARY
FUNCTION
PBG MANIFOLD
(PARK BRAKE
GAUGE)
A
(LOAD SENSE RELIEF
VALVE)
BVG MAQ1510
MAQ1500
M (BRAKE VALVE
(MAIN PUMP GAUGE)
STABIL-TRAK VALVE
PRESSURE)
E
G1 PRV
STABIL-TRAK
ADJUSTMENT
PRESSURE SCREW
MAQ1530
Prior to SN 0160074878, excluding SERVICE BRAKE VALVE

SN 0160074878 to Present, including
0160074813 0160074818 and 0160074882 0160074813 0160074818 and 0160074882
D
D (AXLE BRAKE
(AXLE BRAKE PRESSURE)
PRESSURE)
MAE14330
MAQ1520
6036, 6042, 8042, 10042, 10054 31211015 8-9

Hydraulic Section
Hydraulic Test Adjustment

Procedure Range/Pressure Notes
Circuit Port Location
Standby Connect gauge to M port, run 325-375 psi
(low idle) engine at low idle, no function. (22,4-25,8 bar)
Standby Connect gauge to M port, run 525-575 psi
(high idle) engine at high idle, no function. (36,2-39,6 bar)
Main extend/retract cylinder.
Pump/ NOTE: When bottoming Lift, Tilt,
3050-3100 psi
3 Load M Frame Level or Auxiliary at high idle, LS (A) Park Brake - ON
(210,3-213,7 bar)
Sense the pressure seen at the M port
(high idle) should be within 100 psi (6,4 bar) of
the noted extend/retract cylinder
pressure.
Connect gauge to M port, run Park Brake - ON
4 M engine at low idle, in front steer NA Front Steering
(low idle) (179,3-186,2 bar)
mode, turn steering lock to lock. Mode Selected
Secondary
Function
Manifold 550-560psi
(Service (37,9-38,6 bar)
Brake)
(high idle)
Secondary
Function Connect gauge to BVG port, run
Manifold engine at high idle, stall steering. 580-590psi
6 BVG NA Park Brake - ON
(Service Pressure should not increase more (39,9-40,6 bar)
Brake) than 30 psi (2,0 bar) from pressure 5.
(high idle)
Secondary Connect gauge to PBG port, run
Function engine at high idle, fully retract
Manifold extend/retract cylinder. 0-10 psi
7 PBG NA Park Brake - ON
(Park Brake NOTE: Range/Pressure should (0-6,8 bar)
Pressure) repeat in all machine conditions
(high idle) with park brake ON.
Secondary
Function Connect gauge to PBG port, run
Manifold engine at high idle, fully retract 380-390 psi
8 PBG PRH1(C) Park Brake - OFF
(Park Brake extend/retract cylinder, switch park (26,2-26,8 bar)
Pressure) brake off.
(high idle)
8-10 31211015 6036, 6042, 8042, 10042, 10054

Hydraulic Section

Steering engine at high idle, stall steering. 410-420 psi
(high idle) Pressure should not increase more (28,2-28,9 bar)
than 30 psi (2,0 bar) from pressure 8.
Service Block tire, connect gauge to D port.
10 Brake D Start engine and run at low idle. Do NA 0 psi (0 bar) Park Brake - OFF
(low idle) Not apply brake pedal pressure.
Service Connect gauge to D port, run engine
650 psi (44,8 bar)
11 Brake D at low idle, apply maximum brake NA Park Brake - OFF
Minimum
(low idle) pedal effort.
Connect gauge to D port. Verify
machine is parked on flat ground,
Service
Run engine at low idle, transmission 80 psi (5,5 bar)
12 Brake D NA Park Brake - OFF
in (N) Neutral, turn engine OFF, wait Minimum
(low idle)
3 seconds, apply maximum brake
pedal effort.
Verify Ignition is in the OFF position.
Remove plug G1 and replace with
Stabil-Trak Test Port Fitting (SAE-4 O-Ring Boss
75-150 psi
13 Valve G1 7/16-20 UNF 2B) and connect PRV (E) Park Brake - ON
(5,1-10,3 bar)
(low idle) pressure gauge. Start machine with
boom lowered, frame leveled left at
low idle.
Low idle with boom lowered, frame
level left - 200 psi(13,7 bar)
Stabil-Trak Maximum Pressure
200 psi (13,7 bar)
14 Valve G1 No Adjustment NA Park Brake - ON
Maximum
(low idle) Pressure over
200 psi(13,7 bar) indicates a
Stabil-Trak Valve or cylinder failure
Low idle with boom lowered, frame
Stabil-Trak level right - 50 psi (3,4 bar)
50 psi (3,4 bar)
15 Valve G1 No Adjustment. Pressure under NA Park Brake - ON
Minimum
(low idle) 50 psi (3,4 bar) indicates a
Stabil-Trak Valve or cylinder failure
6036, 6042, 8042, 10042, 10054 31211015 8-11

Hydraulic Section

Block tire, connect gauge to D port.
Start engine and run at low idle,
raise boom above 40° (verify boom
angle sensor is OFF), place the
transmission in 4th gear Forward
Stabil-Trak and release the park brake.
Brake 200-300 psi
16 D A. With the service brake released - NA Park Brake - OFF
Switch (13,7-20,6 bar)
the Stabil-Trak light must be OFF.
(low idle)
B. Slowly apply the service brake -
the Stabil-Trak light must be ON with
a service brake pressure of 200 - 300
psi (13,7 - 20,6 bar) Adjust service
brake switch if required.
8-12 31211015 6036, 6042, 8042, 10042, 10054

Hydraulic Section
c. 6036 - 74 hp (55 kW)

MAIN CONTROL VALVE
M C B
(MAIN PUMP (PRH1) (PRH2)
PRESSURE)
SECONDARY
FUNCTION
MANIFOLD
PBG
(PARK BRAKE
GAUGE)
MAQ1510
BVG
(BRAKE VALVE
MAQ1500 GAUGE)
HYDRAULIC PUMP
C
(LOAD SENSE RELIEF G
VALVE) PUMP LOAD
SENSE PORT
A
STANDBY
PRESSURE
SCREW
B
PUMP MAX
PRESSURE MAQ1540
SCREW 1
Prior to SN 0160074878, excluding SERVICE BRAKE VALVE SN 0160074878 to Present, including

0160074813 0160074818 and 0160074882 0160074813 0160074818 and 0160074882
E
(AXLE BRAKE E
PRESSURE) (AXLE BRAKE
PRESSURE)
MAE14330
MAQ1520
6036, 6042, 8042, 10042, 10054 31211015 8-13

Hydraulic Section
Note: Disconnect the electrical connection (1) on the hydraulic pump BEFORE proceeding with pressure checks.
Connect the electrical connection AFTER the pressure checking procedure has been completed.

Park Brake - ON
Load Connect gauge to G port. All
70-110 psi *Record Load
1 Sense G hydraulic functions and NA
4,8-7,5 bar Sense Value for
(low idle) transmission in Neutral.
use in Step 2
engine at low idle, no function.
*Standby pressure should read
390-410 psi (26,8-28,2 bar)
Standby higher than the Load Sense *460-520 psi
2 M A Park Brake - ON
(low idle) pressure measured in Step 1. (31,7-35,8 bar)
Example - If 80 psi (5,5 bar) is
recorded in Step 1, the Standby
pressure should read 470-490
psi (32,4-33,7 bar).
Temporarily increase the Load
Main Sense Relief pressure by turning
Pump High the adjustment screw (C) two
3250-3300 psi
3 Pressure M turns clockwise. Connect gauge B Park Brake - ON
(224,0-227,5 bar)
Cutoff to M port, run engine at high
(high idle) idle, retract and stall extend/
retract cylinder.
Load NOTE: When bottoming Lift, Tilt,
3050-3100 psi
4 Sense M Frame Level or Auxiliary at high LS (C) Park Brake - ON
(210,2-213,7 bar)
(high idle) idle, the pressure seen at the M
port should be within 100 psi
(6,4 bar) of the noted extend/
retract cylinder pressure.
(low idle) (186,2-200 bar)
Secondary
Function
Manifold 550-560psi
Brake)
(high idle)
8-14 31211015 6036, 6042, 8042, 10042, 10054

Hydraulic Section

Secondary
Function
Manifold 580-590psi
Brake)
(high idle)
Secondary
(Park Brake extend/retract cylinder, switch (26,2-26,8 bar)
Pressure) park brake off.
(high idle)
engine at low idle, stall steering.
10 PBG Pressure should not increase PRH1(C) Park Brake - OFF
(low idle) (28,2-28,9 bar)
more than 30 psi (2,0 bar) from
pressure 9.
Block tire, connect gauge to E
Service
port. Start engine and run at low
11 Brake E NA 0 psi (0 bar) Park Brake - OFF
idle. Do Not apply brake pedal
(low idle)
pressure.
Service Connect gauge to E port, run
650 psi (44,8 bar)
12 Brake E engine at low idle, apply NA Park Brake - OFF
Minimum
(low idle) maximum brake pedal effort.
Connect gauge to E port. Verify
Service ground, Run engine at low idle,
80 psi (5,5 bar)
13 Brake E transmission in (N) Neutral, turn NA Park Brake - OFF
Minimum
(low idle) engine OFF, wait 3 seconds,
effort.
6036, 6042, 8042, 10042, 10054 31211015 8-15

Hydraulic Section
d. 6042 - 74 hp (55 kW)

MAIN CONTROL VALVE
M
(MAIN PUMP C B
PRESSURE) (PRH1) (PRH2)
SECONDARY
FUNCTION
MANIFOLD
C PBG BVG
(LOAD SENSE RELIEF (PARK BRAKE (BRAKE VALVE
GAUGE) GAUGE)
VALVE)
MAQ1510
MAQ1500
STABIL-TRAK VALVE
HYDRAULIC PUMP
G
PUMP LOAD
SENSE PORT
A
STANDBY
PRESSURE F
G1 PRV
SCREW
B STABIL-TRAK ADJUSTMENT
PUMP MAX PRESSURE SCREW
PRESSURE MAQ1540
SCREW 1 MAQ1530
SERVICE BRAKE VALVE

0160074813 0160074818 and 0160074882 0160074813 0160074818 and 0160074882
E
(AXLE BRAKE
PRESSURE)
E
(AXLE BRAKE
PRESSURE)
MAE14330
MAQ1520
8-16 31211015 6036, 6042, 8042, 10042, 10054

Hydraulic Section

Park Brake - ON
use in Step 2
390-410 psi (26,8-28,2 bar)
psi (32,4-33,7 bar).
3250-3300 psi
(224,0-227,5 bar)
retract cylinder.
3050-3100 psi
(210,2-213,7 bar)
(low idle) (186,2-200 bar)
Secondary
Function
Manifold 550-560psi
Brake)
(high idle)
6036, 6042, 8042, 10042, 10054 31211015 8-17

Hydraulic Section

Secondary
Function
Manifold 580-590psi
Brake)
(high idle)
Secondary
(Park Brake extend/retract cylinder, switch (26,2-26,8 bar)
Pressure) park brake off.
(high idle)
engine at low idle, stall steering.
10 PBG Pressure should not increase PRH1(C) Park Brake - OFF
(low idle) (28,2-28,9 bar)
more than 30 psi (2,0 bar) from
pressure 9.
Service
(low idle)
pressure.
650 psi (44,8 bar)
Minimum
(low idle) maximum brake pedal effort.
80 psi (5,5 bar)
13 Brake E transmission in (N) Neutral, turn NA Park Brake - OFF
Minimum
(low idle) engine OFF, wait 3 seconds,
effort.
Verify Ignition is in the OFF
position. Remove plug G1 and
replace with Test Port Fitting
Stabil-Trak
(SAE-4 O-Ring Boss 7/16-20 UNF 75-150 psi
14 Valve G1 PRV (E) Park Brake - ON
2B) and connect pressure gauge. (5,1-10,3 bar)
(low idle)
Start machine with boom
lowered, frame leveled left at
low idle.
8-18 31211015 6036, 6042, 8042, 10042, 10054

Hydraulic Section

Low idle with boom lowered,
frame level left - 200 psi(13,7
bar) Maximum Pressure
Stabil-Trak 200 psi (13,7 bar)
No Adjustment
15 Valve G1 NA Park Brake - ON
Pressure over Maximum
(low idle)
Stabil-Trak Valve or cylinder
failure
frame level right - 50 psi (3,4 bar)
Stabil-Trak 50 psi (3,4 bar)
No Adjustment. Pressure under
50 psi (3,4 bar) indicates a Minimum
(low idle)
failure
idle, raise boom above 40°
(verify boom angle sensor is
OFF), place the transmission in
4th gear Forward and release
Stabil-Trak the park brake.
Brake A. With the service brake 200-300 psi
17 E NA Park Brake - OFF
Switch released - the Stabil-Trak light (13,7-20,6 bar)
(low idle) must be OFF.
B. Slowly apply the service brake
- the Stabil-Trak light must be
ON with a service brake pressure
of 200 - 300 psi (13,7 - 20,6 bar)
Adjust service brake switch if
required.
6036, 6042, 8042, 10042, 10054 31211015 8-19

Hydraulic Section
e. 8042-10042-10054
MAIN CONTROL VALVE
M SECONDARY
(MAIN PUMP D FUNCTION
PRESSURE) (PRH) MANIFOLD
PBG
(PARK BRAKE
GAUGE) BVG
(BRAKE VALVE
GAUGE)
C
(LOAD SENSE RELIEF MAQ1550
VALVE)
MAQ1500
STABIL-TRAK VALVE
HYDRAULIC PUMP
G
PUMP LOAD
SENSE PORT
A
STANDBY
PRESSURE F
SCREW G1 PRV
B STABIL-TRAK ADJUSTMENT
PUMP MAX PRESSURE SCREW
PRESSURE MAQ1540
MAQ1530
SCREW 1
SERVICE BRAKE VALVE

0160074813 0160074818 and 0160074882 0160074813 0160074818 and 0160074882
E
(AXLE BRAKE
PRESSURE)
E
(AXLE BRAKE
PRESSURE)
MAE14330
MAQ1520
8-20 31211015 6036, 6042, 8042, 10042, 10054

Hydraulic Section

Park Brake - ON
use in Step 2
390-410 psi (26,8-28,2 bar)
psi (32,4-33,7 bar).
3250-3300 psi
(224,0-227,5 bar)
retract cylinder.
3050-3100 psi
(210,2-213,7 bar)
(low idle) (186,2-200 bar)
Secondary
Function
Manifold 550-560psi
6 BVG engine at high idle, fully retract PRH (D) Park Brake - ON
(service (37,9-38,6 bar)
the extend/retract cylinder.
brake)
(high idle)
6036, 6042, 8042, 10042, 10054 31211015 8-21

Hydraulic Section

Secondary Connect gauge to BVG port, run
Function engine at high idle, stall
580-590psi
7 Manifold BVG steering. Pressure should not NA Park Brake - ON
(34,9-40,6 bar)
(high idle) increase more than 30 psi
(2,0 bar) from pressure 6.
Secondary
Function
the extend/retract cylinder,
Manifold 0-10 psi
8 PBG switch park brake switch ON. NA Park Brake - ON
Park Brake (0-6,8 bar)
NOTE: Range/Pressure should
Pressure
repeat in all machine conditions
(high idle)
with park brake ON.
Secondary
9 PBG NA Park Brake - OFF
Park Brake the extend/retract cylinder, (37,5-38,2 bar)
Pressure switch park brake switch OFF.
(high idle)
Secondary
Function
Manifold 575-585 psi
10 PBG steering. Pressure should not NA Park Brake - OFF
Park Brake (39,6-40,3 bar)
increase more than 30 psi
Pressure
(2,0 bar) from pressure 9.
(high idle)
Service
(low idle)
pressure.
650 psi (44,8 bar)
Minimum
(low idle) maximum brake pedal pressure.
80 psi (5,5 bar)
13 Brake E transmission in (N) Neutral, N/A Park Brake - OFF
Minimum
(low idle) release Park Brake, turn engine
OFF, wait 3 seconds, apply
maximum brake pedal pressure.
Verify Ignition is in the OFF
position. Remove plug G1 and
Stabil-Trak replace with Test Port Fitting
75-150 psi
14 Valve G1 (SAE-4 O-Ring Boss 7/16-20 UNF PRV (F) Park Brake - ON
(5,1-10,3 bar)
(low idle) 2B) and connect pressure gauge.
Start machine with boom
lowered at low idle.
8-22 31211015 6036, 6042, 8042, 10042, 10054

Hydraulic Section

frame level left - 200 psi(13,7
bar) Maximum Pressure
Stabil-Trak
No Adjustment 200 psi (13,7 bar)
Pressure over Maximum
(low idle)
failure
frame level right - 50 psi (3,4 bar)
Stabil-Trak
No Adjustment. Pressure under 50 psi (3,4 bar)
50 psi (3,4 bar) indicates a Minimum
(low idle)
failure
idle, raise boom above 40°
(verify boom angle sensor is
OFF), place the transmission in
4th gear Forward and release
Stabil-Trak the park brake.
Brake A. With the service brake 200-300 psi
17 E NA Park Brake - OFF
Switch released - the Stabil-Trak light (13,7-20,6 bar)
(low idle) must be OFF.
B. Slowly apply the service brake
- the Stabil-Trak light must be
ON with a service brake pressure
of 200 - 300 psi (13,7 - 20,6 bar)
Adjust service brake switch if
required.
6036, 6042, 8042, 10042, 10054 31211015 8-23

8-24
8.5.3
8 7 6 5 4 3 2 1
Slave Cylinders
ø 3.54 Base x ø 1.77 Rod x 4.34 Stroke Hoist Cylinders ø 3.75 Base x ø 1.5 Rod x 11.40 Stroke
ø 4.72 Base x ø 3.35 Rod x 39.65 Stroke
Steering Valve, Front

Pilot Ratio : 8:1
H Displacement- 400 CC/Rev Setting : 3000 psi
H
Frame Tilt Cylinder
Extend Cylinder ø4.5 Base x ø 2.25 Rod x 8.69 Stroke
3335 psi 3335 psi
ø 4.5 Base x ø 3 Rod x 102.5 Stroke
4 Wheel Crab Pilot Ratio : 3:1

Steer Steer Pilot Ratio : 4:1 Setting : 3500 psi
Setting : 4000 psi
Pilot Ratio : 4:1

Pilot Ratio : 8:1
Setting : 3500 psi
Setting : 3000 psi
Rear
ø 0.047
Fork Tilt Cylinder
ø 5 Base x ø 2 Rod x 16.75 Stroke
2465 psi Pilot Ratio : 4:1
Setting : 3500 psi
Pilot Ratio : 4:1
G Setting : 4000 psi G
Pilot Ratio : 4:1
T LS P Setting : 4000 psi
Hydraulic Section
ø 0.040
Hydraulic Schematics
Aux. Function
Quick Disconnect
F At Boom Gooseneck F
5 psi
M LS D b1 B1 A1 b2 B2 A2 B3 A3 B4 A4 B5 A5
DLS
P2
280 psi
E E
Hoist Extend Aux. Frame Tilt Fork Tilt

Steering Priority
a. 6036 (Prior to SN 0160074884, excluding 0160074882)
3050 psi
3625 psi 3625 psi 3625 psi 3625 psi
31211015
HOC Bypass
65 psi
T
D D
a1 a2 Pr TPr
Front Wheel
T Brake
2 3 4
1
Cooler B2
C C
P T
Filter Bypass
25 psi
Joystick
Engine B1 Rear Wheel
ENG PB JS BV Brake
5 psi 5 psi
380 psi 550 psi
LS
. Gear Pump : 3.5 in³/rev 10 μ
. 330 psi, Stand by
Return Line Filter ø0.073
. Low idle 1050 rpm, 15.9 gpm
High Idle 2750 rpm, 41.6 gpm T P P
Rated 2500 rpm, 37.8 gpm Service Brake Valve
Secondary Function
Manifold_Dana axle
B conguration B
A A
8 7 6 5 4 3 2 1
MAQ1280C
6036, 6042, 8042, 10042, 10054

Hydraulic Section
b. 6036 (SN 0160074884 to Present, including 0160074882)
G
H
C
E
A
F
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
G
H
C
E
A
F
MAE4440A
6036, 6042, 8042, 10042, 10054 31211015 8-25

c.
8-26
8 7 6 5 4 3 2 1
Slave Cylinders
ø 3.54 Base x ø 1.77 Rod x 4.34 Stroke Hoist Cylinders

ø 5 Base x ø 3.25 Rod x 44.36 Stroke
Front
Steering Valve,
H Displacement- 400 CC/Rev H
Extend Cylinder Frame Tilt Cylinder
3335 psi ø 4.5 Base x ø 3 Rod x 131.25 Stroke ø4.5 Base x ø 2.25 Rod x 8.69 Stroke
Setting : 3000 psi
Pilot Ratio : 4:1
4 Wheel Crab Setting : 4000 psi
Steer Steer Pilot Ratio : 4:1
Setting : 4000 psi
Pilot Ratio : 4:1

Setting : 3500 psi
Rear
ø 0.047
Pilot Ratio : 8:1
Setting : 3000 psi

Setting : 3500 psi Fork Tilt Cylinder
G Pilot Ratio : 4:1 ø 5 Base x ø 2 Rod x 16.75 Stroke G
Setting : 4000 psi
T LS P Pilot Ratio : 4:1
Setting : 4000 psi
ø 0.040
Hydraulic Section
Aux. Function
F Quick Disconnect F
At Boom Gooseneck
P2
LS
DLS
E E
Steering Priority
3050 psi
31211015
3625 psi 3625 psi 3625 psi 3625 psi
T T3 65 psi
D D
a1 a2 Pr TPr
320 psi Front Wheel

. Piston Pump : 3.85 in³/rev T
. Low idle : 1100 rpm, 18.3 gpm Brake
High Idle : 2700 rpm, 44.9 gpm
Rated : 2500 rpm, 41.6 gpm 2 3 4
1
Cooler
C B C
B2
Filter Bypass P T
25 psi Joystick
6036 - 74 hp (55 kW) Engine (Prior to SN 0160074884, excluding 0160074882)
ENG PB JS BV
B1
Rear Wheel
5 psi Brake
380 psi 550 psi
5 psi
10 μ
LS
S L2 L1 L
Return Line Filter
T P ø0.073
P
Service Brake Valve
B Secondary Function B
Manifold_Dana axle
conguration
. Pump Cut-off Pressure : 3250 psi

. Standby Pressure : 480 psi
A A
8 7 6 5 4 3 2 1
MAQ2090B
6036, 6042, 8042, 10042, 10054

Hydraulic Section
d. 6036 - 74 hp (55 kW) Engine (SN 0160074884 to Present, including 0160074882)
G
H
C
E
A
F
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
G
H
C
E
A
F
MAE4450B
6036, 6042, 8042, 10042, 10054 31211015 8-27

8-28
8 7 6 5 4 3 2 1
Slave Cylinders

ø 5 Base x ø 3.25 Rod x 44.36 Stroke V FTR G3 G2
Front
H Steering Valve, H
Displacement- 400 CC/Rev
3335 psi 3335 psi

Stabilizer Cylinder
Extend Cylinder ø 0.03 ø 4.50 Base x ø 2.25 Rod x 8.69 Stroke
4 Wheel Crab ø 4.5 Base x ø 3 Rod x 131.25 Stroke
Setting : 4000 psi Pilot Ratio : 4:1
Setting : 4000 psi
Frame Tilt Cylinder

Rear
ø4.5 Base x ø 2.25 Rod x 8.69 Stroke Fork Tilt Cylinder
200 psi ø 5 Base x ø 2 Rod x 16.75 Stroke
ø 0.06 ø 0.06 Pilot Ratio : 4:1
Setting : 4000 psi
2465 psi 100 psi
G G
ø 0.040
Pilot Ratio : 4:1
Setting : 4000 psi
T LS P T P G1
Hydraulic Section
ø 0.047
F Aux. Function F
Quick Disconnect
5 psi
At Boom Gooseneck
DLS
P2
E 280 psi E

e. 6042 (Prior to SN 0160074884, excluding 0160074882)
Steering Priority
3050 psi
31211015
3625 psi 3625 psi 3625 psi 3625 psi
HOC Bypass
65 psi
D T D
a1 a2 Pr TPr
Front Wheel
T
Brake
Cooler 2 3 4
1
C B2 C
Filter Bypass P T
25 psi Joystick
B1
PB JS BV Rear Wheel
Brake
Engine
5 psi
5 psi
380 psi 550 psi
ENG 10 μ LS
Return Line Filter ø0.073

T P P
Service Brake Valve
Secondary Function
B Manifold_Dana axle B
. Gear Pump : 3.5 in³/rev
. 330 psi, Stand by conguration
. Low idle 1050 rpm, 15.9 gpm
High Idle 2750 rpm, 41.6 gpm
Rated 2500 rpm, 37.8 gpm
A A
8 7 6 5 4 3 2 1
MAQ1290C
6036, 6042, 8042, 10042, 10054

Hydraulic Section
f. 6042 (SN 0160074884 to Present, including 0160074882)
G
H
C
E
A
F
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
G
H
C
E
A
F
MAE4460A
6036, 6042, 8042, 10042, 10054 31211015 8-29

8-30
8 7 6 5 4 3 2 1
Slave Cylinders

ø 5 Base x ø 3.25 Rod x 44.36 Stroke V FTR G3 G2
Front
H Steering Valve, H
Displacement- 400 CC/Rev Pilot Ratio : 8:1
Setting : 3000 psi
3335 psi 3335 psi
Stabilizer Cylinder
Extend Cylinder ø 0.03 ø 4.50 Base x ø 2.25 Rod x 8.69 Stroke
4 Wheel Crab ø 4.5 Base x ø 3 Rod x 131.25 Stroke
Setting : 4000 psi Pilot Ratio : 4:1
Setting : 4000 psi
Frame Tilt Cylinder Pilot Ratio : 8:1

Rear
ø4.5 Base x ø 2.25 Rod x 8.69 Stroke Setting : 3000 psi
200 psi
Fork Tilt Cylinder
ø 0.06 ø 0.06
2465 psi 100 psi Pilot Ratio : 4:1
G Setting : 4000 psi G
ø 0.040
Pilot Ratio : 4:1
Setting : 4000 psi
T LS P T P G1
Hydraulic Section
ø 0.047
F Aux. Function F
Quick Disconnect
At Boom Gooseneck
P2
LS
DLS
E E
Steering Priority
3050 psi
31211015
3625 psi 3625 psi 3625 psi 3625 psi
HOC Bypass
T 65 psi
D T3 D
a1 a2 Pr TPr
. Piston Pump : 3.85 in³/rev 320 psi

. Low idle : 1100 rpm, 18.3 gpm
T
High Idle : 2700 rpm, 44.9 gpm Front Wheel
Cooler
Rated : 2500 rpm, 41.6 gpm Brake
2 3 4
1
C B C
Filter Bypass
25 psi B2
P T
g. 6042 - 74 hp (55 kW) Engine (Prior to SN 0160074884, excluding 0160074882)
Joystick
ENG PB JS BV
B1
10 μ 5 psi Rear Wheel
Return Line Filter 380 psi 550 psi Brake
5 psi
S L2 L1 L
LS
T P
ø0.073
B P B
. Pump Cut-off Pressure : 3250 psi Secondary Function Service Brake Valve
. Standby Pressure : 480 psi Manifold_Dana axle
conguration
A A
8 7 6 5 4 3 2 1
MAQ2100B
6036, 6042, 8042, 10042, 10054

Hydraulic Section
h. 6042 - 74 hp (55 kW) Engine (SN 0160074884 to Present, including 0160074882)
G
H
C
E
A
F
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
G
H
C
E
A
F
MAE4470B
6036, 6042, 8042, 10042, 10054 31211015 8-31

i.
8-32
8 7 6 5 4 3 2 1
Slave Cylinders
ø 4.25 Base x ø 1.75 Rod x
Hoist Cylinders 13.75 Stroke
ø 5.7 Base x ø 3.5 Rod x 42.41 Stroke V FTR G3 G2
Front
Pilot Ratio : 8:1
Steering Valve, Setting : 3000 psi
H Displacement- 400 CC/Rev Extend Cylinder H
3335 psi 3335 psi Stabilizer Cylinder
ø 0.03 ø 4.50 Base x ø 2.25 Rod x 8.69 Stroke
4 Wheel Crab
Setting : 3500 psi
Frame Tilt Cylinder
Pilot Ratio : 3:1 ø4.5 Base x ø 2.25 Rod x 8.69 Stroke Pilot Ratio : 8:1
Setting : 3500 psi Setting : 3000 psi
Rear
200 psi Fork Tilt Cylinder

ø 0.06 ø 0.06 ø 6 Base x ø 2.5 Rod x 16.75 Stroke
ø 0.040
2465 psi 100 psi Pilot Ratio : 4:1
Setting : 4000 psi
Pilot Ratio : 3:1
G Setting : 3500 psi
G
T P G1
T LS P
ø 0.047
Hydraulic Section
Aux. Function
At Boom Gooseneck
P2
LS
DLS
E E
Steering Priority
3050 psi
31211015
3625 psi 3625 psi 3625 psi 3625 psi
HOC Bypass T 65 psi

T3
D D
a1 a2 Pr TPr
T
Front Wheel
Brake
8042 (Prior to SN 0160074878, excluding 0160074813 and 0160074818)
2 3 4
1
B2
C C
P T
Joystick
Cooler Rear Wheel
B1 Brake
X PB JS BV
5 psi
. Piston Pump : 3.84 in³/rev 5 psi LS
. Low idle : 1100 rpm, 18.3 gpm 550 psi
High Idle : 2700 rpm, 44.9 gpm
Rated : 2500 rpm, 41.6 gpm ø0.073
Service Brake Valve P

Filter Bypass T P
B 25 psi
B B
Secondary Function
Manifold_Dana axle
Engine conguration
10 μ
ENG
Return Line Filter
S L2 L1 L

A . Standby Pressure : 480 psi A
8 7 6 5 4 3 2 1
MAQ1300C
6036, 6042, 8042, 10042, 10054

Hydraulic Section
j. 8042 (SN 0160074878 to Present, including 0160074813 and 0160074818)
G
H
C
E
A
F
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
G
H
C
E
A
F
MAE4480B
6036, 6042, 8042, 10042, 10054 31211015 8-33

8-34
8 7 6 5 4 3 2 1
Slave Cylinders
ø 4.25 Base x ø 1.75 Rod x
ø 3.93 Base x ø 1.97 Rod x 4.56 Stroke 13.75 Stroke
Hoist Cylinders V FTR G3 G2
Front ø 6 Base x ø 3 Rod x 42.41 Stroke
Steering Valve,
Pilot Ratio : 8:1
H Displacement- 400 CC/Rev Extend Cylinder Setting : 3000 psi H
3335 psi 3335 psi
Stabilizer Cylinder
4 Wheel Crab ø 0.03 ø 4.50 Base x ø 2.25 Rod x 8.69 Stroke
Steer Steer
Pilot Ratio : 3:1
Setting : 3500 psi
Pilot Ratio : 3:1

Rear Setting : 3500 psi Frame Tilt Cylinder Pilot Ratio : 8:1
Setting : 3000 psi
ø4.5 Base x ø 2.25 Rod x 8.69 Stroke
200 psi
ø 0.06 ø 0.06
Fork Tilt Cylinder
2465 psi 100 psi
Pilot Ratio : 4:1
Setting : 4000 psi
ø 0.040
G Pilot Ratio : 3:1 G
P Setting : 3500 psi T P G1
T LS
Hydraulic Section
ø 0.047
Aux. Function
At Boom Gooseneck
P2
LS
DLS
E E
Steering Priority
ø 0.156
ø 0.156
P
T
3050 psi
31211015
3625 psi 3625 psi 3625 psi 3625 psi
HOC Bypass T T3 65 psi

1.2 mm LS
D D
B1 A1 B2 A2 a1 a2 Pr TPr
B1 A1 B2 A2
T
Front Wheel
Pilot Ratio : 4:1
Pilot Ratio : 4:1

Setting : 1000 psi
Brake
Setting : 1000 psi

Left Side Right Side 2 3 4
1
k. 10042 (Prior to SN 0160074878, excluding 0160074813 and 0160074818)
Outrigger Cylinders
C ø 5 Base x ø 3 Rod x 13.31 Stroke B2 C
P T
Joystick
Cooler Rear Wheel
Brake
X B1
PB JS BV
5 psi
. Piston Pump : 3.84 in³/rev
. Low idle : 1100 rpm, 18.3 gpm 5 psi LS
High Idle : 2700 rpm, 44.9 gpm 550 psi
Rated : 2500 rpm, 41.6 gpm ø0.073
Service Brake Valve
Filter Bypass P
B
25 psi T P
B B
Secondary Function
Manifold_Dana axle
Engine conguration
ENG 10 μ
Return Line Filter
S L2 L1 L

8 7 6 5 4 3 2 1
MAQ1310C
6036, 6042, 8042, 10042, 10054

Hydraulic Section
l. 10042 (SN 0160074878 to Present, including 0160074813 and 0160074818)
G
H
C
E
A
F
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
G
H
C
E
A
F
MAE4490B
6036, 6042, 8042, 10042, 10054 31211015 8-35

8-36
8 7 6 5 4 3 2 1
ø 3.93 Base x ø 1.97 Rod x 4.56 Stroke Hoist Cylinders FTR G3 G2 Slave Cylinders
V
ø 6 Base x ø 3.5 Rod x 42.41 Stroke ø 4.25 Base x ø 1.75 Rod x
13.75 Stroke
Front
Steering Valve,
H Displacement- 400 CC/Rev Extend Cylinder H
3335 psi 3335 psi Stabilizer Cylinder
ø 0.03 ø 4.50 Base x ø 2.25 Rod x 8.69 Stroke
4 Wheel Crab
Pilot Ratio : 3:1
Steer Steer Setting : 3500 psi
Pilot Ratio : 3:1

Setting : 3500 psi Frame Tilt Cylinder
Rear Boom Lock Out Valve ø4.5 Base x ø 2.25 Rod x 8.69 Stroke
200 psi Fork Tilt Cylinder
150 psi
ø 0.06 ø 0.06 ø 6 Base x ø 2.5 Rod x 16.75 Stroke
C
2465 psi
Setting : 4000 psi
ø 0.040
G Pilot Ratio : 3:1 G
Setting : 3500 psi T P G1
T LS P T V
Hydraulic Section
ø 0.047
Aux. Function
Quick Disconnect
F At Boom Gooseneck
F
P2
LS
DLS
E E
Steering Priority
ø 0.156
ø 0.156
P
T
3050 psi
31211015
3625 psi 3625 psi 3625 psi 3625 psi
HOC Bypass T T3 65 psi

1.2 mm LS
D D
B1 A1 B2 A2 a1 a2 Pr TPr
B1 A1 B2 A2
T
Front Wheel
Pilot Ratio : 4:1
Pilot Ratio : 4:1

Setting : 1000 psi
Setting : 1000 psi

Brake
Left Side Right Side 2 3 4

1
m. 10054 (Prior to SN 0160074878, excluding 0160074813 and 0160074818)
Outrigger Cylinders
C ø 5 Base x ø 3 Rod x 13.31 Stroke B2 C
P T
Joystick
Cooler
Rear Wheel
X B1 Brake
PB JS BV
. Piston Pump : 3.84 in³/rev 5 psi

. Low idle : 1100 rpm, 18.3 gpm 5 psi LS
High Idle : 2700 rpm, 44.9 gpm 550 psi
Rated : 2500 rpm, 41.6 gpm ø0.073
Service Brake Valve
Filter Bypass P
B 25 psi T P
B B
Secondary Function
Manifold_Dana axle
Engine conguration
ENG 10 μ
Return Line Filter
S L2 L1 L

8 7 6 5 4 3 2 1
MAQ1320C
6036, 6042, 8042, 10042, 10054

Hydraulic Section
n. 10054 (SN 0160074878 to Present, including 0160074813 and 0160074818)
G
H
C
E
A
F
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
G
H
C
E
A
F
MAE4500B
6036, 6042, 8042, 10042, 10054 31211015 8-37

Hydraulic Section
8.6 HYDRAULIC RESERVOIR 8. Wipe up any hydraulic fluid spillage in, on, near and
around the machine and the work area.
3
2 8.6.2 Hydraulic Oil Reservoir Filling
1. Be sure the reservoir is clean and free of all debris.
2. Install a new hydraulic oil filter. Refer to Section 8.6.3,
“Hydraulic Filter Replacement”.
3. Fill the hydraulic reservoir. Refer to Section 2.3, “Fluid
1 Specifications”.
4 MAQ1340 “Battery”, for procedure.
Hydraulic reservoir (1) and fuel tank are one unit located on
the right side of the frame. The hydraulic fluid filler/breather
and filter are accessed under cover (2). 6. Close and secure the engine cover.
Occasionally, fluid may seep, leak or be more forcefully
8.6.3 Hydraulic Filter Replacement
expelled from the filler/breather (3) when system pressure
exceeds the rating of the breather. If the return filter 1. Be sure the reservoir is clean and free of all debris.
becomes plugged, return hydraulic oil will bypass the filter
when pressure reaches 25 psi (1,7 bar) and return to the
5
reservoir unfiltered.
6
Carefully examine fluid seepage or leaks from the hydraulic
reservoir to determine the exact cause. Clean the reservoir 8
9 7
and note where any seepage occurs.
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.
8.6.1 Hydraulic Oil Reservoir Draining

MAQ1330
switch and the steering wheel, stating that the machine 2. Loosen and remove the six nuts (5) securing the filter
should not be operated. cover (6) to the hydraulic reservoir.
3. Open the engine cover. Allow the system fluids to cool. 3. Remove the filter (7) and spring (8) from the hydraulic
4. Properly disconnect the battery. Refer Section 9.8, reservoir allowing any excess hydraulic oil to drain into
“Battery”, for procedure. the reservoir.
5. Remove filter access cover (2). 4. Replace the hydraulic filter head gasket (9) if necessary.
6. Remove the filler/breather cap (3) on the hydraulic oil 5. Install the new hydraulic filter and spring. Lower the
reservoir (1). Remove the drain plug (4) on the bottom hydraulic filter assembly into the hydraulic reservoir.
of the hydraulic oil reservoir. 6. Install the six previously removed nuts securing the
7. Transfer the used hydraulic oil into a suitable covered hydraulic filter cover to the hydraulic reservoir. Torque
container, and label as “Used Oil”. Dispose of used oil at the nuts to 75 lb-in (8.5 Nm).
an approved recycling facility. Clean and reinstall the 7. Install the previously removed access cover (2).
drain plug (4).
8-38 31211015 6036, 6042, 8042, 10042, 10054

Hydraulic Section
8. Wipe up any hydraulic fluid spillage in, on, near and 10. Remove the o-ring (4) located between the
around the machine and the work area. transmission and the pump. Wipe up any hydraulic oil
spillage.
8.6.4 Hydraulic Oil Reservoir Replacement 11. Remove the hydraulic fittings from the pump to use for
The hydraulic reservoir and the fuel tank are one unit and are later installation.
removed together. Refer to Section 7.6.2, “Fuel/Hydraulic Oil Note: Before removing any fittings from the pump, note their
Tank”, for information on hydraulic reservoir/fuel tank orientation to ensure correct installation.
replacement.
Note: DO NOT disassemble the operating pump. The pump is
8.7 HYDRAULIC SYSTEM PUMP pre-set from the manufacturer. Any adjustments or repairs
performed by anyone other than an authorized dealer could
For internal service instructions contact your local void the warranty.
authorized service distributor.
b. Pump Installation
8.7.1 Pump Replacement 1. Install the fittings on the pump in the same orientation
as noted during removal.
a. Pump Removal
2. Place the pump and a new, oiled o-ring into position on
1. Park the machine on a firm, level surface, level the the transmission. Align the pump shaft with the internal
machine, fully retract the boom, raise the boom, place transmission gear, so that the machined teeth mesh
the transmission in (N) NEUTRAL, engage the park brake together.
3. Align the bolt holes with the pump mount holes. Secure
2. Place a Do Not Operate Tag on both the ignition key the pump to the transmission with the previously used
switch and the steering wheel, stating that the machine hardware.
4. Uncap and connect the previously labeled hydraulic hoses
3. Properly support the boom. to their appropriate locations.
4. Open the engine cover. Allow the system fluids to cool. 5. Fill the hydraulic reservoir. Refer to Section 8.6.2,
5. Properly disconnect the battery. Refer Section 9.8, “Hydraulic Oil Reservoir Filling”.
“Battery”, for procedure. 6. Prime the pump by filling the case drain port with fresh,
6. Drain the hydraulic reservoir. Refer to Section 8.6.1, filtered hydraulic oil from a clean container before
“Hydraulic Oil Reservoir Draining”. installing the case drain connector and hose.
7. Check all routing of hoses and tubing for sharp bends or
4 3 interference with any rotating members. All tube and
2 1 hose clamps must be tight.
9. Remove boom support.
12. 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.
MAQ1350
13. Inspect for leaks and check all fluid levels. The hydraulic
7. Thoroughly clean the pump (1) and surrounding area. reservoir oil level must be to the middle of the sight
8. Label, disconnect and cap the hydraulic hoses attached gauge.
to the pump.
9. Remove the bolts (2), lockwashers and washers
securing the pump to the transmission (3).
6036, 6042, 8042, 10042, 10054 31211015 8-39

Hydraulic Section
c. Pump Test
1. Refer to Section 8.5.1, “Pressure Checks and
Adjustments”.
8.8 VALVES AND MANIFOLDS
8.8.1 Main Control Valve

The main control valve is mounted on the frame under the
lower transmission cover.
The main control valve assembly consists of individual
working sections with their own valve assemblies, each
providing a specific hydraulic function.
2
3 MAQ1390
a. Main Control Valve Removal
Note: Record the location, and label all cables to ensure correct
installation.
the transmission in (N) NEUTRAL, engage the park brake 10. Disconnect the control cables:
and shut the engine OFF. a. Remove the clip and anchor pin (2). Retain the clip
2. Place a Do Not Operate Tag on both the ignition key and anchor pin for installation.
switch and the steering wheel, stating that the machine b. Loosen and remove the two bolts (3), and remove
should not be operated. the bracket/control cable.
3. Temporarily block up or support the raised boom. c. Route the cable clear of the main control valve.
4. Open the engine cover. Allow the system fluids to cool. d. Repeat steps for the remaining control cables.
5. With the engine OFF, operate all the hydraulic functions 11. Remove the two bolts and nuts securing the main
to relieve trapped pressure. control valve to the frame.
6. Remove the transmission covers. Thoroughly clean the 12. Remove the main control valve from the frame.
main control valve and surrounding area, including all
hoses and fittings, before proceeding. b. Main Control Valve Disassembly
7. Place a suitable container to collect hydraulic fluid
drainage beneath the frame.
MAQ1880
MAQ1380
4
1. To disassemble the individual sections of the main
8. Label, disconnect and cap all the hydraulic hoses, tubes
control valve, remove the three nuts from one end of
and wires at the main control valve (1).
the tie rods.
9. Wipe up any hydraulic fluid spillage in, on, near and
2. Disassemble each section assembly as required.
around the machine and the work area.
8-40 31211015 6036, 6042, 8042, 10042, 10054

Hydraulic Section
Some sections include a pre-adjusted relief valve that Assemble the Main Control Valve.
regulates pressure in a specific circuit.
Note: DO NOT adjust any of the relief valve assemblies.
Tampering with a relief valve will irrevocably alter pressure in the
affected circuit, requiring recalibrating or a new relief valve.
Disassemble each Valve Section.
1. Carefully separate the load sense outlet section from the
next section. 5
2. Remove the o-rings from between the two sections.

3. Carefully separate each remaining sections, being
careful not to lose the load sense shuttle ball.
4. Remove both end caps from each end of the valve
sections then remove each control spool.
MAQ1880
5. Remove any check valves, compensator valves,
4
anti-cavitation valves or shock valves from individual
valve section if equipped. 1. Stand the end main control valve section on end.
6. Keep all parts being removed from individual valve 2. Install the proper o-rings and load sense shuttle on the
sections tagged and kept together. inner face of the end main control valve section. Align
the next valve section over the three tie rods and slide
c. Main Control Valve Parts Cleaning onto the end main control valve section.
Clean all components with a suitable cleaner, such as 3. Using the proper o-rings and load sense shuttle, repeat
triclorethylene, before continuing. Blow dry. step two for the remaining valve sections and lastly the
inlet end valve section.
d. Main Control Valve Parts Inspection 4. Install the three nuts on the tie rods. Torque the two
Inspect all parts and internal passageways for wear, damage, bottom nuts (4) to 43 - 53 lb-ft (58 - 72 Nm). Torque the
etc. If inner surfaces of any component DO NOT display an top nut (5) to 66 - 82 lb-ft (89 - 111 Nm).
ultra-smooth, polished finish, or are damaged in any way, 5. Replace all fittings in the previously noted locations and
replace the damaged part. Often, dirty hydraulic fluid causes torque as required.
failure of internal seals, damage to the polished surfaces
within the component, and wear of and/or harm to other
parts.
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.
6036, 6042, 8042, 10042, 10054 31211015 8-41

Hydraulic Section
f. Main Control Valve Installation 7. Start engine and run at approximately one-third to one-
half throttle for about one minute without moving the
1. Install the main control valve onto the frame, aligning
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 position, 8. Inspect for leaks and check the level of the hydraulic
and tighten the bolts. Torque as required. 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 continuing.
openings with fresh, filtered hydraulic oil from a clean Add hydraulic fluid to the reservoir as needed.
container, before attaching the hoses.
3. Use new oiled o-rings as required. Uncap and connect around the machine, work area and tools.
all previously labeled hoses, clamps, etc. to the main
10. Install the transmission covers.
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 8.5.1,
“Pressure Checks and Adjustments”.
Note: DO NOT loosen, disassemble or attempt to adjust any of
pressure valves unless specifically instructed by manufacturer
to do so. Tampering with a pressure valve will irrevocably alter
pressure in the affected circuits.
2
MAQ1390
3 4
4. Connect the control cables to the main control valve:

a. Install the two bolts (3), and secure the bracket/
control cable to the main control valve.
b. Connect the end of the cable to the shaft from the
control valve. Secure with the pin and clip (2).
c. If required, adjust the jam nuts (4)until the distance
from the outer jam nut to the end of the ferrule is
the same as recorded during removal. Tighten the
jam nuts.
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 8.6.2,
“Hydraulic Oil Reservoir Filling”.
8-42 31211015 6036, 6042, 8042, 10042, 10054

Hydraulic Section
8.8.2 Service Brake Valve SN 0160074878 to Present, including 0160074813

0160074818 and 0160074882
a. Service Brake Valve Removal
2. Place a Do Not Operate Tag on both the ignition key 1
5. Remove the lower and front dash panels.
Prior to SN 0160074878, excluding 0160074813
0160074818 and 0160074882
MAE4430
6. Label, disconnect and cap all hose attached to the

service brake valve (1).
7. Remove the four capscrews and four lockwashers
1 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.
8.8.3 Service Brake Valve Installation

1. Install the service brake valve with the four capscrews
and four lockwashers onto the steering column
support.
MAQ1870 2. Use new oiled o-rings as required. Uncap and connect
the previously labeled hoses to the service brake valve.
3. Check the routing of all hoses, and tubing for sharp
install tie wraps and/or protective conduit as required.
Tighten all tube and hose clamps.
6. Start the engine and run at approximately one-third to
one-half throttle for about one minute, without moving
the machine or operating any of the hydraulic functions.
7. Inspect the service brake valve and connections for
leaks, and check the level of the hydraulic fluid in the
reservoir. Shut the engine OFF.
6036, 6042, 8042, 10042, 10054 31211015 8-43

Hydraulic Section
Note: Check for leaks, and repair as required before 2. Remove the plastic cap from the brake bleeder (2).
continuing. Add hydraulic fluid to the reservoir as needed. Attach one end of a length of transparent tubing over
the brake bleeder. Place the other end of this tubing in a
8. Wipe up any hydraulic fluid spillage in, on, near and suitable transparent container that is partially filled with
around the machine, work area and tools. hydraulic oil. The end of the tubing must be below the
9. Install the lower and front dash panels. oil level in the container.
10. Close and secure the engine cover. 3. DO NOT open the brake bleeder without holding the
tubing firmly on the bleeder. There is pressure at the
8.8.4 Brake Bleeding brakes. Carefully open the bleeder with a wrench. Have
Carefully bleed the brake lines as soon as the brake valve is the assistant depress the brake pedal. Close the brake
installed in the machine. Air in the system will not allow the bleeder when air bubbles no longer appear in the oil.
brakes to apply properly. There are four brake bleeder Release the brake pedal. Remove the tubing from the
locations on the axles. Work with an assistant to perform this brake bleeder.
procedure. 4. Repeat Steps 2 and 3 for remaining brake bleeders.
5. Conduct a pressure and function check of service brake.
a. Prior to SN 0160074878, excluding 0160074813 Refer to Section 8.5.2, “Pressure Specifications”.
0160074818 and 0160074882
1. Place the transmission in (N) NEUTRAL, engage the park b. SN 0160074878 to Present, including 0160074813
brake, and start the engine. 0160074818 and 0160074882
2
1. Place the transmission in (N) NEUTRAL, engage the park
brake, and start the engine.
Note: Verify brake reservoir oil is at the full mark. DO NOT
allow the brake reservoir oil to go below the minimum level
during the bleeding procedure.
2. Depress the brake pedal 4 - 5 times, then hold at the
bottom of the last stroke.
Note: Work with an assistant to perform this procedure.
3. Attach one end of a length of transparent tubing over
the brake bleeder at left hand side of the rear axle. Place
the other end of this tubing in a suitable transparent
container that is partially filled with automatic
transmission fluid (ATF oil). The end of the tubing must
6036, 6042 be below the oil level in the container.
4. Remove the bleed screw (2) with a wrench and allow
MAQ1860
the fluid to escape. As the fluid escapes, maintain the
same pressure on the brake pedal not allowing it to
raise. Close the brake bleeder when brake pedal is fully
depressed. Repeat the procedure until oil is not aerated
further. Remove the tubing from the brake bleeder.
5. Repeat steps 2, 3 and 4 for remaining brake bleeders.
8042, 10042, 10054
MAQ1850
8-44 31211015 6036, 6042, 8042, 10042, 10054

Hydraulic Section
8.8.5 Brake System Check

1. Place the transmission in (N) NEUTRAL, engage the park 8.8.6 Steering Orbitrol Valve
brake, and start the engine.
3
2 MZ0370
The power steering valve (3) is located at the base of the

steering wheel shaft, concealed by the lower dash cover. The
valve is not serviceable and must be replaced in its entirety if
defective. For detailed information refer toSection 4.3.2,
MAE14330
“Steering Column and Steering Valve”.
2. Attach pressure gauge to brake pressure tap (3).
8.8.7 Steer Select Valve
3. Apply service brakes with a single pedal press to STOP.
Hold the brake pedal in this position and measure the
gauge pressure. the allowable pressure limit is
725 - 760 psi (50 - 52.4 bar).
MAQ1420
The machine can be used in the front-wheel, four-wheel or

crab steering mode. The steer select valve (4) controls the
direction of hydraulic fluid flow to the steering cylinders
MAE13530 mounted on each axle. The steer select valve is attached to a
A
manifold mounted to a mounting plate inside the frame near
4. Measure the distance from the back of the pedal arm to the fuel tank.
cab firewall. This distance should be 73 mm (2.88 in).
Verify the correct operation of the steer select valve
solenoids before considering replacement of the valve. The
housing of the steer select valve is not serviceable and must
be replaced if defective.
6036, 6042, 8042, 10042, 10054 31211015 8-45

Hydraulic Section
a. Steer Select Valve Removal 7. Install the solenoid valves in the steer select housing.
1. Park the machine on a firm, level surface, level the 8. Attach steer select valve to the manifold using four new,
machine, fully retract the boom, raise the boom, place oiled o-rings and four socket head capscrews.
and shut the engine OFF. c. Steer Select Valve Installation
2. Place a Do Not Operate Tag on both the ignition key 1. Install the steer select valve to the mounting plate on
switch and the steering wheel, stating that the machine the frame using two capscrews.
should not be operated. 2. Connect all the previously labeled hydraulic hoses,
3. Temporarily block up or support the raised boom. fittings, solenoid wire terminal leads, etc., to the steer
4. Open the engine cover. Allow the system fluids to cool. select valve.
5. Properly disconnect the battery. Refer Section 9.8, 3. Check the routing of all hoses, wiring and tubing for
“Battery”, for procedure. sharp bends or interference with any rotating members,
and install tie wraps and/or protective conduit as
6. Remove the transmission covers. required. Tighten all hose clamps.
7. Label, disconnect and cap hydraulic hoses and electrical 4. Properly connect the battery. Refer Section 9.8,
plugs connected to steering select valve. “Battery”, for procedure.
8. Remove the bolts holding the steer select valve to the 5. Remove the Do Not Operate Tags from both the ignition
mounting plate on the frame. key switch and the steering wheel.
9. Remove steer select valve from machine. Wipe up any 6. Start the engine and run at approximately 1/3-1/2
hydraulic fluid spillage in, on, near and around the throttle for about one minute without moving the
machine. machine or operating any hydraulic functions.
b. Steer Select Valve Disassembly, Cleaning, Inspection 7. Inspect for leaks and check the level of the hydraulic
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 continuing.
work surface. Add hydraulic fluid to the reservoir as needed.
2. Separate the steer select valve from the manifold by 8. Wipe up any hydraulic fluid spillage in, on, near and
removing the four socket head capscrews. Discard the around the machine, work area and tools.
four o-rings. 9. Install the transmission covers.
3. Remove the solenoid valves and spool from the steer 10. Close and secure the engine cover.
select housing.
4. Clean all the components with a suitable cleaner before d. Steering Test
inspection. Refer to Section 8.5.2, “Pressure Specifications”.
5. Inspect the solenoids for proper operation. Check by 1. Conduct a pressure check of the steering
shifting the spool to ensure that it is functioning hydraulic circuit.
properly. Check the spring is intact. Inspect the
cartridge interior for contamination. 2. Check each steering mode for proper function.
6. Inspect internal passageways of the steer select

manifold and valve for wear, damage, etc. If inner
surfaces of the manifold DO NOT display an
ultra-smooth, polished finish, or components are
damaged in any way, replace the manifold or
appropriate part. Often, dirty hydraulic fluid causes
failure of internal seals and damage to the polished
surfaces within the valve.
8-46 31211015 6036, 6042, 8042, 10042, 10054

Hydraulic Section
8.8.8 Secondary Function Manifold 8. Remove the bolts holding the secondary manifold to
the mounting plate on the frame.
The secondary function manifold is a directional control
valve. Hydraulic oil from the pump flows into the secondary 9. Remove secondary manifold with attached steer select
function manifold where the pressure is reduced before the valve from machine. Wipe up any hydraulic fluid spillage
oil is directed to the park brake. in, on, near and around the machine.
The secondary function manifold is a machined block with b. Secondary Function Manifold Disassembly,
the ports for two pressure reducing valves, a pressure relief Cleaning, Inspection and Assembly
valve, two park brake solenoid valves (one normally open
and one normally closed), a check valve and diagnostic test 1. Secure the secondary function manifold assembly in a
nipples. The secondary function manifold is secured on the suitable bench vise if possible. Label and remove the
left side of the frame with two carriage bolts and two hex solenoid nut, coil, reducing valve(s) and test ports from
flange nuts. the valve.
Verify the correct operation of the solenoids before 2. Clean all components with a suitable cleaner
considering replacement of the secondary function before inspection.
manifold. The manifold itself is not serviceable and must be 3. Inspect the solenoid cartridge for proper operation.
replaced if defective. Check by shifting the spool to ensure that it is
functioning properly. Check the spring is intact. Inspect
a. Secondary Function Manifold Removal the cartridge interior for contamination.
1. Park the machine on a firm, level surface, level the 4. Inspect internal passageways and the secondary
machine, fully retract the boom, raise the boom, place manifold overall for wear, damage, etc. If inner surfaces
the transmission in (N) NEUTRAL, engage the park brake of the component DO NOT display an ultra-smooth,
and shut the engine OFF. polished finish, or are damaged in any way, replace the
valve assembly. Often, dirty hydraulic fluid causes
3. Temporarily block up or support the raised boom. Note: ALWAYS replace seals, o-rings, gaskets, etc., with new
4. Open the engine cover. Allow the system fluids to cool. seals and o-rings with clean hydraulic oil.
5. Install the solenoid valve.
6. Install previously removed reducing valve(s) and test
ports. Torque as required.
6036 & 6042

SECONDARY MANIFOLD
SHOWN
MAQ1510
7. Label, disconnect and cap hydraulic hoses and electrical

plugs connected to secondary manifold.
6036, 6042, 8042, 10042, 10054 31211015 8-47

Hydraulic Section
c. Secondary Function Manifold Installation 6. Remove the transmission covers.

1. Place the secondary function manifold into position on 7. Label, disconnect and cap the hydraulic hoses and the
the mounting plate on the machine frame. electrical plugs connected to the outrigger valve.
2. Install bolt and nut securing valve to frame. 8. Remove the two flange nuts and two carriage bolts
securing the outrigger valve to the frame. Remove the
3. Connect all the previously labeled hydraulic hoses,
outrigger valve from the machine.
fittings, solenoid wire terminal leads, etc., to the
secondary function manifold. 9. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
4. Check the routing of all hoses and wiring for sharp
b. Outrigger Valve Disassembly, Cleaning, Inspection
and Assembly
Tighten all hose clamps.
5. Properly connect the battery. Refer Section 9.8, 1. Place the outrigger valve assembly on a suitable work
“Battery”, for procedure. surface.
3
7. Start the engine and run at approximately 2
1/3 - 1/2 throttle for about one minute without moving
the machine or operating any hydraulic functions.
8. 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 reservoir as needed.
around the machine, work area and tools. 4
MAQ1400
2. Remove the solenoid valve assemblies (2) from the
8.8.9 Outrigger Valve (10042 & 10054 only) outrigger valve by removing the four capscrews (3).
Discard the four o-rings.
The outrigger valve allows the left and right outriggers to be
raised or lowered depending on the position of the outrigger 3. Remove four shuttle cartridges (4) from outrigger valve.
switches located on the side console in the cab. CV3 and CV4 are located on the opposite end of the
valve body.
Verify the correct operation of the outrigger valve solenoids
before considering replacement of the valve. 4. Clean all components with a suitable cleaner
before inspection.
a. Outrigger Valve Removal 5. Inspect the solenoid cartridges for proper operation.
1. Park the machine on a firm, level surface, level the Check by shifting the spool to ensure that it is
machine, fully retract the boom, raise the boom, place functioning properly. Check that the spring is intact.
the transmission in (N) NEUTRAL, engage the park brake Inspect the cartridge interior for contamination.
and shut the engine OFF. 6. Inspect internal passageways of the outrigger
2. Place a Do Not Operate Tag on both the ignition key valve for wear, damage, etc. If inner surfaces of the valve
switch and the steering wheel, stating that the machine DO NOT display an ultra-smooth, polished finish, or
should not be operated. components are damaged in any way, replace the valve
or appropriate part. Often, dirty hydraulic fluid causes
3. Temporarily block up or support the raised boom. failure of internal seals and damage to the polished
4. Open the engine cover. Allow the system fluids to cool. surfaces within the valve block.
8-48 31211015 6036, 6042, 8042, 10042, 10054

Hydraulic Section
Note: ALWAYS replace seals, o-rings, gaskets, etc., with new 8.8.10 Extend Lockout Valve (10054 only)
seals and o-rings with clean hydraulic oil. 5
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.
c. Outrigger Valve Installation

1. Insert the previously used bolts through the bottom of
the outrigger valve and loosely attach the flange nuts to
the carriage bolts.
2. Position the outrigger valve so that the heads of the
carriage bolts go through the slots in the frame. Tighten
the flange nuts.
3. Connect all the previously labeled hydraulic hoses, MH6190
fittings, solenoid wire terminal leads, etc., to the
outrigger valve. Model 10054 has an extend lockout valve (5) which prevents
4. Check the routing of all hoses and wiring for sharp the boom from being extended beyond 42 feet unless the
bends or interference with any rotating members, and outriggers are lowered onto firm terrain. Once the outriggers
install tie wraps and/or protective conduit as required. are lowered, pressure switches located on each outrigger
Tighten all hose clamps. cylinder close and energize the solenoid on the boom extend
lockout valve. The boom can then be fully extended.
5. Properly connect the battery. Refer to Section 9.8,
“Battery”, for procedure. a. Extend Lockout Valve Removal
7. Start the engine and run at approximately the transmission in (N) NEUTRAL, engage the park brake
1/3 - 1/2 throttle for about one minute without moving and shut the engine OFF.
8. Inspect for leaks and check the level of the hydraulic switch and the steering wheel, stating that the machine
fluid in the reservoir. Shut the engine OFF. should not be operated.
Note: Check for leaks and repair as required 3. Temporarily block up or support the raised boom.
before continuing. Add hydraulic fluid to the reservoir 4. Open the engine cover. Allow the system fluids to cool.
as needed.
9. Wipe up any hydraulic fluid spillage in, on, near and “Battery”, for procedure.
7. Label, disconnect and cap hydraulic hoses and electrical
11. Close and secure the engine cover. plugs connected to extend lockout valve.
8. Remove nut and bolt securing extend lockout valve to
the frame. Remove the valve from the machine.
6036, 6042, 8042, 10042, 10054 31211015 8-49

Hydraulic Section
b. Extend Lockout Valve Disassembly, Cleaning, 4. Check the routing of all hoses and wiring for sharp
Inspection and Assembly bends or interference with any rotating members, and
Tighten all hose clamps.
7
7. Start the engine and run at approximately
1/3 - 1/2 throttle for about one minute without moving
6
8. 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.
MAQ1410
Add hydraulic fluid to reservoir as needed.
1. Secure the extend lockout valve assembly in a suitable 9. Wipe up any hydraulic fluid spillage in, on, near and
bench vise if possible. Remove the solenoid nut, coil around the machine, work area and tools.
and cartridge (6) from the valve. Remove the pressure 10. Install the transmission covers.
sense valve (7) from the valve block. 11. Close and secure the engine cover.
2. Clean all components with a suitable cleaner
before inspection. d. Extend Lockout Valve Test
3. Inspect the solenoid cartridge for proper operation. Conduct a test of the extend lockout valve.
Check by shifting the spool to ensure that it is
1. Park the machine on a firm, level surface.
functioning properly. Check the spring is intact. Inspect
the cartridge interior for contamination. 2. With the boom fully retracted and lowered, lower
the outriggers.
4. Inspect internal passageways and the extend lockout
valve overall for wear, damage, etc. If inner surfaces of 3. Extend the boom to 54 ft. The boom should extend fully
the component DO NOT display an ultra-smooth, and should not stop at 42 ft.
polished finish, or are damaged in any way, replace the
extend lockout valve. Often, dirty hydraulic fluid causes
5. Install the solenoid valve.
6. Install the pressure sensing valve. Torque to
65 lb-ft (88 Nm).
c. Extend Lockout Valve Installation

1. Place the extend lockout valve into position on the
mounting plate on the machine frame.
2. Install bolt and nut securing valve to frame.
3. Connect all the previously labeled hydraulic hoses,
fittings, solenoid wire terminal leads, etc., to the extend
lockout valve.
8-50 31211015 6036, 6042, 8042, 10042, 10054

Hydraulic Section
8.9 HYDRAULIC CYLINDERS 2. Clamp the barrel end of the cylinder in a soft-jawed vise
or other acceptable holding equipment if possible.
8.9.1 General Cylinder Instructions
a. Cylinder Removal
WARNING
Significant pressure may be trapped inside the cylinder.
1. Remove any attachment from the machine. Park the Exercise caution when removing a counterbalance valve
machine on a firm level surface and fully retract the or a pilot-operated check valve from a cylinder.
boom. Allow sufficient work space around the hydraulic
cylinder being removed. Support the boom if the Note: Avoid using excessive force when clamping the cylinder
lift/lower cylinder is being removed. Place the in a vise. Apply only enough force to hold the cylinder securely.
transmission in (N) NEUTRAL, engage the park brake, Excessive force can damage the cylinder tube.
shut the engine OFF and chock wheels. 3. If applicable, remove the counterbalance valve from the
2. Place a Do Not Operate Tag on both the ignition key side of the cylinder barrel.
switch and the steering wheel, stating that the machine Note: DO NOT tamper with or attempt to adjust the
should not be operated. counterbalance valve cartridge. If adjustment or replacement is
3. Open the engine cover. Allow the system fluids to cool. necessary, replace the counterbalance valve with a new part.
4. Label, disconnect and cap or plug hydraulic hoses in 4. Extend the rod as required to allow access to the base of
relation to the cylinder. the cylinder.
5. Attach a suitable sling to an appropriate lifting device Note: Protect the finish of the rod at all times. Damage to the
and to the cylinder. Make sure the device used can surface of the rod can cause seal failure.
actually support the cylinder. 5. Using a pin spanner wrench, unscrew the head gland
from the tube. A considerable amount of force will be
6. Remove the lock bolt and/or any retaining clips
needed to remove the head gland. Carefully slide the
securing the cylinder pins. Remove the cylinder pins. head gland down along the rod toward the rod eye and
7. Remove the cylinder. piston, away from the cylinder barrel.
8. Wipe up any hydraulic fluid spillage in, on, near and Note: When sliding the rod and piston assembly out of the
around the machine, work area and tools. barrel, prevent the threaded end of the barrel from damaging
the piston. Keep the rod centered within the barrel to help
b. Cylinder Disassembly prevent binding.
6. Carefully pull the rod assembly along with the head
1. Clean the cylinder with a suitable cleaner before
gland out of the cylinder barrel.
disassembly. Remove all dirt, debris and grease from the
cylinder. 7. 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.
TYPICAL TILT CYLINDER 8. Remove the set screw from the piston head.
9. Remove the lock nut from the piston rod.
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 threads and other parts, which must be
MAQ2060 removed by brushing with a soft brass wire brush prior to
reassembly.
6036, 6042, 8042, 10042, 10054 31211015 8-51

Hydraulic Section
10. Remove the piston head from the rod and carefully slide Note: Protect the finish on the cylinder rod at all times.
the head gland off the end of the rod. Damage to the surface of the rod can cause seal failure.
11. Remove all seals, back-up rings and o-rings from piston 4. Lubricate and slide the head gland over the cylinder
head and all seals, back-up rings and o-rings from the rod. Install the piston head on to the end of the cylinder
head gland. rod. Loctite® 243TM and install the set screw in the piston
Note: The head gland bearing will need to be inspected to head. Refer to Section 8.9.4, “Cylinder Torque
determine if replacement is necessary. Specifications”, for torque specifications for the piston
head and the set screw.
DO NOT attempt to salvage cylinder seals, sealing rings or
o-rings. ALWAYS use a new, complete seal kit when Note: Avoid using excess force when clamping the cylinder
rebuilding hydraulic components. Consult the parts catalog barrel in a vise. Apply only enough force to hold the cylinder
for ordering information. barrel securely. Excessive force can damage the cylinder barrel.
5. Place the cylinder barrel in a soft-jawed vise or other
c. Cylinder Cleaning Instructions acceptable holding devise.
1. Discard all seals, back-up rings and o-rings. Replace with Note: When sliding the rod and piston assembly into the
new items from seal kit to ensure proper cylinder cylinder barrel, prevent the threaded end of the cylinder barrel
function. from damaging the piston head. Keep the cylinder rod centered
2. Clean all metal parts with an approved cleaning solvent within the barrel to prevent binding.
such as trichlorethylene. Carefully clean cavities, 6. Carefully insert the cylinder rod assembly into the
grooves, threads, etc. cylinder barrel.
Note: If a white powdery residue is present on threads or parts, 7. Screw the head gland into the cylinder barrel and
it can be removed by using a soft brass wire brush. Wipe clean tighten with a spanner wrench. Refer to Section 8.9.4,
with Loctite Cleaner prior to reassembly. “Cylinder Torque Specifications”, for torque
specifications for the head gland.
d. Cylinder Inspection 8. If applicable, install new counter balance valve into
1. Inspect internal surfaces and all parts for wear, damage, block on the cylinder barrel.
etc. If the inner surface of the cylinder barrel does not
display a smooth finish, or is scored or damaged in any f. Cylinder Installation
way, replace the barrel.
1. Grease the bushings at the ends of the hydraulic
2. Remove light scratches on the piston, head gland, rod cylinder. Using an appropriate sling, lift the cylinder into
with a 400 - 600 grit emery cloth. Use the emery cloth in it’s mounting position.
a rotary motion to polish out and blend the scratch(es)
into the surrounding surface. 2. Align cylinder bushing and install pin, lock bolt or
retaining clip.
3. Proper honing is required to smooth the inner surface
of the cylinder barrel. 3. Connect the hydraulic hoses in relation to the labels or
markings made during removal.
4. Check the piston rod assembly for run-out. If the rod is
bent, it must be replaced. 4. Before starting the machine, check fluid level of the
hydraulic fluid reservoir and if necessary fill to full mark.
5. Inspect rod eye bushing and replace if worn or
damaged. 5. Start the machine and run at low idle for about one
minute. Slowly activate hydraulic cylinder function in
both directions allowing the cylinder to fill with
e. Cylinder Assembly Instructions
hydraulic oil.
1. Use the proper tools for specific installation tasks. Clean 6. Inspect for leaks and check level of hydraulic fluid in
tools are required for installation. reservoir. Add hydraulic fluid if needed. Shut the engine
2. Install new seals, back-up rings and o-rings on the OFF.
piston and new seals, back-up rings, o-rings and 7. Wipe up any hydraulic fluid spillage in, on, near and
bearing on the head gland. around the machine, work area and tools.
Note: The extend/retract cylinder has a spacer that MUST be 8. Close and secure the engine cover.
installed over the rod AFTER the head gland 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.
8-52 31211015 6036, 6042, 8042, 10042, 10054

Hydraulic Section
8.9.2 Cylinder Pressure Checking

Attach a digital or 4000 psi (276 bar) gauge to test port on
hydraulic pump to check system pressure. For more
information, refer Section 8.5.1, “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.
8.9.3 Steering Cylinders

The steer cylinder is attached to each axle center housing.
The steer cylinder assembly can be found in Section 5.3,
“Axle Assemblies”. The steer cylinder is covered in the
appropriate manufacturer’s axle literature.
STEERING CYLINDER
AXLE CENTER SECTION

MAQ2070
6036, 6042, 8042, 10042, 10054 31211015 8-53

Hydraulic Section
8.9.4 Cylinder Torque Specifications
a. Lift/Lower Cylinder
Model Head Piston Piston Lock Nut Valve Set Screw

295lb-ft 966 lb-ft 33 - 37 lb-ft 7.4 lb-ft
6036, 6042 NA
(400 Nm) (1310 Nm) (45 - 50 Nm) (10 Nm)
8042, 10042, 300 - 400 lb-ft 1750 - 2000 lb-ft 30 - 35 lb-ft 10 - 26 lb-ft
NA
10054 (407 - 542 Nm) (2372 - 2556 Nm) (41 - 47 Nm) (13 - 35 Nm)
b. Extend/Retract Cylinder
Model Head Piston Valve Set Screw

300 - 400 lb-ft 330 - 390 lb-ft 40 - 50 lb-ft 9 - 11 lb-ft
6036
(407 - 542 Nm) (447 - 529 Nm) (54 - 67 Nm) (12 - 15 Nm)
300-400 lb-ft 330-390 lb-ft 40 - 50 lb-ft 9 - 11 lb-ft
6042
(407-542 Nm) (447-529 Nm) (54 - 67 Nm) (12 - 15 Nm)
8042, 10042, 10054
(407 - 542 Nm) (529 - 624 Nm) (203 - 217 Nm) (12 - 15 Nm)
c. Tilt Cylinder
Model Head Piston Piston Locknut Valve Set Screw

6036, 6042 NA
(407-542 Nm) (325 - 380 Nm) (41 - 47 Nm) (12 - 15 Nm)
8042, 10042, 500 - 600 lb-ft 1850 - 2000 lb-ft 30 - 35 lb-ft
NA N/A
10054 (678-813 Nm) (2508 - 2712 Nm) (41 - 47 Nm)
d. Frame Level Cylinder
Head Piston Locknut Valve Plug

(407 - 542 Nm) (1491 - 1695 Nm) (47 - 54 Nm) (13 - 16 Nm)
e. Stabil-TRAK Cylinder
Pressure Reducing/PO
Head Piston Locknut Check Valve Set Screw Solenoid Coil
Check Valve
300 - 350 lb-ft 1175 - 1400 lb-ft 20 - 25 lb-ft 3 - 4 lb-ft 35 - 40 lb-ft 25 - 30 lb-ft
(407 - 475 Nm) (1593 - 1898 Nm) (27 - 34 Nm) (4 - 5 Nm) (47 - 54 Nm) (34 - 41 Nm)
300 - 350 lb-ft 1175 - 1400 lb-ft 20 - 25 lb-ft 3 - 4 lb-ft 35 - 40 lb-ft 25 - 30 lb-ft
(407 - 475 Nm) (1593 - 1898 Nm) (27 - 34 Nm) (4 - 5 Nm) (47 - 54 Nm) (34 - 41 Nm)
8-54 31211015 6036, 6042, 8042, 10042, 10054

Hydraulic Section
f. Compensation Cylinder
Model Head Locknut Valve Set Screw

6036, 6042
(339 - 474 Nm) (881 - 949 Nm) (40 - 47 Nm) (4 - 5 Nm)
8042, 10042, 300 - 400 lb-ft 900 - 1050 lb-ft
NA
10054 (407 - 542 Nm) (1220 - 1424 Nm)
g. Swing Carriage Cylinder (If Equipped)
Model Piston Head Set Screw Valves

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

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

10042, 10054 250 - 350 lb-ft 1650 - 1800 lb-ft 30 - 35 lb-ft
(339 - 474 Nm) (2237 - 2440 Nm) (41 - 47 Nm)
6036, 6042, 8042, 10042, 10054 31211015 8-55

Hydraulic Section
8-56 31211015 6036, 6042, 8042, 10042, 10054

Section 9
Electrical System
Contents

9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.1.1 General Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4.1 Engine Compartment Fuse and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4.2 Cab Harness Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.5 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.5.1 Cab Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.5.2 Chassis - Engine Schematic (85 hp (63 kW), 110 hp (82 kW) if equipped for ULS) 9-8
9.5.3 Chassis - Engine Schematic (85 hp (63 kW), 110 hp (82 kW) if equipped for LS) 9-9
9.5.4 Chassis - Engine Schematic (74 hp (55 kW) if equipped) . . . . . . . . . . . . . . . . . . . . . 9-10
9.5.5 Cab O/R Option Schematic (10042 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.5.6 Cab O/R Option Schematic (10054 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
9.5.7 HVAC Option Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
9.5.8 Road Light Option Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
9.5.9 Worklights/Beacon Option Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
9.5.10 Telematics Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
9.6 Dielectric Grease Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
9.6.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
9.6.2 Exclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
9.7 Engine Start Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
9.7.1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
9.8 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
9.8.1 Battery Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
9.8.2 Battery Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
9.8.3 Battery Disconnect/Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
9.9 Charging Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
9.9.1 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
9.10 Window Wiper/Washer Windshield Wiper Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
9.10.1 Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
9.10.2 Skylight Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
9.10.3 Windshield Washer Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
9.11 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
9.11.1 Cab Heater Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
6036, 6042, 8042, 10042, 10054 31211015 9-1

Electrical System
9.12 Solenoids, Sensors and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27

9.12.1 Coolant Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
9.12.2 Transmission Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
9.12.3 Transmission Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
9.12.4 Service Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
9.12.5 Boom Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
9.12.6 Boom Extend Interlock Sensor (10054 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
9.12.7 Outrigger Pressure Switches (10054 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
9.13 Display Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
9.14 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
9.14.1 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
9.14.2 Dash Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35
9.15 Machine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
9.15.1 Machine Data Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
9.15.2 Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
9.15.3 Mobile Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
9.15.4 Analyzer Software Version P1.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
9.16 Analyzer Software Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
9.16.1 Access Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
9.16.2 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
9.16.3 Machine Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
9.16.4 Personalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41
9.16.5 Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
9.17 Telematics Gateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43
9.17.1 Telematics-Ready (TCU) Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44
9.17.2 Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44
9.17.3 Telematics Gateway Harness Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-45
9.18 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49
9.18.1 Fault Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49
9.18.2 Offboard Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49
9.19 Machine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-50
9.19.1 Help Comment (00X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-50
9.19.2 Power-Up (21x). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-50
9.19.3 Cabin Controls (23x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-50
9.19.4 Function Prevented (25x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-51
9.19.5 Output Drivers (33x). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-51
9.19.6 Engine (43x). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-52
9.19.7 Battery Supply (44x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-52
9.19.8 Communications (66x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-52
9.19.9 Hardware (99x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-53
9.20 Engine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-54
9-2 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
9.1 ELECTRICAL COMPONENT

TERMINOLOGY
To understand the safety, operation, and service information
presented in this section, it is necessary that the operator/
mechanic be familiar with the name and location of the
electrical components of the machine. The following
9.1.1 General Overview
COOLANT TEMPERATURE
SENSOR
ALTERNATOR DASH SWITCHES
CAB HEATER
CONTROLS
TRANSMISSION INSTRUMENT
TEMPERATURE PANEL
SENDER
STARTER PARK BRAKE

SWITCH
IGNITION
SWITCH
TRANSMISSION
SOLENOID SERVICE
VALVES BRAKE
SWITCH
ACCELERATOR
DIAGNOSTIC
PEDAL
LOCATION
BOOM ANGLE
BOOM EXTEND SENSOR
(FOUR SECTION BOOM SHOWN)
INTERLOCK SENSOR
(10054 ONLY)
MAQ0363
6036, 6042, 8042, 10042, 10054 31211015 9-3

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 Fuse and Relays
Starter relay (1), one 250 amp fuse (2) two 60 amp power
9.3 SAFETY INFORMATION module fuses (3) 150 amp relay for cold start grid heater (4)
and DEF System Power Module (4) are located inside engine
compartment in protective case next to battery.
WARNING
this manual.
5
2
3
4
MAQ1450
1
R1 R2 R3
2
R4 R5
MAQ4500
No. Amp Circuit

R1 35 Amp Starter Lockout Relay
R2 35 Amp DEF Heater Suction Relay
R3 35 Amp DEF Heater Diagnostic Relay
R4 35 Amp DEF Heater Pressure Relay
R5 35 Amp DEF Heater Supply Module Relay
1 15 Amp Supply Module Heater
2 15 Amp DEF Heater
9-4 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
9.4.2 Cab Harness Fuses and Relays
6036, 6042, 8042 & 10042
1 R1 R5
2
3 R2 R6
4
5 R3 R7
6
7 R4 R8
8 R9
D1
9 16
22 R10
10 17
D2
11 18
30
R13 12 19 R11
D3
13 20 R12
R14
30
14 BLANK
MAQ1461
23
10054
1 R1 R15
R5 24
BLANK
2
3 R2 R6 R16
4
5 R3 R7 R17
6
7 R4 R8 R18
8 R9 R19
D1
9 16 25
22
10 17 R10 R20
D2
11 18
30
R13 12 19 R11 R21

D3
13 20 R12
R14
30
14 BLANK R22
23 MAQ1561
6036, 6042, 8042, 10042, 10054 31211015 9-5

Electrical System
No. Amp Circuit No. Amp Circuit

1 20 Amp Hazard Lights R19 35 Amp Right Outrigger Lock Out
2 15 Amp Outriggers/Beacon R20 35 Amp Left Outrigger Lock Out
3 7.5 Amp Work Lights Relay R21 35 Amp Park Brake Interlock
4 10 Amp Boom Switch R22 35 Amp Boom Extension Lock Out
5 7.5 Amp Park Brake Disengage/Transmission 24 7.5 Amp Outrigger 1 (Mini-Fuse)
6 10 Amp Steering/Stabilizer 25 7.5 Amp Outrigger 2 (Mini-Fuse)
7 10 Amp Gauge Cluster/Park Brake Interlock
8 20 Amp Work Lights Relay
9 7.5 Amp AC Switch
10 20 Amp Heater Blower Motor
11 7.5 Amp Accessory Plug
12 10 Amp AC Relay
13 20 Amp Horn/Heater
14 5 Amp Alternator Excite
15 BLANK
16 10 Amp Diagnostic Battery
17 10 Amp Diagnostic Ignition
18 5 Amp ECM Key Switch
19 10 Amp Wipers
20 40 Amp Main
21 BLANK
22 30 Amp Work Lights (if equipped)
23 30 Amp Road Lights (if equipped)
R1 35 Amp Boom Switch (Removed on 6036)
R2 35 Amp Park Brake Switch
R3 35 Amp Neutral Relay
R4 35 Amp Back-Up Relay
R5 35 Amp Relay 2
R6 35 Amp Ground Fault Relay
R7 35 Amp HVAC Relay 1
R8 35 Amp HVAC Relay 2
R9 35 Amp Lights Relay (*Diode)
Stabilizer Lock Relay (*Diode)
R10 35 Amp
(Removed on 6036)
R11 35 Amp Ignition Relay (*Diode)
R12 BLANK
R13 35 Amp Work Lights (if equipped)
R14 35 Amp Road Lights (if equipped)
R15 BLANK
R16 35 Amp Stabilizer Interlock
R17 35 Amp Stabilizer Lockup
R18 35 Amp Boom Extend Interlock
9-6 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
9.5 ELECTRICAL SYSTEM SCHEMATICS
9.5.1 Cab Schematic
G
H
C
E
A
F
8
8
7
7
6
6
5
5
4
4
3
3
2
2
1
1
G
H
C
E
A
F
MAQ1590F
6036, 6042, 8042, 10042, 10054 31211015 9-7

6036, 6042, 8042, 10042, 10054 31211015 9-8
MAQ1600F
F
A
B
E
C
D
H
TILT VALVES ANTISTALL

/TEMP
/LEVEL
TILT DOWN TILT UP

FUEL SENDER
COOLANT LEVEL
TO CAB HARNESS ENG_BULK2_15F ENG_BULK1_15M
DRT NOx
120
SCR NOx
DEF QUALITY
SCR TEMP
2
1
CAN TERMINATION
DEF TANK H VLV
24 WAY OEM
DEF DOS INJ VLV
WIF SENSOR
HV551
Empty: 240
Full: 30
1
2
3
4
5
6
7
8
1
2
1
2
C5
C4
C3
C2
C1
B5
B4
B3
B2
B1
A5
A4
A3
A2
A1
C5
C4
C3
C2
C1
B5
B4
B3
B2
B1
A5
A4
A3
A2
A1
22
23
A
B
C
1
2
2
1
1
4
2
1
3
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
A
B
C
X73
X74
X555
X442
HV549
HV550
Hydraulic Temp Switch
X349
X524
X523
X522
X519
X548
X1055
EC517
EC516
EC292
2
1
Eliminated X327 (wire151) -
1
1
SN574
5 YEL (16)
41 WHT (16)
1
1
18 GRN (16)
8 GRN (16)
27C RED (12)

17 GRY (16)
47 ORN (16)
105(S4) GRN (16)

T87
T88
103(S3) BLU (16)

34 ORG (18)
6 GRN (16)
104(S1) YEL (16)

9 GRN (16)
102(S2) PNK (16)

158 WHT (16)
106 DBL (12)

28 WHT (16)
24A BLK (16)
ANTISTALL WHT (16)
31 ORN (16)
38 YEL (16)
27D RED (12)
HEST WHT (18)

150(S6) VIO (16)
TILT UP YEL (16)

TILT UP YEL (16)
ANTISTAL GND BLK (16)
35 BRN (16)
REGEN WHT (18)

10 TAN (16)
VLV GND BLK (16)

40 BLK (18)
101(S5) BRN (16)
AC COMP WHT (16)

AC COMP WHT (16)
TILT DOWN VIO (16)

TILT DOWN VIO (16)
CAN4 HI YEL (18)

CAN4 HI YEL (18)
CAN4 HI YEL (18)
CAN4 HI YEL (18)
CAN4 HI YEL (18)
ANTISTALL WHT (16)
VLV GND BLK (16)
CAN4 HI YEL (18)

BAT NEG BLK (18)
BAT NEG BLK (18)
BAT NEG BLK (18)
BAT NEG BLK (18)
KEY IGN ORG (18)

KEY IGN ORG (18)
KEY IGN ORG (18)
CAN4 LO GRN (18)

ELEVATE IDLE YEL (16)
CAN4 LO GRN (18)
CAN 4 LO GRN (18)

CAN 4 LO GRN (18)
CAN 4 LO GRN (18)
WIF SIG WHT (18)

WIF RET WHT (18)
KEY IGN ORG (18)
CAN4 LO GRN (18)

DEF VLV RET WHT (18)
COLNT LVL RTN BLK (18)
2A BLK (16)
EC302
COLNT LVL SPLY ORG (18)
COLNT LVL SIG WHT (18)
DEF DOS VLV HI WHT (18)

DEF TANK H VLV WHT (18)
DEF DOS VLV LO WHT (18)

17 GRY (16)
41 WHT (16)
VLV GND BLK (16)
A
SFV
2E BLK (18)
B
S1057
S1056
2C BLK (16)
B
8 GRN (16)
A
STM_CR
HV313
X329 S445
S527
BAT POS 1 RED (16)

S526
1
2 HV111
DEF HTR REL WHT (18) 2B BLK (16)
CAN4 LO GRN (18)
3 B
STEER MODE VALVE
STM_4
9 GRN (16)
4 A
34 ORG (18) 34 ORG (18)
KEY IGN 5
DEF SM TEMP WHT (18) S520
6 T316
DEF SMDEF
HTRSM
RLY
HTR
WHT
RLY
(16)
WHT (16) 18 GRN (16) TRANS TEMP SW
7 1
DEF SM SNSR 5V WHT (18)
8
2
2

9 T312
2G BLK (16)
10 1
TRANS GND
11
12 X52
WIF SIG WHT (18) 40 BLK (18)
13 A
LOCK_2F
14 B
15
DEF PRESS SNSR SIG WHT (18)
16
S 47
17 X54
47A WHT (18)
18 A
2M BLK (18) 4A-2F
19 B
1
2
3
4
20
S1
S525
X346
21
CAN1 H YEL (18)
22 X55
REGEN WHT (18) 47B WHT (18)
23 A
2N BLK (18) 4B-2F
24 B
BAT POS 2 RED (16)
25
BAT POS 3 RED (16) S 20
26
GND
27
BAT POS 5 RED (16) 2P BLK (18)
28 B
S528
12B-2F
S 20D
29 A
30 X56
STABILTRAK VALVES
S 28 28B WHT (18)

31
COLNT LVL RTN BLK (18) 28A WHT (18)
32 X53
AAP WHT (18)
5V SUP WHT (18)
CIT WHT (18)
SENS RET WHT (18)
33 A
2L BLK (18) 12A-2F
TBAP SENSOR
34 B
35
3
3
36
37
DEF HTR1 PRESS WHT (18)
38
S 20A
DEF HTR2 BFL WHT (18)

39
DEF HTR3 SUCT WHT (18)
S2
40
41
X347
42
1
2
3
4
AH330
43
44 A
158 WHT (16)
45
CAN1 LO GRN (18) 24A BLK (16)
GND
46
47 B
48
BAT NEG 1 BLK (16) X325
49
BAT NEG 2 BLK (16) 31 ORN (16)
50 A
BAT NEG 3 BLK (16) 2X BLK (16) BACK UP ALARM
51 B
BAT NEG 4 BLK (16)
52
DEF DOS VLV LO WHT (18)
53
DEF PUMP RET WHT (18)
CM2350 96 PIN CONN (J2)

54
35 BRN (16)
55 A
10 TAN (16)
56 B
DEF VLV RET WHT (18) 2T BLK (16)
57 C
BOOM ANGLE
S518
58 SN112
59
60
DEF PRES SNSR RET WHT (18) X4
61
S 20B
WIF RET WHT (18) 23 ORN (16) TO LOGIC HARNESS

62 B
4
4
49 RED (16)
63 A X462
64
ELEVATE IDLE YEL (16)
65
66
67
49 RED (16) GREEN WIRE GRN (16)
68 A A A
23 ORN (16) BLACK WIRE BLK (16)
69 B B B
2R BLK (16) WHITE WIRE WHT (16)
70 C C C
BOOM EXTEND
71 SN113 X601 X602

S GND
72
BAT NEG 5 BLK (16)
73
BOOM EXTEND
74
IAH REL SIG WHT (18) HARNESS
75
IAH REL RTN WHT (18)
76
DEF DOS VLV HI WHT (18)
77 T298
HTR PWR RED (2) 250A BUSSBAR
78 1
DEF PUMP SPLY WHT (18)
79
80
DEF VLV SIG WHT (18)
81
DEF TANK H VLV WHT (18)
82
STRT LKO REL WHT (18)
83
DEF HTER CRT MNTR WHT (18)
84
S1067
DEF HTR CRT MNTR WHT (18) GRID HTR PWR RED (2)
85 1
ENGINE
86 T299
87
88
89
5
5
90
S RTN
91 RL109-87
GRID HTR PWR RED (2) 87
92 1
IP1069
93 RL109-30
HTR PWR RED (2) 30
94 1
HEST WHT (18)
95 RL109-86
IAH REL SIG WHT (18) 86
96 1
GRID HTR RLY
RL109-85
OUTPUT RTN 2 BLK (18) OUTPUT RTN 2 BLK (18) 85
1
S1068
T350
CASE GND BLK (10)
1
S508
RL478-B+
BUSSBAR
1
RL478
FC1070 STRT ORN (16)
ECM BATT RED (12) 1
B 2Y BLK (16)
S509
RED ECM BATT - 2
ECM CASE GND

A
ECM PWR
30A
SF = 30A
NSF = 30A
START RELAY
161 RED (10)

C 1
BAT POS RED (16)
A
1
RL478_2
S1076
S510
X1094
2U-1 BLK (18)
6
6
A
TELE PWR-1 RED (18)
S1102 B
CNH1 YEL (18)
C
CNL1 GRN (18)
S511
D
CANBUS
S1103
E
F
TELEMATICS
G
H
5A
IP1088
J
HTR PWR RED (16) X1087
46 TELE PWR RED (18)
HTR PWR RED (16) 1
F2
42 S1096 2U BLK (18)
BAT POS RED (16) 2
45 S1095 5 YEL/RED (18)
HEATER RED (16) 3
F1
41
HEATER RED (16) 4
S 102
85
24
S 101
S 105
TELEMATICS
DEF SM HTR RLY WHT (16)
86
15
SM HR WHT (16)
87
16
R5
HEATER RED (16)
30
23
S1071
S499
87a
20 EC291-B-
DEF HTR REL WHT (16) STRT GND BLK (2/0)
85
12 S501 1
HTR PWR RED (16) S502
86
3 EC291
HTR DIAG WHT (16) 161 RED (10)
87
4 1
R4
HTR PWR RED (16)
ENGINE
30
11 EC291-B+
STRT PWR RED (2/0)
87a
8 1 M
DEF HTR REL WHT (16)
85
34
HTR PWR RED (16) ALT PWR RED (4)
86
7
7
25 1
HTR DIAG WHT (16)
FUSE RELAY MODULE

87
26
R3
HTR PWR RED (16)
30
33
87a
30 CANH1-1 YEL (18) 120
S 103
DEF HTR REL WHT (16) A
85
22 CANL-1 GRN (18)
HTR PWR RED (16) B
86
S 104
13
DEF HTR3 SUCT WHT (16) C CAN TERMINATION
87
14
R2
HTR PWR RED (16)
30
21 X44
87a
18
OUTPUT RTN 1 BLK (18)
85
10
STRT LKO REL WHT (18)
86
1
87
2
R1
106 DBL (12)
30
9
200A
STRT ORN (16)
87a
6
X554
EC513
S 150
WHT DEDF HTR CRT MNTR -
1
27B RED (12)

IP1062
HTR DIAG 1 WHT (16)

2
120 OHM
X324
5 YEL (16)
1
1
EC514
1
HTR DIAG 2 WHT (16) ALT PWR RED (4)
T1036
2 S507 1
2J BLK (18)
RELAY2-30 RED (12)

2H BLK (18)
BLOCK GND BLK (10)
27F RED (12)

27B RED (12)
27F RED (12)
27D RED (12)
160 RED (12)

DEF PUMP SPLY WHT (18)
DEF VLV RET WHT (18)

DEF VLV SIG WHT (18)
BAT NEG BLK (18)
BLOCK GND BLK (10)
DEF SM TEMP WHT (18)

DEF PUMP RET WHT (18)
DEF PRES SNSR RET WHT (18)
STRT GND BLK (2/0)
SM HR WHT (16)
DEF PRESS SNSR SIG WHT (18)
DEF SM SNSR 5V WHT (18)
FRAME GND BLK (2/0)
FRAME GND BLK (2/0)
8
150B(S6) VIO (18)
8
ALTERNATOR
STRT PWR RED (2/0)

2D BLK (16)
1
CASE GND BLK (10)
RELAY2-30 RED (12)

EC515
101B(S5) BRN (18)
N/A
N/A
101A BRN (16)
105B(S5) GRN (18)
150A(S6) VIO (18)
2DD BLK (16)

104B(S1) YEL (18)
105A(S4) GRN (16)

103B(S3) BLU (18)
102 PNK (16)

104A YEL (16)
103A BLU (16)
ECM GND 5 BLK (12)

12OB(S2) PNK (18)
27C RED (12)

1
160 RED (12)

T352
1
DEF HTR3 SUCT WHT (16)
RED ECM BATT -

2
X2
T444
T284
T351
X301
X300
D305
D304
T328
X495
1
2
3
1
4
9
8
7
6
5
4
3
2
1
1
1
1
1
1
1
1
1
1
1
1
7
6
5
4
1
2
3
7
3
2
1
4
5
6
BT512-
F
F
E
B
A
E
B
A
D
C
D
C
BT512+
11
12
10
T58
T61
GND
TO CAB HARNESS LOWER UPPER
PFM
12V BATTERY
60A
60A
SUPPLY MODULE
ENG_BULK3_IN
TRANSMISSION
ENG BLOCK
FRAME GND
VP1 VP2
PWR BUSS
A
B
E
C
D
H
G
Chassis - Engine Schematic (85 hp (63 kW), 110 hp (82 kW) if equipped for ULS) 9.5.2
Electrical System
1 2 3 4 5 6
NSF = 30A
7 8
9.5.3
STARTER
BOOM ANGLE BOOM EXTEND SF = 30A
GRID HTR GRID HTR RLY ENGINE
STEER MODE VALVE STABILTRAK VALVES START RELAY
ENGINE
SFV
M
STM_CR STM_4
ALTERNATOR
TELEMATICS
BE_3F
1
2
3
4
250ABUSSBAR
BOOM_3F
87
30
86
85
BACK UP ALARM
12B-2F
12A-2F
4A-2F
4B-2F
X1093
LOCK_2F
TO LOGIC HARNESS
X462
TRANS TEMP SW
TRANS GND
A
B
B
A
B
A
1
1
A
B
A
B
A
B
B
A
A
B
A
B
A
B
A
B
C
B
A
A
B
C
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
H H
X4
X325
AH330
X52
X54
X55
X56
X53
T316
T319
X324
T312
T298
T299
X602
EC302
RL478
EC291-B+
HV313
HV111
SN112
EC291
RL478-Y
RL109-85
RL109-87
RL109-30
RL109-86
EC291-B-
RL478-B+
C
A RL478-R
49 RED (16)
RL478_2
23 ORN (16)
41 WHT (16)
24A BLK (16)
5 YEL (16)
161 RED (10)
2M BLK (16)
2E BLK (16)
2L BLK (16)
18 GRN (16)
2X BLK (16)
2B BLK (16)
2K BLK (16)
8 GRN (16)
2T BLK (16)
2C BLK (16)
47A BLK (16)
2G BLK (16)
2N BLK (16)
2P BLK (16)
158 WHT (16)
9 GRN (16)
BUSSBAR
5 YEL/RED (18)
2U BLK (18)
2Y BLK (16)
28B BLK (16)

28A BLK (16)
31 ORN (16)
47B BLK (16)

BATT POS BLK (14)
40 BLK (16)
35 BRN (16)
10 TAN (16)
GRID HTR PWR RED (2)
ALT PWR RED (4)
ALT PWR RED (4)
HTR PWR RED (2)

HTR PWR RED (2)
STRT GND BLK (Feb-00)
STRT PWR RED (Feb-00)
STRT (87A) ORG (16)
BLACK WIRE BLK (16)

WHITE WIRE WHT (16)
GREEN WIRE GRN (16)

BOOM EXTEND
S 28
IAH REL SIG WHT (16)
HARNESS # 7112592
BATT POS RED (10)
OUTPUT RTN 2 BLK (16)

161 RED (10)
X74
6036, 6042, 8042, 10042, 10054

40 BLK (16) 2K BLK (16) S 20D 5 YEL (16)
S1102 120 OHM
5 YEL (16)
A1
X601
A
B
C
41 WHT (16) 2AA ORN (16) IP1062
A2
A
B
C
47 ORN (16) 200A
A3
201 BLU LRC ENABLE (16)
A4 S 47 S1067 6
SN113
158 WHT (16) S1068
A5 5
18 GRN (16)
B1 4
24A BLK (16) 104B(S1) YEL (18)
B2 5A 1
G 28 WHT (16) 12OB(S2) PNK (18) G
B3 IP1069 2
49 RED (16)
23 ORN (16)
35 BRN (16) IP1094 103B(S3) BLU (18)
B4 3
2R BLK (16)
38 YEL (16) 2J BLK (18)
B5 7
6 GRN (16) S 104
C1 X300
ENG_BULK1_15M
8 GRN (16)
C2
9 GRN (16)
C3
UPPER
10 TAN (16)
C4 3
20D BLK (12)

ANTISTALL WHT (16) S 102
C5 2
S 103
1
105B(S5) GRN (18)
4
101B(S5) BRN (18)
5
2U BLK (18) S 101 150B(S6) VIO (18)
TRANSMISSION
S 20B 6
ANTISTALL WHT (16) 2E BLK (16) 20B BLK (12) 2H BLK (18)
LOWER
1 7
ANTISTAL GND BLK (16) 20C BLK (12)
2 X301
S 20
HV551 S 20A S 105
5.5 OHM
S 150
ANTISTALL
150(S6) VIO (16) 150A(S6) VIO (16)
A
105A(S4) GRN (16)
B
104A YEL (16)
C
2A BLK (16)
FUEL SENDER 1 D
VP2
1 T88 E
GENERIC 2D BLK (16)
F 2 F F
Full: 30 Ω 17 GRY (16)
SN574 1 D304
Empty: 240 Ω
T87
103A BLU (16)
A
101A BRN (16)
SN1084 B
2AA ORN (16) 102 PNK (16)
B C
VP1
AIR FLTR SW ORG (16)

A D
E
2DD BLK (16)
F
AIR FILTER
X73 D305
SWITCH 5 YEL (16)
A1
17 GRY (16)
A2 T351
AIR FLTR SW ORG (16) BLOCK GND BLK (10)
A3 1
27C RED (12) ENG BLOCK
A4
31 ORN (16) CASE GND BLK (10)
A5 T284
34 RED (0.75) ECM GND 5 BLK (12) GND
B1 1
106 (30) DBL (16)
B2
150(S6) VIO (16)
B3 S1071 2Y BLK (12) T58
B4 1
27D RED (12) 20E BLK (12)
B5
101(S5) BRN (16) FRAME GND BLK (Feb-00)
C1 1
E C2
102(S2) PNK (16) FRAME GND E
ENG_BULK2_15F
103(S3) BLU (16) FRAME GND BLK (Feb-00)
C3 1
104(S1) YEL (16)
C4
105(S4) GRN (16)
C5
STRT GND BLK (Feb-00)

1
S445
HV550
VLV GND BLK (16) BLOCK GND BLK (10)
2 1 1
TILT UP YEL (16)
T352 BT512-
TILT UP
1
3.5 OHM
1000CCA
ECM BATT RED (12)

1
12V BATTERY
HV549 BT512+
VLV GND BLK (16) S RTN STRT PWR RED (Feb-00)
2 1
TILT VALVES
TILT DOWN VIO (16)
1
3.5 OHM
TILT DOWN
27D RED (12)
31211015
1 T61
AC COMP WHT (16) 27F RED (12)
1
27B RED (12) 60A
X442 1 T1036
27C RED (12)
1
8
160 RED (12) PFM
T328
D 60A D
7 T444
RELAY2-30 RED (12)
PWR BUSS
6 1
5
AC COMP WHT (16)
4
VLV GND BLK (16)
3
TILT DOWN VIO (16)
2
TILT UP YEL (16)
1
TO CAB HARNESS
X555
EC292
COLNT LVL RTN BLK (0.75)
C
COLNT LVL SIG WHT (0.75)
B
COLNT LVL SPLY ORG (0.75)
A
27B RED (12)
COOLANT LEVEL
4
27F RED (12)
3
RELAY2-30 RED (12)
2
160 RED (12)
1
X2
C C
TO CAB HARNESS
ENG_BULK3_IN
STRT LKO REL (86) WHT (18)
S1086
S1085
S 117
106 (30) DBL (16)
STRT (87A) ORG (16)
OUTPUT RTN 1 (85) BLK (18)

B S GND B
WIF RET WHT (0.75)

ECM BATT RED (12)
2
2
5
3
1
4
ECM BATT RED (12)

RL1083
WIF SENSOR 1
WIF SIG WHT (0.75)
X349
86
85
30
87
87a
S1096
2
1
FC1070
Chassis - Engine Schematic (85 hp (63 kW), 110 hp (82 kW) if equipped for LS)
STARTER LOCKOUT
30A GENERIC
GENERIC
GENERIC
6 CAN LO GRN (0.75)
34 RED (0.75)
IAH REL SIG WHT (0.75)
IAH REL RTN WHT (0.75)
WIF RET WHT (0.75)
WIF SIG WHT (0.75)
COLNT LVL SIG WHT (0.75)
COLNT LVL RTN BLK (0.75)
X44
38 CAN HI YEL (0.75)
BAT NEG 2 BLK (2.5)

BAT POS 2 RED (2.5)
BAT POS 1 RED (2.5)

CASE GND BLK (10)
BAT POS 3 RED (2.5)

BAT NEG 3 BLK (2.5)
BAT NEG 1 BLK (2.5)

A CAN TERMINATION A
C C
STRT LKO REL (86A) WHT (0.75)

COLNT LVL SPLY ORG (0.75)
B B
A A
T350
X329
120 Ω
1
2
3
4
5
6
7
8
9
1
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
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
LRC ECM CONN (J2) ECM CASE GND

Electrical System
1 2 3 4 5 6 7 8
MAQ1660H
9-9
6036, 6042, 8042, 10042, 10054 31211015 9-10
MAQ2080D
F
A
B
E
C
D
H
5.5 OHM
TILT VALVES ANTISTALL
3.5 OHM 3.5 OHM
GENERIC
TILT DOWN TILT UP

FUEL SENDER
COOLANT LEVEL
TO CAB HARNESS ENG_BULK2_15F ENG_BULK1_15M
2
1
WIF SENSOR
HV551
Empty: 240
Full: 30
1
2
3
4
5
6
7
8
1
2
1
2
C5
C4
C3
C2
C1
B5
B4
B3
B2
B1
A5
A4
A3
A2
A1
C5
C4
C3
C2
C1
B5
B4
B3
B2
B1
A5
A4
A3
A2
A1
1
X74
1
2
A
B
C
X73
X555
X442
HV549
HV550
Hydraulic Temp Switch
X349
EC292
2
1
Eliminated X327 (wire151) -

SN574
1
1
5 YEL (16)
41 WHT (16)
24A BLK (16)
1
1
18 GRN (16)
8 GRN (16)
27C RED (12)

17 GRY (16)
47 ORN (16)
105(S4) GRN (16)

103(S3) BLU (16)
34 ORG (18)
6 GRN (16)
104(S1) YEL (16)

T87
T88
9 GRN (16)
102(S2) PNK (16)

158 WHT (16)
28 WHT (16)
ANTISTALL WHT (16)

201 BLU (16)
31 ORN (16)
38 YEL (16)
27D RED (12)

106 (30) DBL (16)
150(S6) VIO (16)
TILT UP YEL (16)

TILT UP YEL (16)
ANTISTAL GND BLK (16)
35 BRN (16)
10 TAN (16)
VLV GND BLK (16)

40 BLK (18)
101(S5) BRN (16)
AC COMP WHT (16)

AC COMP WHT (16)
TILT DOWN VIO (16)

TILT DOWN VIO (16)
ANTISTALL WHT (16)
VLV GND BLK (16)
WIF SIG WHT (18)

WIF RET WHT (18)
COLNT LVL RTN BLK (18)
2A BLK (16)
EC302
17 GRY (16)
41 WHT (16)
VLV GND BLK (16)
A
SFV
2E BLK (18)
B
HV313
2C BLK (16)
B
8 GRN (16)
A
STM_CR
X329
BAT POS 1 RED (16)
1
2 S445 HV111
2B BLK (16)
3 B
STEER MODE VALVE
STM_4
9 GRN (16)
4 A
34 ORG (18)
5
6 T316
18 GRN (16) TRANS TEMP SW
7 1
8
2
2
9 T312
2G BLK (16)
10 1
TRANS GND
11
12 X52
WIF SIG WHT (18) 40 BLK (18)
13 A
LOCK_2F
14 B
15
16
S 47
17 X54
47A WHT (18)
18 A
2M BLK (18) 4A-2F
19 B
S1
20
21
CAN1 H YEL (18)
22 X55
47B WHT (18)
23 A
2N BLK (18) 4B-2F
24 B
BAT POS 2 RED (16)
25
26
BAT POS 4 RED (16) S 117 X56
GND
27
BAT POS 5 RED (16) 2P BLK (18)
28 B
12B-2F
S 20D
29 A
30 S 28
STABILTRAK VALVES
28B WHT (18)

1
2
3
4
31
COLNT LVL RTN BLK (18) 28A WHT (18)
X346
32 X53
33 A
2L BLK (18) 12A-2F
34 B
3 35
3
36
37
38
S 20A
39
S2
40
41
42
AH330
43
AAP WHT (18)
5V SUP WHT (18)
CIT WHT (18)
SENS RET WHT (18)
44 A
2U BLK (18)
158 WHT (16)

TBAP SENSOR
45
CAN1 LO GRN (18) 24A BLK (16)
GND
46
47 B
48
BAT NEG 1 BLK (16) X325
49
BAT NEG 2 BLK (16) 31 ORN (16)
50 A
BAT NEG 3 BLK (16) 2X BLK (16) BACK UP ALARM
51 B
BAT NEG 4 BLK (16)
52
X347
53 BOOM_3F
1
2
3
4
SN112
CM2350 96 PIN CONN (J2)

54
35 BRN (16)
55 A
10 TAN (16)
56 B
2T BLK (16)
57 C
BOOM ANGLE
58
59
60
61 X4
S 20B
WIF RET WHT (18) 23 ORN (16) TO LOGIC HARNESS

62 B
49 RED (16)
4
4
63 A
X462
64
65
66 BE_3F
67 SN113 X601 X602
49 RED (16) GREEN WIRE GRN (16)
68 A A A
23 ORN (16) BLACK WIRE BLK (16)
69 B B B
2R BLK (16) WHITE WIRE WHT (16)
70 C C C
BOOM EXTEND
71 S GND
72
BAT NEG 5 BLK (16)
73
BOOM EXTEND
74
IAH REL SIG WHT (18) HARNESS
75
IAH REL RTN WHT (18)
76
77 T298 250ABUSSBAR
HTR PWR RED (2) 250A
78 1
79
80
81
82 STRT LKO REL (86) WHT (18)
83
84 T299
S1067
85 1
ENGINE
86
GRID HTR
20E BLK (12)
87
88
89
5
5
90
S RTN
20C BLK (12)
91 RL109-87
GRID HTR PWR RED (2) 87
92 1
IP1069
93 RL109-30
HTR PWR RED (2) 30
94 1
95 RL109-86
IAH REL SIG WHT (18) 86
96 1
GRID HTR RLY
RL109-85
OUTPUT RTN 2 BLK (18) 85
1
S1068
T350
CASE GND BLK (10)
1
BUSSBAR RL478-B+
1
RL478
FC1070 STRT (87A) ORG (16)
ECM BATT RED (12) 1
B 2Y BLK (16)
ECM BATT RED (12) 2
ECM CASE GND

A
ECM PWR
30A
SF = 30A
161 RED (10) RL478_2

START RELAY
C 1
BAT POS-1 RED (10)
A
1
S1092
S1095
S1094
X1090
2U-1 BLK (18)
A
TELE PWR-1 RED (18)
6
6
B
CNH1 YEL (18)
C
CNL1 GRN (18)
D
CANBUS
E
F
TELEMATICS
5A
IP1088
G
H
J
S1091
X1087
TELE PWR-3 RED (18)
1
2U BLK (18)
2
S1093 5 YEL/RED (18)
3
4
S 102
TELEMATICS
S 101
S 105
RL1089
S1071
2 EC291-B-
86 OUTPUT RTN 1 (85) BLK (18) STRT GND BLK (2/0)
5 1
85 STRT (87A) ORG (16)
3 EC291
87a 106 (30) DBL (16) 161 RED (10)
GENERIC
1 1
30
ENGINE
EC291-B+
STARTER
STARTER LOCKOUT
87 STRT PWR RED (2/0)
1 M
ALT PWR RED (4)
1
7
7
S 103
S 104
CANH1-1 YEL (18) 120

A
CNL1-1 GRN (18)
B
C CAN TERMINATION
X44
200A
S 150
IP1062
27B RED (12)

120 OHM
X324
5 YEL (16)
1
1
2Y BLK (10)
ALT PWR RED (4)
T1036
1
2J BLK (18)
RELAY2-30 RED (12)

2H BLK (18)
BLOCK GND BLK (10)
27F RED (12)

27B RED (12)
27F RED (12)
27D RED (12)
160 RED (12)

BLOCK GND BLK (10)
STRT GND BLK (2/0)

FRAME GND BLK (2/0)
FRAME GND BLK (2/0)
150B(S6) VIO (18)
ALTERNATOR
STRT PWR RED (2/0)

2D BLK (16)
1
CASE GND BLK (10)
RELAY2-30 RED (12)

101B(S5) BRN (18)
101A BRN (16)
8
8
105B(S5) GRN (18)
150A(S6) VIO (18)
2DD BLK (16)

104B(S1) YEL (16)
105A(S4) GRN (16)

103B(S3) BLU (18)
102 PNK (16)

104A YEL (16)
103A BLU (16)
ECM GND 5 BLK (12)

12OB(S2) PNK (16)
ECM BATT RED (12)
27C RED (12)

160 RED (12)
T352
1
X2
T58
T444
T284
T351
T61
X301
D304
X300
D305
T328
BT512+
1
2
3
4
1
1
1
1
1
1
1
1
1
1
1
1
7
6
5
4
1
2
3
7
3
2
1
4
5
6
BT512-
F
F
E
B
A
E
B
A
D
C
D
C
LOWER UPPER
GND
TO CAB HARNESS
PFM
12V BATTERY
60A
60A
ENG_BULK3_IN 1000CCA TRANSMISSION
ENG BLOCK
FRAME GND
VP1 VP2
PWR BUSS
A
B
E
C
D
H
G
Chassis - Engine Schematic (74 hp (55 kW) if equipped) 9.5.4
Electrical System
1 2 3 4 5 6 7 8 9.5.5
H H
LEFT O/R SWITCH RIGHT O/R SWITCH
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
SW610
SW611
6036, 6042, 8042, 10042, 10054

60A YEL/GRN (16)
60C YEL/GRN (16)

G G
62 VIO/WHT (16)
64 GRY/VIO (16)
63 BRN/YEL (16)
61 RED/GRY (16)
60C YEL/GRN (16)

60A YEL/GRN (16)
F F
SPL 60
62 VIO/WHT (16)
1
2F BLK (16)
2
HV605
60E YEL/GRN (16)

RIGHT O/R DOWN
X995
60E YEL/GRN (16)
1
TO CAB POWER HARNESS (X1020) 20 BLK (14)
2
61 RED/GRY (16)
1
2G BLK (16)
2
2F BLK (16)
HV607
20 BLK (14) 2G BLK (16)
RIGHT O/R UP
2D BLK (16)
SPL 2
2E BLK (16)
E E
HV606
2D BLK (16)
2
Cab O/R Option Schematic (10042 only)
64 GRY/VIO (16)
1
LEFT O/R DOWN
HV608
2E BLK (16)
2
63 BRN/YEL (16)
1
LEFT O/R UP
31211015
D D
10042 MACHINES ONLY

HARNESS, WIRING, OUTRIGGERS
C C
B B
A A
Electrical System
1 2 3 4 5 6 7 8
MAQ1610F
9-11
6036, 6042, 8042, 10042, 10054 31211015 9-12
MAQ1620F
F
A
B
E
C
D
H
TO CAB POWER HARNESS (X1013)

11
1
2
3
4
5
6
7
8
9
10
12
X1001
1
1
7 TAN (16)
2 BLK (14)
3 RED (14)
3C RED (14)
52 DBL/RED (16)
35 BRN/GRN (16)
51B BLU/WHT (16)
45A1 DBL/ORG (16)
2C1 BLK (16)

2C2 BLK (16)
RL254-85
2JB BLK (14)
50B RED/WHT (16)

RL254-86
70C ORG/BLK (16)
2 BLK (14)
RL254-87
2JB BLK (14)
71 ORG/WHT (16)
RL254
RL254-30
STAB INTERLOCK
70B ORG/BLK (16)

RL254-87a
S1014
SPL 2A
2C1 BLK (16)

RL255-85
70C ORG/BLK (16)
RL255-86
45A1 DBL/ORG (16)
RL255-87
RL255
7 TAN (16)
RL255-30
STAB LOCKUP
2JA BLK (14)
35 BRN/GRN (16)
2A3 BLK (16)
RL255-87a
2
2
61 RED/GRY (16) 2A2 BLK (16)

1 RL256-85
2G BLK (16) 23 ORG/GRN (16)
2 RL256-86
65 DBL (16)
HV599 RL256-87
66 BLK (16)
RIGHT O/R UP
RL256
RL256-30
71 ORG/WHT (16)
RL256-87a
71A ORG/WHT (16)
BOOM EXT INTERLOCK
3 RED (14)
3C RED (14)
2A1 BLK (16)

62 VIO/WHT (16) 2A2 BLK (16)
1 RL257-85
2F BLK (16) 71A ORG/WHT (16)
2 RL257-86
71B ORG/WHT (16)
HV600 RL257-87
RL257
68 RED/BLK (16)
RL257-30
LOCKOUT
RIGHT O/R DOWN
2G BLK (16) 61 RED/GRY (16)

RIGHT OUTRIGGER
RL257-87a
SPL 3
2F BLK (16)
2E BLK (16) 2JA BLK (14) 2A3 BLK (16)
2D BLK (16) 2H BLK (16) 2A1 BLK (16)
GENERIC
RL258-85
71B ORG/WHT (16)
RL258-86
3A RED (14)
3B GRY/BLU (16)
SPL 2B
RL258-87
RL258
67 BRN/BLK (16)
HV597 RL258-30
LOCKOUT
2E BLK (16) 63 BRN/YEL (16)

LEFT OUTRIGGER
2 RL258-87a
63 BRN/YEL (16)
1
LEFT O/R UP
2B2 BLK (16)

RL259-85
70B ORG/BLK (16)
RL259-86
RL259-87
52 DBL/RED (16)
2K1 BLK (16)
RL259
3
3
HV598 RL259-30
INTERLOCK
2D BLK (16) 51A BLU/WHT (16)

PARK BRAKE
2 RL259-87a
64 GRY/VIO (16)
1
2B2 BLK (16)
LEFT O/R DOWN
2B3 BLK (16)

RL260-85
65 DBL (16)
RL260-86
55 ORN/RED (16)
RL260
RL260-87
LOCK OUT
58 GRN (16)
RL260-30
BOOM EXTENSION
50C RED/WHT (16) 50C RED/WHT (16)

1 RL260-87a
57 GRY/ORG (16) 50B RED/WHT (16)
2
3B GRY/BLU (16) OUTRIGGER 2
SN596 FC999-1
56A GRY/BLU (16) 7.5A
FC999-2
49 RED/BLU (16) OUTRIGGER 1
FC998-1
3A RED (14) 7.5A
FC998-2
60A GRN (16)
SN595
57 GRY/ORG (16)
2
56 GRY/BLU (16)
1
HV250
2K1 BLK (16)
B
SFA
51C BLU/WHT (16) 51C BLU/WHT (16)
4
4
SEC. FUNC. VALVE

SPL 51
23 ORG/GRN (16)
56 GRY/BLU (16)
B
49 RED/BLU (16)
A
X462
66 BLK (16)
5
5
ENGINE HARNESS
TO BOOM EXTEND SENSOR
SPL 56
55 ORN/RED (16)
56A GRY/BLU (16)
HV253
2H BLK (16)
B
58 GRN (16)
BOOM EXT SOL.

A
6
6
60A GRN (16)

60B YEL/GRN (16)
SPL 60
60D YEL/GRN (16)
7
7
HARNESS, LOGIC
10054 MACHINES ONLY
68 RED/BLK (16)
62 VIO/WHT (16)
60D YEL/GRN (16)
67 BRN/BLK (16)
64 GRY/VIO (16)
60B YEL/GRN (16)
8
8
SW594
SW593
8
7
6
5
4
3
2
1
8
7
6
5
4
3
2
1
RIGHT O/R SWITCH LEFT O/R SWITCH
A
B
E
C
D
H
G
Cab O/R Option Schematic (10054 only) 9.5.6
Electrical System
1 2 3 4 5 6 7 8
9.5.7
H H
1
2
3
4
5
6
7
8
9
10
11
12
X408
6036, 6042, 8042, 10042, 10054

WHT AC 2 16 GXL
WHT AC 3 16 GXL
RED IGN 12 GXL

BLK GND 12 GXL
BLK GND 12 GXL
RED PWR 12 GXL

WHT THEMOSTAT 16 GXL
ORG AC PWR 12 GXL

WHT FLOOR HEATER 16 GXL
WHT AC COMP 16 GXL

WHT AC 16 GXL
G G
S418
S424
S426
X412 X413
RED IGN 12 GXL WHT FAN H1 14 GXL ORG FAN H1 14 GXL
PWR B 1 1
HVAC Option Schematic
WHT FAN L 14 GXL WHT FAN L 14 GXL WHT FAN L 14 GXL

LOW L 2 2
WHT FAN M 14 GXL BLK GND 14 GXL BLK GND 14 GXL
MED. M 3 3
FAN
WHT FAN H 12 GXL WHT THEMOSTAT 16 GXL WHT THERMOSTAT 14 GXL
HI H 4 4
S416 BLK GND 14 GXL BLK GND 2 14 GXL S432
F AC C 5 5 F
ORG RLY PWR 1 14 GXL ORG RLY PWR 1 14 GXL
SW407-F 6 6
WHT AC 2 16 GXL S427 ORG RLY PWR 2 14 GXL TO HARNESS, AC TO HARNESS, HVAC ORG RLY PWR 2 14 GXL
A 7 7
WHT AC 3 16 GXL S431
B 8 8
AC
BLK AC GND 16 GXL WHT AC COMP 16 GXL WHT AC COMP 14 GXL
C 9 9
SWITCH, HVAC CONTROL WITH AC

BLK GND 14 GXL BLK GND 14 GXL BLK GND 18 GXL
SW407-AC 10 10
WHT FAN M 14 GXL RED FAN M 14 GXL S429 S433
11 11
WHT FAN H2 14 GXL ORG FAN H2 14 GXL
12 12
S430
WHT FLOOR HEATER 16 GXL

BLK GND 16 GXL
WHT POT SIG 16 GXL
WHT POT SIG 16 GXL

BLK GND 16 GXL
WHT AC COMP 14 GXL
RED PWR 16 GXL

GRN AC PRESS 14 GXL
RED POT PWR 16 GXL

BLK GND 16 GXL
WHT THERMOSTAT 14 GXL
WHT AC RLY 14 GXL

ORG RLY PWR 12 GXL
GRN AC PRESS 14 GXL
RED COND FAN 14 GXL

RED COND FAN 14 GXL
BLK GND 12 GXL

BLK GND 18 GXL
BLK GND 18 GXL
X419
BLK GND 2 14 GXL
WHT FAN L 14 GXL
3
2
1
RED FAN M 14 GXL
ORG FAN H 12 GXL
3
2
1
X437
4
3
2
1
5
2
3
1
4
3
2
1
2
1
1
1
RL435
SN396
SN438-2
SN438-1
WH434-F
X422
X423
H
G
A
B
E
B
A
C
D
C
E E
86
85
30
87
87a
HEATER VALVE POT MOTORIZED VALVE
M
HI
MED
GND
LOW
TO AC COND FAN
HARNESS, HVAC FLOOR HEATER
M
CONDENSER FAN THERMOSTAT PRESSURE SW
HEATER FAN MOTOR
HARNESS, AC
FOR REFERENCE ONLY
31211015
WINDSHIELD WIPER SWITCH ROOF WIPER SWITCH
WASHER SWITCH
D D
1
2
3
4
5
6
7
9
1
2
3
4
5
6
7
9
1
2
3
4
5
6
7
8
SW1040
SW1044
SW1048
RED 6D IGN PWR
BLK 1C GND
ORG 10 WASHER PWR
RED 6 IGN PWR
WHT 4 FRT WIPER

BLK 1A GND
RED 6E IGN PWR
RED 6E IGN PWR
RED 6A IGN PWR
WHT 2 FRT WIPER

WHT 3 FRT WIPER
RED 6A IGN PWR
RED 6B IGN PWR
RED 6C IGN PWR

RED 6C IGN PWR
YEL 9 TOP WIPER

ORG 7 TOP WIPER
WHT 5 TOP WIPER
BLK 1B GND
WHT 11 TOP WIPER

WHT 11 TOP WIPER
WHT 3 WIPER
WHT 3 WIPER
X1067
ORG 7 TOP WIPER
1 SLOW
C C
X468
BLK 1E GND
1 GND
X469 TO ROOF WIPER MOTOR
WHT 5 TOP WIPER
BLK 1E GND 1 PARK
BLK 1 GND BLK 1C GND BLK 1B GND
1
BLK 1A GND BLK 1G GND BLK 1G GND BLK 1D GND
X467
S493 BLK 1F GND
S492
WHT 4 FRT WIPER
L
WHT 2 FRT WIPER
G
WHT 3 FRT WIPER S494
R
TO WINDSHIELD WIPER MOTOR X470
2 YEL 9 TOP WIPER
1 FAST
X
X466
HARNESS, WIPER
B B
BLK 1F GND
ORG 10 WASHER PWR
RED 6F IGN PWR

BLK 1D GND
X1012
1
2

2
1
WH1075
M
WASHER BOTTLE
A A
Electrical System
1 2 3 4 5 6 7 8
MAQ1630F
9-13
9-14
9.5.8
1 2 3 4 5 6 7 8
H H
LB947
RED
1
BLK
2
WORKLIGHTS SWITCH
HAZARD SWITCH FRONT ROADLIGHT ASSEMBLY LH
LOW BEAM LEFT

BLK S948 BLK
BLK
BLK LB946
BLU/BLK
1
1
2
3
4
5
6
7
8
1
2
3
4
5
17
18
7
8
10
G BLK
2
G
RL498
Electrical System
HIGH BEAM LEFT

FLASHER MODULE
1
2
3
4
5
6
7
8
1
2
3
4
5
17
18
7
8
10
P
X
L
SW945
SW944
LB949
WHT
1
BLK
2
LEFT SIDE
X503 X504
3A LBL (14)
4A YEL (14)
2K BLK (16)
1F RED (14)
1E RED (14)
1A RED (14)
21A RED (16) RED
1 1
20A WHT (16) WHT LB950
2 2
22A ORN (16) ORN ORN
27 PPL/WHT (16)
28B PURPLE (16)
33 PURPLE (16)
28 PURPLE (16)
2B BLK (16)
33 PURPLE (16)
23C GRN (16)

22C ORN (16)
32 GRN (14)
1J RED (14)
1J RED (14)
3 3 1
1B RED (14)
24A DBL (16) BLU/BLK BLK
4 4 2
TAIL LEFT
5 5
2J BLK (16) BLK
6 6
LB951
RED
1
BLK
2
F F
LOW BEAM RIGHT

1F RED (14)
SPLICE 1 LB952
1A RED (14) 1 RED (12) BLU/BLK
X505 X506 1
1E RED (14) 1B RED (14) 21B RED (16) RED BLK
L
1 1 2
Road Light Option Schematic
SW975 1C RED (14) 20B WHT (16) WHT BLK

2 2
1D RED (14) 23A GRN (16) ORN BLK S955 BLK
2B BLK (16)
SW1
3 3
HIGH BEAM RIGHT

R
22 ORN (16) 24B DBL (16) BLU/BLK BLK
LEFT TURN 9 4 4
28A PURPLE (16) BLK
TURN SIGNAL B+ 11 5 5
23 GRN (16) 2H BLK (16) 2H BLK (16) BLK LB953
RIGHT TURN 10 6 6
21 RED (16) 2A BLK (12) WHT
LOW BEAM 5 1
SW2
24 DBL (16) SPLICE 2 2J BLK (16) BLK
FLASH MODE B+ 1 2
25 PNK (16) 2K BLK (16) 2D BLK (16)
RIGHT SIDE
HIGH BEAM 3
GENERIC
20 WHT (16) 2F BLK (16) 2G BLK (16)
O
SIDE MARKER LIGHTS 6
P 1C RED (14) 2E BLK (16) 2C BLK (16) LB954
LIGHT SWITCH B+ 8
SW3
TURN SIGNAL CONTROL

1 SPLICE 20 20C WHT (16) ORN
1
20 WHT (16) 20A WHT (16) BLK
2
20B WHT (16)
TAIL RIGHT
O
FRONT ROADLIGHT ASSEMBLY RH
SW4
P
20D WHT (16)
1
E E
21 RED (16) 21A RED (16)
SPLICE 21 21B RED (16)
LB535+
4A YEL (14) 4B YEL (14) 4B YEL (14)
1
23C GRN (16) SPLICE 4 4C YEL (14)
23 GRN (16) 23B GRN (16) 2D BLK (16)
1
SPLICE 23 23A GRN (16)
LB535-
WORKLIGHT LT REAR
SPLICE 22
LB536+
4C YEL (14)
1
2G BLK (16)
1
LB536-
SPLICE 28
WORKLIGHT RT REAR
31211015
SPLICE 26
D D
25 PNK (16) 24B DBL (16)
24 DBL (16) 24A DBL (16) BOOM WORKLIGHT HARNESS
2F BLK (16)
2E BLK (16)
26B GRY (14)

26A GRY (14)
23B GRN (16)

22B ORN (16)
20D WHT (16)

20C WHT (16)
SPLICE 24 24C DBL (16) LB966+
X968 X967
3A LBL (14) WHT WHT
A A 1
2C BLK (16) BLK
X962
X964
B B
1
2
3
4
1
2
3
4
BLK
1
1
2
3
4
1
2
3
4
LB966-
WORKLIGHT BOOM
X961
X963
HARNESS
BLK
BLK
GRY
GRY
GRN
GRN
WHT
WHT
BLK BLK
S529 BLK S965 BLK
BLK BLK
C C
BLK
BLK
BLK
BLK
BLK
BLK
GRY
GRY
GRN
GRN
WHT
WHT
LEFT REAR TAIL LIGHT
RIGHT REAR TAIL LIGHT

2
1
2
1
2
1
2
1
2
1
2
1
27 PPL/WHT (16)
24C DBL (16)
LB959
LB960
LB956
LB521
LB958
LB957
2A BLK (12)
32 GRN (14)
1 RED (12)
26 GRY (14)
1D RED (14)
HARNESS, ROAD LIGHT OPTION

2
1
8
7
6
5
4
3
2
1
4
5
X1090
RR TURN HAZ RF TURN HAZ RIGHT BRAKE LF TURN HAZ LR TURN HAZ LEFT BRAKE X992 SW351
TO CAB POWER HARNESS (X1004) TO LIGHTING BRAKE SWITCH
B B
A A
1 2 3 4 5 6 7 8
MAQ1640F
6036, 6042, 8042, 10042, 10054

1 2 3 4 5 6 7 8
9.5.9
H H
6036, 6042, 8042, 10042, 10054

G G
WORKLIGHT SWITCH LEFT FRONT WORKLIGHT RIGHT FRONT WORKLIGHT LEFT REAR WORKLIGHT RIGHT REAR WORKLIGHT
1
1
1
1
1
1
1
1
1
2
3
4
5
6
7
8
SW403
LB978N
LB979N
LB980N
LB981N
LB978P
LB979P
LB980P
LB981P
2B1 BLK (14)
3B LBL (14)
3C LBL (14)
4B YEL (14)
4C YEL (14)
2B2 BLK (14)

2B3 BLK (14)
2B5 BLK (14)
X404
4A YEL (14)
2C BLK (14)
1B RED (14)
1A RED (14)
1C RED (14)
3A1 LBL (14)

2A BLK (12)
2
TO CAB POWER HARNESS (X1009) 1 RED (12)
1
F 2B1 BLK (14) F

1B RED (14) 2B2 BLK (14)
1C RED (14) 2C BLK (14) 2B3 BLK (14)
1A RED (14) SPLICE2 2B5 BLK (14)
SPLICE 1
2B4 BLK (14)
4B YEL (14) BOOM WORKLIGHT HARNESS

4A YEL (14) 4C YEL (14) LB538_1P
SPLICE 4 WHT - -
X983 X540 1
3D LBL (14) 3D LBL (14) WHT - -
A A
3A1 LBL (14) 3B LBL (14) 2B4 BLK (14) BLK - - BLK - -
B B 1
SPLICE 3 3C LBL (14)
LB538_1N
WORKLIGHT BOOM
HARNESS
WORK LIGHTING OPTION

HARNESS
E E
Worklights/Beacon Option Schematic
6 WHT/RED (16)
X06
8 WHT/RED (16) 8 WHT/RED (16)
8 1
2 BLK (16) 2 BLK (16) TO CAB POWER HARNESS (X1008)
7 2
S1053 2A BLK (16)
31211015
6
5
4
3 RED (16) 3 RED (16) BEACON/ STROBE
3 1
6 WHT/RED (16) 2A BLK (16)
2 2
D D
BEACON/STROBE SWITCH
1 LB421
SW01
BEACON HARNESS
X1101
S1108 2A BLK (12)

2
2AD BLK (12) 1 RED (12)
2 1
12B RED (12)
C 1 C
X1097
S1109
12D RED (12)
12E RED (12)
27B RED (12) 2Q BLK (12)

1 2
1 RED (12)
X1099 1
X1098
27F RED (12)

1
X1100
B B
1 RED (12)
1 RED (12)
2V BLK (12)
2S BLK (12)
123 RED (12)

122 RED (12)
122 RED (12)
123 RED (12)
27F RED (12)
12E RED (12)

27B RED (12)
12D RED (12)
FC1000
FC380-1
FC380-2
FC381-1
FC381-2
RL1103-30
RL1103-87
RL1103-86
RL1103-85
RL1102-30
RL1102-87
RL1102-86
RL1102-85
RL1103-87a
RL1102-87a
87a
30
87
86
85
87a
30
87
86
85
1
2
1
2
30A
30A
A A
FUSE 2
FUSE 1
Electrical System
1 2 3 4 5 6 7 8
MAQ1650F
9-15
9-16
9.5.10
1 2 3 4 5 6 7 8
S1119
TO CAB X1106 J IGN ORN (16) IGN ORN (16)
J
CANH1 YEL (18) IGN ORN (16)
A H H
HARNESS CANL1 GRN (18) G
B G
C F F
X332 (2-A6) E E
D CANL GRN (18)
D
D C CANH YEL (18)
C D
B PWR RED (16) PWR RED (16)
B
A GND BLK (16) GND BLK (16)
A
X1116 X1105
USE TERMINATOR
Electrical System
FROM CAB X332
S1143
S1144
Telematics Option
(2-A6) TO X1147
CAN TERMINATION C
CANL1 GRN (18) S1115
B
CANH1 YEL (18)
A
X1149
S1114
1
2
3
4
C 5 C
TELEMATICS GND BLK (16)

6
CAN-2 LOW 7
CAN-2 HIGH 8
CANL1 GRN (18)
CAN-1 LOW 9 X1145
CANH1 YEL (18) TELEMATICS PWR RED (16)
CAN-1 HIGH 10 S1123 1
TELEMATICS GND BLK (18) TELEMATICS GND BLK (16)
GROUND 11 2
TELEMATICS IGN ORG (18)
IGNITION 12 3
TELEMATICS IGN ORN (16)
CO1117-J1 GRAY 4
1 5
2 6
CAN-2 - SHIELD 3 7
4 8
GATEWAY CONTROLLER
CANL2 GRN (18)
5 9
CANH2 YEL (18)
6 10
7 S1142 11
8 12
31211015
CANL2 GRN (18)
9
CANH2 YEL (18) S1139 S1141
10
TO TELEMATICS CONTROLLER
11
12 S1140
CO1117-J2 BLACK
CANH2 YEL (18)
A
CANL2 GRN (18)
B
C CAN TERMINATION
TELEMATICS HARNESS X1132
B X1128
C
B
CAN TERMINATION
B CANL2 GRN (18)
A CANH2 YEL (18)
A A
MAQ4850
1 2 3 4 5 6 7 8
6036, 6042, 8042, 10042, 10054

Electrical System
9.6 DIELECTRIC GREASE APPLICATION 2. AMP Seal
Dielectric grease helps to prevent corrosion of electrical

contacts and improper conductivity between contacts from
moisture intrusion. Open and sealed connectors benefit
from the application of dielectric grease.
9.6.1 Installation
MAE3250
MAE3230
1. Apply dielectric grease to plug/male connector housing

which typically contains sockets contact/female
terminals.
Note: Use dielectric grease in a tube for larger connection
points or apply with a syringe for small connectors.
2. Leave a thin layer of dielectric grease on the face of the
connector.
3. Assemble the connector system immediately to prevent
moisture ingress or dust contamination.
4. Pierce one of the unused wire seals prior to assembly if
the connector system tends to trap air (i.e. AMP Seal)
and then install a seal plug.
The following connector systems are specifically addressed MAE3260
because of their widespread use. However, this guidance
may be applied to similar devices: The AMP Seal connector system is used on the Control ADE
Platform and Ground Modules.
1. Deutsch HD, DT, DTM, DRC Series Apply dielectric grease to the plug/male connector housing
which typically contains socket contacts/female terminals. If
trapped air prevents the connector from latching, pierce one
of the unused wire seals. After assembly, install a seal plug in
that location to prevent moisture ingress.
Note: Seal plugs may be installed by the wire harness
manufacturer if an unused wire seal becomes compromised
(wire inserted in the wrong cavity during assembly and the
corrected).
MAE3240
The Deutsch connector system is widely used for harsh

environment interconnect. Follow the general guidance for
installation.
6036, 6042, 8042, 10042, 10054 31211015 9-17
Electrical System
3. AMP Mate-N-Lok 9.6.2 Exclusions

1. M12 with Gold Contact Material:
MAE3270
This connector system is widely used inside enclosures for

general-purpose interconnect. Follow the general guidance
for installation.
4. DIN Connectors
MAE3290
MAE3280
This connector system is typically used on hydraulic valves.

Follow the general guidance for installation.
MAE3300
The connector uses gold contact material to resist corrosion

and an o-ring seal for moisture integrity. If dielectric grease is
mistakenly applied to this connector system, the low-force
contacts cannot displace the grease to get electrical contact.
Once contaminated, there is no practical way to remove the
dielectric grease (replacement of female contacts required).
9-18 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
2. Engine Control Unit Connectors 4. MIL-C-5015 Spec Connector’s
MAE3330
The dielectric grease is not recommended for this series

MAE3310
connector. For similar model series connectors, the
manufacturer should be contacted for confirmation before
Many times, these types of connectors use back-seals for applying dielectric grease.
moisture integrity. However, the low-force contacts cannot
5. CMC Series Connectors
displace dielectric grease and create electrical contact. It is
possible to use solvents (i.e. contact cleaner or mineral
spirits) for the removal of improperly applied dielectric
grease.
3. Sealed Enclosures
MAE3340
The CMC connector family is a sealed, high-density

connection system using matte-seal technology for
CP 0.635 and 1.50mm terminals. To guarantee IP6K7 and
IP6K9 sealing, a seal plug option is used. However, the
low-force contacts cannot displace dielectric grease and
create electrical contact. It is possible to use solvents (i.e.
MAE3320
contact cleaner or mineral spirits) for the removal of
Application of dielectric grease is not required in properly improperly applied dielectric grease.
sealed enclosures. To meet criteria, the enclosure must be
rated to at least IP66 (dust tight; protected from powerful jets
of water). The enclosure must be fitted with a high quality,
continuous gasket and all wiring must pass through cable
entrances.
6036, 6042, 8042, 10042, 10054 31211015 9-19

Electrical System
9.7 ENGINE START CIRCUIT 3. Check battery condition. Clean the battery posts and
the connectors at each end of the battery cables.
9.7.1 Starter 4. Check for broken wiring and damaged insulation on the
wiring. Replace all broken or damaged wiring.
IF EQUIPPED FOR ULS
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 from cranking
engine.
1 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 charge and
battery condition first, then check cables and cable
IF EQUIPPED FOR LS
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 doors. Allow the system
fluids to cool.
1 “Battery”, for procedure.
4. Remove wires from solenoid stud. Remove positive (+)
MAQ1670 battery cable from starter. Label and disconnect wire
from starter solenoid housing stud. Record how wires
The starter (1) is located on the left side of the engine. are installed to ensure correct installation later.
5. Loosen, but DO NOT remove, fasteners securing starter
a. Testing the Starter on the Engine to flywheel housing. Support starter securely, as it is
If the starter does not engage when the ignition key switch is relatively heavy and will fall if not supported.
turned, check the following: 6. Support starter and remove fasteners securing starter to
1. The main fuse may be blown, requiring replacement. engine. Remove negative (-) ground cable from its
Check for the cause of the blown fuse. starter mounting bolt.
2. There may be a defect in the ignition key switch, 7. Remove the starter from the machine.
ignition wiring or starter solenoid.
9-20 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
d. Starter Installation 7. Close and secure engine cover.

1. Position starter in its mounting on flywheel housing. 8. Remove Do Not Operate Tag from ignition key switch
Position ground cable over correct starter mounting and steering wheel.
bolt. Secure starter with previously used hardware.
2. Connect positive (+) battery cable to upper solenoid
9.8.2 Battery Removal/Installation
stud. Install wires to upper solenoid stud, and secure
a. Removal
with lock washer and nut.
3. Connect the wire to the solenoid mounting stud. 1. Park machine on a firm, level surface, level machine,
fully retract boom, lift boom, place transmission in
4. Properly connect the battery. Refer Section 9.8, (N) NEUTRAL, engage parking brake and shut engine
“Battery”, for procedure. OFF.
5. Remove the Do Not Operate Tags from both the ignition 2. Place a Do Not Operate Tag on both ignition key switch
key switch and the steering wheel. and steering wheel.
6. Close and secure the rear and side engine doors. 3. Open engine cover. Allow system fluids to cool.
4. Turn OFF electrical master switch.
9.8 BATTERY
5. Disconnect Negative battery cable (2).
Note: Eye protection is recommended before inspecting 6. Disconnect Positive battery cable (3).
and/or replacing the battery.
7. Loosen and remove clamp securing battery (1).
9.8.1 Battery Inspection 8. Remove battery (1).
1. Park machine on a firm, level surface, level machine,
a. Installation
fully retract boom, lower boom, place transmission in
(N) NEUTRAL, engage parking brake and shut engine 1. Properly install battery (1) and secure in place with
OFF. previously removed clamp.
2. Place a Do Not Operate Tag on both ignition key switch 2. Connect Positive battery cable (3).
and steering wheel. 3. Connect Negative battery cable (2).
3. Open engine cover at rear side of the frame. Allow 4. Turn ON electrical master switch.
5. Close and secure engine cover.
6. Remove Do Not Operate Tag from ignition key switch
and steering wheel.
2 3
9.8.3 Battery Disconnect/Connect
a. Disconnect
(N) NEUTRAL, engage parking brake and shut engine
OFF.
and steering wheel.
1 3. Open engine cover at rear side of the frame. Allow
MAE4390
4. Disconnect Negative battery cable (2).
4. Visually inspect the battery (1).
5. Disconnect Positive battery cable (3).
5. Check terminals for corrosion.
6. Replace the battery if it has a cracked, melted or
damaged case.
6036, 6042, 8042, 10042, 10054 31211015 9-21

Electrical System
b. Connect If the engine alternator charging warning indicator

illuminates, perform the following checks:
1. Connect Positive battery cable (3).
1. Check all battery cable connections at the battery, and
2. Connect Negative battery cable (2).
verify that they are clean and tight.
3. Close and secure engine cover.
2. Check the external alternator wiring and connections,
4. Remove Do Not Operate Tag from ignition key switch and verify that they are in good condition.
and steering wheel.
3. Check the fan belt condition and tension.
9.9 CHARGING CIRCUIT 4. Run the engine and check the alternator for noise. A
loose drive pulley, loose mounting hardware, worn or
IF EQUIPPED FOR ULS dirty internal alternator bearings, a defective stator or
defective diodes can cause noise. Replace a worn or
defective alternator.
9.9.1 Alternator
a. Alternator Removal
2. Open the rear and side engine doors. Allow the system
fluids to cool.
2 “Battery”, for procedure.
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.
IF EQUIPPED FOR LS 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
2 alternator mount on the engine bracket. Insert the
upper (longer) mounting hardware through the
MAQ1670 alternator mount. Thread the longer capscrew into the
Before using a battery charger, an attempt can be made to alternator front mount. DO NOT tighten completely at
recharge the battery by jump-starting the machine (Refer to this time.
the appropriate Operation & Safety Manual). Allow the 2. Align the lower alternator mount hole with the lower
engine to run, which will enable the mounting bracket on the engine, and insert the lower
alternator (2) to charge the battery.
9-22 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
mounting cap screw. Tighten the lower cap screw and 9.10 WINDOW WIPER/WASHER WINDSHIELD
upper cap screw securely. WIPER MOTOR
3. Place a drive ratchet into the square hole on the
serpentine belt tensioner bracket. Apply pressure
9.10.1 Windshield Wiper Motor
against the tensioner bracket and route the serpentine
belt onto the alternator and engine pulleys. Release and a. Removal
check the tensioner pulley to verify that it is pivoting
freely in order to provide the proper tension on the belt. Note: It may be necessary to remove several hydraulic hoses
Check for proper belt alignment. (Refer to the from behind the dash in order to remove and install the wiper
appropriate Operation & Safety Manual.) motor housing. Refer to Section 4.3.2, “Steering Column and
Steering Valve”.
4. Connect the previously labeled wire leads to the
alternator. 1. Park the machine on a firm, level surface, level the
5. Properly connect the battery. Refer Section 9.8, machine, fully retract the boom, lower the boom, place
“Battery”, for procedure. the transmission in (N) NEUTRAL, engage the park brake
key switch and the steering wheel. 2. Place a Do Not Operate Tag on both the ignition key
7. Close and secure the rear and side engine doors. should not be operated.
5. Remove the right side instrument panel.
6. Remove the lower access panel below the instrument
panel.
7. Disconnect the right side defroster hose from the dash
panel hose connector.
3
MA8431
8. Disconnect the cab harness connectors from the wiper

motor (3).
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.
6036, 6042, 8042, 10042, 10054 31211015 9-23

Electrical System
12. Remove the metal hex jam nut and metal washer from 9. Turn ignition key switch to the RUN position, and
the motor shaft. operate windshield wiper in both LOW and HIGH
13. Remove the motor mounting bolts, pan adapter and speeds to ensure proper operation and that correct
gasket from the motor shaft. wiper travel is achieved.
10. If previously removed, install hydraulic hoses under the
Note: Retain all hardware removed from the wiper assembly
dash. Refer to Section 4.3.2, “Steering Column and
for possible reuse on the replacement motor housing.
Steering Valve”.
14. Remove the motor from the inside of the cab. 11. Install the previously removed dash panels.
b. Disassembly 12. Close and secure the engine rear and side engine doors.
DO NOT disassemble the motor. The motor is not 9.10.2 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 machine, fully retract the boom, lower the boom, place
continuity is not found. the transmission in (N) NEUTRAL, engage the park brake
d. Installation and Testing
1. Install all required hardware to the motor assembly. switch and the steering wheel, stating that the machine
Align spacer and wiper motor bracket, and apply should not be operated.
masking tape in order to hold the two components
3. Open the rear side door of the engine. Allow the system
together during installation.
fluids to cool.
2. Align motor with the mounting holes and insert motor
through cab.
3. Have an assistant insert gasket, panto adapter onto the
motor shaft. Insert bolts through front cab holes 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. Tighten
5
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
wiper motor connectors. 6
MA8361
5. Remove the wiper arm (5) from the wiper motor shaft.
6. Disconnect the washer hose from the top hose fitting.
7. From inside the cab, remove screws from top locknut
plate.
9-24 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
8. Unclip the plastic motor cover (6) and remove. 9.10.3 Windshield Washer Reservoir
9. From the top of the cab, remove the nut from the wiper
motor shaft.
10. From inside the cab, pull the wiper motor down and
away from the roof.
11. Label and disconnect the cab harness connectors from
the wiper motor.
b. Disassembly 7
DO NOT disassemble the motor. The motor is not

serviceable. Replace motor if found to be defective.

Inspect the motor terminals for continuity. Replace motor if
continuity is not found.
d. Installation and Testing

1. Hold wiper motor up toward cab top and install the cab
harness connectors. MAQ1690
2. With the help of an assistant, insert the wiper motor The windshield washer motor and reservoir (7) is a unit and
through the roof hole and have the assistant thread the cannot be serviced separately.
nut onto the wiper motor shaft. Ensure that the motor
housing is facing the front of the cab. a. Removal
3. Install the wiper arm onto the wiper motor shaft. 1. Park machine on a firm, level surface, level machine,
4. Install the screws through the plastic motor cover and fully retract boom, lower boom, place transmission in
into the top locknut plate and tighten. (N) NEUTRAL, engage parking brake, and shut engine
5. Connect washer hose to top hose fitting. OFF.
6. Properly connect the battery. Refer Section 9.8, 2. Place a Do Not Operate Tag on both the ignition key
“Battery”, for procedure. switch and the steering wheel, stating that the machine
key switch and the steering wheel. 3. Open the engine rear and side engine doors. Allow the
8. Turn the ignition key to the RUN position and turn
skylight wiper switch to the ON position. Ensure wiper 4. Properly disconnect the battery. Refer Section 9.8,
stays on the window through a full stroke. Turn the “Battery”, for procedure.
skylight wiper switch to the OFF position. 5. Remove the nuts and the lock washers from the washer
9. Engage the washer switch and ensure washer fluid is mounting bolts.
sprayed on the skylight window. Turn the ignition key 6. Pull the washer reservoir out and away from the
switch to the OFF position. mounting bracket.
10. Close and secure the engine rear and side engine doors. 7. Rotate the washer reservoir, label and remove the cab
harness connectors from the washer reservoir
connectors.
8. Remove the windshield washer hose from the reservoir.
6036, 6042, 8042, 10042, 10054 31211015 9-25

Electrical System
b. Disassembly 9.11 CAB HEATER AND FAN

DO NOT disassemble the pump. The pump is not serviceable.
Replace pump if found to be defective. 9.11.1 Cab Heater Controls
Note: If the suspect component is found to be within the heater
c. Installation and Testing
box, the heater box must be removed as a complete unit and
1. Connect windshield washer hoses to reservoir. replaced.
2. Connect the cab wiring harness connectors to the
reservoir connectors. a. Cab Heater Controls Removal
3. Install the reservoir tank onto the welded studs.
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.
MAQ1680

(N) NEUTRAL, engage the park brake and shut the
engine OFF.
and steering wheel, stating that machine should not be
operated.
5. Remove the setscrew from the variable speed fan
control knob or temperature control knob.
6. Remove the right side control panel screws.
7. Remove the screws and backing locknuts from the cab
heater and fan control panel.
8. Pull the control panel out from the dash panel, and if
removing variable speed fan control, remove the cab
harness connector.
9. If removing the temperature control knob, disconnect
the cable connector and remove control knob.
10. Remove the locknut from the suspect control shaft.
9-26 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
11. Remove the control panel from the panel. 9.12 SOLENOIDS, SENSORS AND SENDERS
b. Disassembly
9.12.1 Coolant Level Sensor
DO NOT disassemble the cab heater and fan controls. The
controls are not serviceable. Replace controls if found to be a. Coolant Level Sensor Removal
defective.
fully retract boom, raise the boom, place transmission in
c. Installation and Testing
(N) NEUTRAL, engage the park brake and shut the
1. Check that the variable speed fan control is in the OFF engine OFF.
position. 2. Place a Do Not Operate Tag on both ignition key switch
2. If installing the temperature control, attach the control and steering wheel, stating that machine should not be
cable to the back of the control. operated.
3. Insert the control shaft through the panel, ensuring that 3. Open the engine rear and side engine doors. Allow the
the knob is in the VERTICAL position. system fluids to cool.
4. Install the locknut on the shaft and tighten. 4. Temporarily block up or support the boom.
5. Connect the cab harness connector to the variable 5. Properly disconnect the battery. Refer Section 9.8,
speed fan control. “Battery”, for procedure.
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. Install the right side control panel.
key switch and the steering wheel. 8
11. Turn the ignition key to the ON position and check the
fan speeds. If further repair is needed, refer to Section
9.5, “Electrical System Schematics”.
MAQ1700
12. Start the machine and allow engine to warm to
operating temperature. Check heat control at different 6. Label and disconnect the wiring connector from the
levels. Coolant Level Sensor (8).
13. Close and secure the engine rear and side engine doors. 7. Unthread switch from surge tank.
b. Coolant Level Sensor Disassembly

DO NOT disassemble the Coolant Level Sensor. Replace a
defective switch with a new part.
c. Coolant Level Sensor Installation

1. Thread switch into engine. Tighten securely.
2. Connect previously labeled wiring connector
to switch.
6036, 6042, 8042, 10042, 10054 31211015 9-27

Electrical System
5. Start engine. Allow it to reach operating temperature 9.12.3 Transmission Temperature Sender
and observe the operator instrument cluster for
warning indication. If switch is not defective, problem a. Transmission Temperature Sender Removal
could be elsewhere; possibly in a shorted wire,
The transmission temperature sender (11) is threaded into
improper running engine, improper or low coolant,
the top of the transmission housing.
obstructed or faulty radiator, coolant pump, loose fan
belt, defective instrument cluster, etc. 1. Park machine on a firm, level surface, level machine,
(N) NEUTRAL, engage parking brake, and shut engine
OFF.
9.12.2 Transmission Solenoid Valves
11
4. Temporarily block up or support the boom.
10 6. Remove the transmission covers.
7. Unplug the transmission temperature sender connector
from the wiring harness connector.
MH6380
8. The sender is threaded into the transmission housing.
Note: If the transmission is not shifting properly, the Remove the sender.
transmission shift control switch (travel select lever), wiring
harness or transmission shift solenoids (10) should be b. Transmission Temperature Sender Inspection and
checked in order to determine which component is Replacement
defective. Specific information to determine which travel Inspect the sender and the wiring harness connector
position and corresponding component is not responding terminals for continuity. Replace a defective or faulty sender
can be found in the detailed transmission service with a new part.
instructions (covering repair, disassembly, reassembly and
adjustment information) are provided in the c. Transmission Temperature Sender Installation and
ZF 4 WG-98 TC Repair Manual P/N 5871 135 002 Testing
(JLG P/N 8990455). and can be obtained by calling your local
Authorized Service Department. 1. Thread the transmission temperature sender into the
transmission housing snugly, then connect the sender
The transmission should be checked, serviced and repaired connector to the wiring harness connector.
only by experienced service technicians who are aware of all
safety instructions and particular component features. 2. Properly connect the battery. Refer Section 9.8,
Note: Contact your local authorized Service Department if
internal transmission repair is required during the warranty
period.
4. Check for proper fluid level.
5. Start the engine, allow it to reach operating
temperature and observe the operator display cluster
for warning indication. If the sender is not defective, the
problem could be elsewhere; possibly in a shorted wire,
damaged transmission, improper or low fluid, etc.
9-28 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
9.12.4 Service Brake Switch a. Service Brake Switch Removal

If equipped with brake reservoir 1. Park machine on a firm, level surface, level machine,
12 OFF.
13 should not be operated.
5. Label and disconnect the electrical connectors attached
to the service brake switch.
6. Loosen locknut (13) and remove switch dust cover.
Remove switch body.
b. Service Brake Switch Installation

1. Ensure that there is only one thread showing above the
locknut on the shaft of the switch body.
MAQ1720
If not equipped with brake reservoir 2. Insert switch body through the top of the service brake
switch bracket.
3. Thread the switch dust cover onto the switch body until
finger tight against the service brake switch bracket.
4. Use a wrench and fully tighten the locknut against the
service brake switch bracket. 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.
12
6. Connect the cab harness electrical connectors to the
service brake switch connectors.
13 7. Properly connect the battery. Refer Section 9.8,
9. Adjust the brake switch. Refer to Section 9.12.4, “Service
Brake Switch”.
MAG3860
The service brake switch (12) works in conjunction with the

Stabil-TRAK system. With the boom above 40°, the
transmission shifter in either forward or reverse, and the
service brake depressed, the Stabil-TRAK system engages. If
the Service Brake Switch is suspect in the proper operation of
the Stabil-TRAK system, refer to Section 10.7, “Stabil-TRAK™
System Test”.
6036, 6042, 8042, 10042, 10054 31211015 9-29

Electrical System
c. Service Brake Switch Adjustment 9.12.5 Boom Angle Sensor

Note: The service brake switch adjustment will require two
people. Enlist the help of an assistant before attempting to
follow the adjustment procedure.
1. Remove the lower access panel. 14
2. Loosen locknut securing the switch body to the service
brake switch bracket.
3. Connect a 1000 psi (69 bar) pressure gauge to the test
port on the service brake valve.
WARNING
NEVER attempt to adjust the service brake switch MAQ0240
without an assistant. Anytime the engine is running and
the parking brake is disengaged, there must be an The boom angle sensor (14) is located at the rear of, and on
operator located in the cab and the two front tires must the right side of the machine. When the boom is lifted above
be blocked. 40°, the boom sensor sends a signal to the Stabil-TRAK
indicator on the instrument cluster.
4. Block both front tires.
5. Start the engine and run at low idle. a. Boom Angle Sensor Removal
6. Position the boom above 40°, release the park brake 1. Park machine on a firm, level surface, level machine,
and place the transmission in forward 4th gear. fully retract boom, lower boom, place transmission in
7. Slowly depress and hold the brake pedal to maintain (N) NEUTRAL, engage parking brake, and shut engine
200-300 psi (13,8-20,6 bar) brake pressure. OFF.
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 switch and the steering wheel, stating that the machine
Stabil-TRAK dash light comes ON at the 200-300 psi should not be operated.
(13,8-20,6 bar) brake pressure. 3. Open the engine rear and side engine doors. Allow the
9. Repeat steps 6 through 8 until the Stabil-TRAK dash system fluids to cool.
light comes ON at 200-300 psi (13,8-20,6 bar) brake 4. Properly disconnect the battery. Refer Section 9.8,
pressure. “Battery”, for procedure.
10. After the required pressure is achieved, use a wrench 5. Unplug the engine boom angle sensor connector from
and fully tighten the locknut against the service brake the wiring harness connector.
switch bracket.
6. Loosen and remove the sensor locknut.
In order to test the switch for proper operation, the boom
7. Remove the sensor from the outside of boom frame.
must be raised above the 40° position, the parking brake
switch must be in the OFF position and the machine must be
b. Disassembly
in a forward or reverse gear mode. Proper operation of the
switch will activate the Stabil-TRAK dash panel indicator. If DO NOT disassemble the sensor. The sensor is not
the Stabil-TRAK indicator does not activate when all serviceable. Replace the sensor if found to be defective.
conditions are met, the boom angle sensor must be
adjusted. Refer to Section 9.12.5, “Boom Angle Sensor”.
11. Shut off the engine.
12. Remove the blocks from the front tires.
13. Remove the pressure gauge.
14. Install the lower access panel.
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Electrical System
c. Boom Angle Sensor Installation 9.12.6 Boom Extend Interlock Sensor

1. Install boom angle sensor through outside of boom
(10054 only)
frame. The boom extend interlock sensor is located on the left side
2. Install locknut onto sensor. of the machine, on the outer boom frame and just behind the
cab. The boom extend interlock sensor prohibits the last
boom section from extending unless both outriggers are
15 down and pressure is applied to the ground surface.
a. Boom Extend Interlock Sensor Removal

OFF.
MH6310
3. Measure the clearance between the sensor and frame, switch and the steering wheel, stating that the machine
and adjust sensor distance (15) to 0.120” should not be operated.
(3,05 mm) and tighten locknut.
4. Properly connect the battery. Refer Section 9.8, system fluids to cool.
5. Remove the Do Not Operate Tags from both the ignition “Battery”, for procedure.
5. Make note of wire tie locations and clip wire ties where
6. Close and secure the engine rear and side engine doors. necessary.
17
20
18 19
16
MH6121
6. Disconnect the boom interlock sensor electrical

connector (16).
6036, 6042, 8042, 10042, 10054 31211015 9-31

Electrical System
7. Loosen the inside locknut (17) on the sensor (18). 5. Place a Do Not Operate Tag on both the ignition key
8. Slide the sensor out of the bracket and remove. switch and the steering wheel, stating that the machine
b. Boom Extend Interlock Sensor Installation
1. Partially install inside locknut (17) onto the sensor (18).
1
2. Make sure that there are four to six threads,
approximately 0.975 in (24,7mm) and
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. 3
4. Connect the boom extend interlock sensor connector 2

(16) to the boom extend harness connector.
5. Replace wire ties as necessary.
key switch and the steering wheel. MAQ0250
8. Close and secure the engine rear and side engine doors. 6. Disconnect the pressure switch wiring connector (1)
from the harness connector (2).
9.12.7 Outrigger Pressure Switches 7. Remove the outrigger pressure switch (3) from the
(10054 Only) outrigger cylinder.
a. Removal 8. Wipe up any spilled hydraulic oil.
1. Park the machine on a firm, level surface. Level the b. Installation

machine, ground the attachment, place the transmission
in (N) NEUTRAL, place the neutral lock lever in the (N) 1. Install the pressure switch (3), and torque to
NEUTRAL LOCK position and engage the parking brake 25-38 lb-ft (34-41 Nm).
switch. 2. Connect the pressure switch wiring connector (1) to the
2. Raise both outriggers fully, and shut the engine OFF. harness connector (2).
3. Open the engine rear and side engine doors. Allow the 3. Properly connect the battery. Refer Section 9.8,
system fluids to cool. “Battery”, for procedure.
4. Properly disconnect the battery. Refer Section 9.8, 4. Remove the Do Not Operate Tags from both the ignition
“Battery”, for procedure. key switch and the steering wheel.
9-32 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
9.13 DISPLAY MONITOR 9.14 DASH SWITCHES

Note: For information on the front windshield wiper, rear
a. Display Monitor Removal
window wiper and washer systems, refer to Section 9.10,
1. Park the machine on a firm, level surface, level the “Window Wiper/Washer Windshield Wiper Motor”.
the transmission in (N) NEUTRAL, engage the park brake 9.14.1 Ignition Key Switch
2. Place a Do Not Operate Tag on both the ignition key a. Ignition Switch Removal
switch and the steering wheel, stating that the machine 1. Park the machine on a firm, level surface, level the
should not be operated. machine, fully retract the boom, lower the boom, place
3. Open the engine doors. Allow the system fluids to cool. the transmission in (N) NEUTRAL, engage the park brake
“Battery”, for procedure. 2. Place a Do Not Operate Tag on the steering wheel,
stating that the machine should not be operated.
5
4 6
MAQ1730 7
5. Remove the bottom access panel (4).

MAQ1710
6. Loosen and remove the wing nuts from the back of the
display monitor (5) and remove the mounting bracket. 5. Remove the lower access panel (6).
Pull the instrument cluster up and away from the cut- 6. From under the dash, remove the hex nut securing the
out, and unplug the harness connector. ignition key switch (7) to the dash.
7. Label and disconnect the ignition switch connectors
b. Display Monitor Installation
and remove the switch from the machine.
1. Connect the harness connector to the display monitor.
2. Place the display monitor into the cut-out, and secure b. Disassembly
with the previously removed hardware. DO NOT disassemble the ignition switch. Replace a defective
3. Install the bottom access panel. switch with a new part.
6. Close and secure the engine doors.
6036, 6042, 8042, 10042, 10054 31211015 9-33

Electrical System
c. Inspection and Replacement Note: If further information is needed, refer to Section 9.5,
“Electrical System Schematics”.
To determine the proper operation of the ignition key switch,
test the terminals on the back of the switch for continuity
with an ohmmeter.
Test the ignition key switch for continuity, by checking from
the ignition (BLUE) wire to each of the following wires in each
corresponding switch position. Continuity (X) should be
present as indicated in the following chart:
Switch Position
Test from BLUE wire to: OFF RUN START
GRN Wire (8 ga), X
Pin B on 3 Pin Connector
Test the ignition key switch for continuity, by checking from

the ignition (RED) wire to each of the following wires 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
YEL Wire (10 ga), X X
Pin B on 5 Pin Connector
YEL Wire (16 ga), X X
Pin C on 5 Pin Connector
If all terminals do not show proper continuity, replace the

ignition switch.
d. Ignition Switch Installation

1. Connect the ignition key switch to the previously
labeled connectors.
2. The ignition switch has a drain hole located on the shaft,
between the backing nut and the face of the ignition
switch cylinder, behind the dash panel. Align the
ignition switch so that when it is in the OFF position, the
key slot is positioned vertically (straight up and down) and
the indicator mark for the drain hole, is pointing down.
Install the nut securing the ignition switch to the dash.
DO NOT overtighten.
3. Install the lower access panel.
6. Close and secure the engine doors.
9-34 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
9.14.2 Dash Switches d. Switch Installation

1. Connect the switch to the cab harness connector.
a. Switch Removal
2. Position the switch over the rectangular switch bezel
1. Park the machine on a firm, level surface, level the and snap into position.
the transmission in (N) NEUTRAL, engage the park brake 3. Properly connect the battery. Refer Section 9.8,
and shut the engine OFF. “Battery”, for procedure.
2. Place a Do Not Operate Tag on both the ignition key 4. Remove the Do Not Operate Tags from both the ignition
switch and the steering wheel, stating that the machine key switch and the steering wheel.
should not be operated. 5. Start the machine and check the replaced switch for
3. Open the engine doors. Allow the system fluids to cool. proper function.
4. Properly disconnect the battery. Refer Section 9.8, 6. Close and secure the engine doors.
7 8
MAQ1740
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.

Inspect the switch terminals for continuity and shorting in
both the engaged and disengaged positions. Replace a
defective or faulty switch with a new switch.
6036, 6042, 8042, 10042, 10054 31211015 9-35

Electrical System
9.15 MACHINE DATA 9.15.2 Hand Held Analyzer

The hand held Analyzer (PN 2901443) provides machine
9.15.1 Machine Data Access diagnostic, configuration and troubleshooting capabilities.
Machine and engine data can be accessed by connecting to
the appropriate locations shown below.
3 4
1
5 6
2
MZ6040
1. Cable Connector.
MAQ4300 2. Analyzer Display Screen.
The machine analyzer plugs into connector (1) directly below 3. Escape Key: To return home or access previous menu.
the ignition key. For machine diagnostics, refer to Section 4. Enter Key: Stores and selects Top Level, Sub Level and
9.18.1, “Fault Detection”. Items Menus.
The engine data can be accessed through connector (2). For 5. Up/Down Arrow Keys: Change adjustable values.
engine diagnostics, refer to Section 9.18.2, “Offboard 6. Left and Right Arrow Keys: Used to move between Top
Diagnostics”. Level, Sub Levels and Item Menus.
For more information, contact the local JLG dealer.
9-36 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
9.15.3 Mobile Analyzer

The mobile analyzer (PN 1001147542) is a Wi-Fi enabled
evolution of the hand held analyzer kit provides machine
diagnostic, configuration and troubleshooting capabilities
with an extended operator range of up to 150 ft (45,72 m).
2 3
4
5
MAE0930
6
1. Analyzer Display Screen: To display full description
readouts.
2. Escape Key: To return home or access previous menu.
3. Enter Key: Stores and selects Top Level, Sub Level and
Items Menus.
4. Up/Down Arrow Keys: Change adjustable values.
5. Left and Right Arrow Keys: Used to move between Top
Level, Sub Levels and Item Menus.
6. Disconnect: To disconnect the connection of the mobile
from the system.
6036, 6042, 8042, 10042, 10054 31211015 9-37

9-38
9.15.4
note, some screens ma

Note: The layout shows all possible analyz er screens. Please note, le depending upon machine configuration.
may not be a vailable configur
Electrical System
ANALYZER MENU
STRUCTURE
MENU: MENU: MENU: MENU: MENU: MENU:

HELP: PRESS ENTER MACHINE SETUP DIAGNOSTICS ACCESS LEVEL X PERSONALITIES CALIBRATIONS
Analyzer Software Version P1.2
HELP: *(XXXXX) MODEL: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: ACCESS LEVEL: PERSONALITIES: CALIBRATIONS:
???????????????? XXXXX TILT / JOYSTICK ACCEL PEDAL ANTISTALL SYSTEM VERSIONS CODE XXXXX FORK TILT FORK TILT
CAB JOYSTICK: ACCEL PEDAL ANTISTALL CONTROL MODULE CONTROL MODULE: FORK TILT: CAL FORK TILT ?
TILT: NEUTRAL OUTPUT: X% ENG SPD: X RPM VOLTAGE: XX.XV SOFTWARE PX.X ACCEL UP: X.XS YES: ENTER, NO: ESC
CAB JOYSTICK: ACCEL PEDAL ANTISTALL CONTROL MODULE ANALYZER: FORK TILT: FORK TILT ROLLER
TILTA: X.XXV ACCELA: X.XXV ENG TRQ: X% EXCITE: X.XXV ANAL. VER. X.X DECEL UP: X.XS FWD TO MAX
31211015
CAB JOYSTICK: ACCEL PEDAL ANTISTALL FAULT RELAY: FORK TILT: FORK TILT ROLLER
TILTB: X.XXV ACCELB: X.XXV AS CMD: XXXMA CLOSED ACCEL DOWN: X.XS CENTER
FORK TILT ANTISTALL FORK TILT: FORK TILT ROLLER

INPUT: XXX% AS ACT: XXXMA DECEL DOWN: X.XS REV TO MAX
FORK TILT FORK TILT: FORK TILT ROLLER

COMMAND: XXMA MIN UP: XXXXMA CENTER
FORK TILT FORK TILT: CALIBRATIONS:

ACTUAL: XXMA MAX UP: XXXXMA COMPLETE
FORK TILT: CALIBRATIONS:

MIN DOWN: XXXXMA FAILED
FORK TILT:
MAX DOWN: XXXXMA
MAQ42OO
6036, 6042, 8042, 10042, 10054

Electrical System
9.16 ANALYZER SOFTWARE ACCESSIBILITY
9.16.1 Access Level

The access level screen allows to enter a five digit numeric
code to qualify user capability. Code entry determines level
of access.
a. Operator (Access Level 3) - No code required.
b. Service (Access Level 2) - 33271.
Note: Options listed in each analyzer menu may vary based on
machine configuration.
9.16.2 Diagnostics
Menu Description Access Level
Tilt/Joystick Displays the parameter related to the joystick Access Level 2
Accel Pedal Displays the cabin joystick input for the auxiliary Access Level 2
Antistall Displays the parameter related to the outrigger functions if equipped Access Level 2
System Displays the parameter related to the frame leveling. Access Level 2
Displays the version of the software, hardware and constant data of
Versions Access Level 2
control modules in the machine
6036, 6042, 8042, 10042, 10054 31211015 9-39

Electrical System
9.16.3 Machine Set-up
Menu SETTING Description Access Level
6036 63KW HRC

6036 63KW LRC
6036 55KW
6042 63KW HRC
6042 63KW LRC
6042 55KW
8042 82KW HRC
Allows to configure the model number and
Model 8042 82KW LRC Engine for the telehandler Access Level 2, 3
8042 55KW
10042 82KW HRC
10042 82KW LRC
10042 55KW
10054 82KW HRC
10054 82KW LRC
10052 55KW
Note: Settings in BOLD are default values.
9-40 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
9.16.4 Personalities
Menu/ Default Values (Range)

Sub- Access
Function Description
menu 6036, 6042, 8042, 10042, 10052, 10054 Level
Items
0.1
Accel Up: x.xS
(0.0 – 5.0S)
0.3
Decel Up: x.xS
(0.0 – 5.0S)
0.1
Accel Down: x.xS
(0.0 – 5.0S)
Fork tilt screen allows 0.3
Decel Down: x.xS
Fork Tilt
the operator to view (0.0 – 5.0S) Access

the parameters (min/
600mA Level 2, 3
Min Up: xxxxmA max values) related to
fork tilt (100 – 1000mA)
1300mA
Max Up: xxxxmA
(500 – 1700mA)
600mA
Min Down: xxxxmA
(100 – 1000mA)
1300mA
Max Down: xxxxmA
(500 – 1700mA)
6036, 6042, 8042, 10042, 10054 31211015 9-41

Electrical System
9.16.5 Calibrations
Menu Sub-Menu Description Access Level

Allows the operator to calibrate the cabin
Cal. Fork Tilt?
joystick’s fork tilt roller. Press Enter to continue or
Yes: Enter, No: Esc
ESC to exit from the menu.
Fork Tilt Roller Knurl the fork tilt roller to +AR position and press
Fwd To Max Enter key to confirm.
Release the fork tilt roller to center position and

Fork Tilt Roller Center
press Enter key to confirm.
Fork Tilt Roller Knurl the fork tilt roller to -AR position and press
Fork TIlt Access Level 2, 3
Rev To Max Enter key to confirm.
Release the fork tilt roller to center position to

Fork Tilt Roller Center
and press Enter key to confirm.
The control system will display this message if
Complete the procedure is successful. Press the ESC key to
exit from the menu.
The control system will display this message if
Failed the procedure is failed. Press the ESC key to exit
from the menu.
9-42 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
9.17 TELEMATICS GATEWAY

Personnel using machines equipped with an optional
telematics gateway will be able to view the following data
through their telematics device:
JLG LABEL DESCRIPTION UNIT
Engine Speed Actual engine speed. RPM
If machine is equipped, indicates level of DEF (diesel exhaust fluid) within DEF
tank.
DEF Tank Level (If
Percentage (%)
Equipped) • 0% = Empty
• 100% = Full
• 00 - No Machine Faults
JLG Machine Faults: • 01 - Active Machine Fault

Bit
Active / Not-Active • 10 - Error
• 11 - Not available
Total Idle Fuel Used Total amount of fuel used during vehicle operation during idle conditions. Liters
Total Idle Hours Total time of engine operation during idle conditions. Seconds
Total Engine Hours Total time of engine operation. Seconds
Total Fuel Used Total amount of fuel used during vehicle operation. Liters
Fuel Rate Amount of fuel consumed by engine per unit of time. Liters/Hour
Ratio of fuel volume to total volume of fuel storage container. When a low fuel
limit switch is present, fuel level indicates "full" until switch opens, indicating
10% fuel remaining.
Fuel Level Percentage (%)
When Fuel Level 2 (SPN 38) is not used, Fuel Level 1 represents total fuel in all
fuel storage containers. When Fuel Level 2 is used, Fuel Level 1 represents fuel
level in primary or left side fuel storage container.
DM1 Engine Faults Shows actual engine fault codes. N/A
6036, 6042, 8042, 10042, 10054 31211015 9-43

Electrical System
9.17.1 Telematics-Ready (TCU) Plug 9.17.2 Component Locations

The telematics-ready (TCU) plug is a standard 12-pin Deutsch
connector. Pin-out locations are shown below:
12 1 1
11 2
10 3
9 4
8 5
7 6
MAQ4820
1. POWER 7. Not Used

2. GROUND 8. Not Used
3. Not Used 9. CAN-LO 2 2
4. IGNITION 10. CAN-HI 2 3

5. Not Used 11. Not Used
6. Not Used 12. Not Used MAQ4810
1. Gateway Module 3. Telematics-Ready

2. Diagnostics Plug (TCU) Plug
9-44 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
9.17.3 Telematics Gateway Harness Breakdown
a. 2D Harness View
X1145
MAQ4830
X1132
S1142
S1141
X1106
X1105
S1143
S1119
S1144
X1116
S1123
S1114
S1115
S1139
S1140
X1149
X1128
CO1117-J2
CO1117-J1
6036, 6042, 8042, 10042, 10054 31211015 9-45

Electrical System
b. Connector Tables S1123
CO1117-J1 (GATEWAY 1) CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 BLK TELEMATICS GND 16 AWG GXL S1143 (2)
9 GRN CANL1 18 AWG GXL S1115 (1) 1 BLK TELEMATICS GND 16 AWG GXL X1145 (2)
10 YEL CANH1 18 AWG GXL S1114 (1) 2 BLK TELEMATICS IGN 16 AWG GXL CO1117-J1 (11)
11 BLK TELEMATICS GND 18 AWG GXL S1123 (2)

S1143
12 ORN TELEMATICS IGN 16 AWG GXL S119 (2)
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO
CO1117-J2 (GATEWAY 2) 1 BLK GND 16 AWG GXL X1105 (A)
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 BLK GND 16 AWG GXL X1116 (A)
9 GRN CANL1 18 AWG GXL S1139 (1) 2 BLK TELEMATICS GND 16 AWG GXL S1123 (1)
10 YEL CANH1 18 AWG GXL S1140 (1)

S1144
X1128 (CAN2 TERMINATOR) CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 1 RED PWR 16 AWG GXL X1105 (B)
A YEL CANH2 18 AWG GXL S1140 (1) 1 RED PWR 16 AWG GXL X1116 (B)
B GRN CANL2 18 AWG GXL S1139 (1) 2 RED TELEMATICS PWR 16 AWG GXL X1145 (1)
X1149 (CAN1 TERMINATOR) S1119
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO
A YEL CANH1 18 AWG GXL S1114 (1) 1 ORN IGN 16 AWG GXL X1105 (J)
B GRN CANL2 18 AWG GXL S1115 (1) 1 ORN IGN 16 AWG GXL X1116 (J)
2 ORN TELEMATICS IGN 16 AWG GXL CO1117-J1 (12)

S1139
2 ORN TELEMATICS IGN 16 AWG GXL X1145 (4)
1 GRN CANL2 18 AWG GXL CO1117-J2 (9) X1116 (DIAGNOSTIC)
1 GRN CANL2 18 AWG GXL X1128 (B) CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO
2 GRN CANL2 18 AWG GXL S1141 (1) A BLK GND 16 AWG GXL S1143 (1)
B RED PWR 16 AWG GXL S1144 (1)

S1140
C YEL CANH 18 AWG GXL X1105 (C)
D GRN CANL 18 AWG GXL X1105 (D)
1 YEL CANH2 18 AWG GXL CO1117-J2 (10)
H ORN IGN 16 AWG GXL X1105 (H)
1 YEL CANH2 18 AWG GXL X1128 (A)
J ORN IGN 16 AWG GXL S1119 (2)
X1105 (CAB PWR)
S1114
A BLK GND 16 AWG GXL S1143 (1)
1 YEL CANH1 18 AWG GXL CO1117-J1 (10)
B RED PWR 16 AWG GXL S1144 (1)
C YEL CANH 18 AWG GXL X1116 (C)
D GRN CANL 18 AWG GXL X1116 (D)
S1115 H ORN IGN 16 AWG GXL X1116 (H)
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO J ORN IGN 16 AWG GXL S1119 (I)
1 GRN CANL1 18 AWG GXL CO1117-J1 (9)
1 GRN CANL1 18 AWG GXL X1149 (B)
9-46 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
X1145 (TELEMATICS)
1 RED TELEMATICS POWER 16 AWG GXL S1144 (2)
2 BLK TELEMATICS GND 16 AWG GXL S1123 (1)
4 ORN TELEMATICS IGN 16 AWG GXL S1119 (2)
9 GRN CANL2 16 AWG GXL S1141 (2)
X1106 (CAB CAN1)

A YEL CANH1 18 AWG GXL S1114 (2)
B GRN CANL1 18 AWG GXL S1115 (2)
S1142
2 YEL CANH2 16 AWG GXL X1145 (10)
S1141
1 GRN CANL2 18 AWG GXL S1139 (2)
2 GRN CANL2 16 AWG GXL X1145 (9)
X1132 (CAN2 TERMINATOR

A YEL CANH2 18 AWG GXL S1142 (2)
B GRN CANL2 18 AWG GXL S1141 (2)
6036, 6042, 8042, 10042, 10054 31211015 9-47

c.
9-48
3D Harness View
Electrical System
X1105
X1106
S1143
S1144
CO1117-J2
S1119 CO1117-J1
31211015
X1116
X1106
X1149
X1128
S1139 X1132
X1145
S1140
S1114
S1115 S1141 S1142
MAQ4850
S1123
6036, 6042, 8042, 10042, 10054

Electrical System
9.18 TROUBLESHOOTING
9.18.1 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,
engine faults will appear as a SPN:FMI fault. Fault codes will
display in the instrument cluster display (9).
For more information, contact your local authorized engine
service distributor.
Note: If indicator (10 & 11) illuminates, refer to Section 9.20,
“Engine Fault Codes,” for a full list of fault codes.
Note: If indicator (12) illuminates, refer to Section 9.19.1, “Help
Comment (00X),” for a full list of fault codes.
10 11
12
9
MAQ4400
9.18.2 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.
6036, 6042, 8042, 10042, 10054 31211015 9-49

Electrical System
9.19 MACHINE FAULT CODES

Note: Some fault codes may not be applicable depending upon machine configuration.
9.19.1 Help Comment (00X)

Fault
Message Actions Trigger for Fault Latch Condition
Code
EVERYTHING OK 1 - The system detects no problems exist. -
9.19.2 Power-Up (21x)

Fault
Code
POWER CYCLE 211 - Triggered every power cycle -
JOYSTICK ROLLER NOT Fork Tilt Up Valve prevented One of the following occur at power-up:
Fork Tilt A Position and Fork
IN NEUTRAL POSITION 216 Tilt Position A not 0% Tilt B Position 0%
AT POWER UP Fork Tilt Down Valve prevented
Tilt Position B not 0%
THROTTLE PEDAL NOT
2130 Closed Throttle RPM forced Accel Pedal A greater than or equal to 10% at power-up Accel Pedal A less than 10%
RELEASED AT POWER UP
9.19.3 Cabin Controls (23x)

Fault
Code
FORK TILT JOYSTICK – Fork Tilt Up Valve prevented
Tilt Position A and Tilt Position B differ by more than
VOLTAGE 2397 Power cycled
25% for at least 1000mS
DISAGREEMENT Fork Tilt Down Valve prevented
Fork Tilt Up Valve prevented

FORK TILT JOYSTICK – One of the following occur: Tilt Voltage A greater than
2398 Power cycled
OUT OF RANGE HIGH 4.85V Tilt Voltage B greater than 4.85V
Fork Tilt Down Valve prevented
Fork Tilt Up Valve prevented One of the following occur:

FORK TILT JOYSTICK –
2399 Tilt Voltage A less than 0.15V Power cycled
OUT OF RANGE LOW Fork Tilt Down Valve prevented
Tilt Voltage B less than 0.15V
FUNCTION PROBLEM –
Pedal Cal OK is NO; Pedal Cal OK is YES
THROTTLE PEDAL 23194 Closed Throttle RPM forced
refer to Accelerator Pedal Calibration OK functionality (calibration completed)
CALIBRATION FAULTY
FUNCTION PROBLEM – Fork Tilt Up Valve prevented

Tilt Cal OK is NO; refer to Fork Tilt Calibration OK Tilt Cal OK is YES (calibration
JOYSTICK CALIBRATION 23195
functionality completed)
FAULTY Fork Tilt Down Valve prevented
9-50 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
9.19.4 Function Prevented (25x)

Fault
Code
MODEL CHANGED – Fork Tilt Up Valve prevented
HYDRAULICS
259 Machine Setup’s MODEL changed via the JLG Analyzer Power cycled
SUSPENDED – CYCLE Fork Tilt Down Valve prevented
EMS
9.19.5 Output Drivers (33x)

Fault
Code
All of the following occur for 1000mS:
FORK TILT UP VALVE – Fork Tilt Up Command greater than 250mA
33191 - Power cycled
OPEN CIRCUIT Fork Tilt Up Actual less than 75mA
DTC33192 not active
Fork Tilt Up Command is 0mA and driver feedback is
FORK TILT VALVES – Fork Tilt Down Valve prevented
33192 low Power cycled
SHORT TO BATTERY
Low-Side Fault Relay de- Fork Tilt Down Command is 0mA and driver feedback is
energized low
All of the following occur with no debounce:

FORK TILT UP VALVE –
33193 Fork Tilt Up Valve prevented Power cycled
SHORT TO GROUND Fork Tilt Up Actual greater than 20mA
Driver feedback is low
FORK TILT DOWN VALVE Fork Tilt Down Command greater than 250mA
33194 - Power cycled
– OPEN CIRCUIT
Fork Tilt Down Actual less than 75mA
DTC33192 not active
All of the following occur with no debounce:

FORK TILT DOWN VALVE
33195 Fork Tilt Down Valve prevented Power cycled
– SHORT TO GROUND Fork Tilt Down Actual greater than 20mA
All of the following occur: Torque-Based or Speed-
ANTI-STALL VALVE –
33426 - Based Anti-Stall enabled Anti-Stall Command is 0mA Power cycled
SHORT TO BATERY
Torque-Based or Speed-Based
ANTI-STALL VALVE –
33427 - Anti-Stall enabled Anti-Stall Valve Actual (mA) < Anti- Power cycled
OPEN CIRCUIT
Stall Valve Open-Circuit Limit (mA)
DTC 33426 not active
All of the following occur for 500mS: Torque-Based or
ANTI-STALL VALVE – Speed-Based Anti-Stall enabled
33428 Anti-Stall Valve prevented Power cycled
SHORT TO GROUND Anti-Stall Valve Actual (mA) > Anti-Stall Valve Short to
Ground Limit (mA)
6036, 6042, 8042, 10042, 10054 31211015 9-51

Electrical System
9.19.6 Engine (43x)

Fault
Code
One of the following occur:
THROTTLE PEDAL – Pedal A Voltage greater than 4.50V
Engine speed set to Closed
VOLTAGE OUT OF 4337 Pedal B Voltage greater than 4.50V Power cycled
Throttle RPM
RANGE Pedal A Voltage less than 0.40V
Pedal B Voltage less than 0.40V
THROTTLE PEDAL –
Engine speed set to Closed Accel Pedal A (%) and Accel Pedal B (%) differ by more
VOLTAGE 4338 Power cycled
Throttle RPM than 6%
DISAGREEMENT
Machine Setup’s MODEL is 6036 55KW, 6042 55KW,

WRONG ENGINE Engine speed set to Closed
4367 8042 55KW, 10042 55KW, or 10054 55KW; Power cycled
SELECTED Throttle RPM
SPN166EngRatedPower > 53KW or < 57KW
9.19.7 Battery Supply (44x)

Fault
Code
BATTERY VOLTAGE TOO Fork Tilt Down Valve prevented

Ignition Voltage > 10.0V for
LOW – SYSTEM 441 Ignition Voltage < 8.0V for 3000mS
Anti-Stall Valve prevented 3000mS
SHUTDOWN
Throttle RPM

BATTERY VOLTAGE TOO
HIGH – SYSTEM 442 Anti-Stall Valve prevented Ignition Voltage > 16.0V for 3000mS Power cycled
SHUTDOWN Low-Side Fault Relay de-
energized
Throttle RPM

VOLTAGE REFERENCE
447 Anti-Stall Valve prevented Analog Voltage Reference > 5.4V or < 4.6V for 1000mS Power cycled
OUT OF RANGE
Low-Side Fault Relay de-
energized
Throttle RPM
9.19.8 Communications (66x)

Fault
Code
SPN1172InletTemp defaults to
CANBUS FAILURE – +20°C CANbus messages from ECM not detected for at least
666 Messages resume for 1000mS
ENGINE CONTROLLER All other signals from the ECM 1000mS
default to 0
9-52 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
9.19.9 Hardware (99x)

Fault
Code
Fork Tilt Down Valve prevented Machine Setup setting outside adjustment limits
Machine Setup’s MODEL

EEPROM FAILURE – Anti-Stall Valve prevented Personality setting outside adjustment limits
998 changed to trigger defaults;
CHECK ALL SETTINGS
Low-Side Fault Relay de- power-cycled
Calibration setting outside calibration limits
energized
Non-volatile storage checksum issue
Throttle RPM
6036, 6042, 8042, 10042, 10054 31211015 9-53

Electrical System
9.20 ENGINE FAULT CODES

Revision 16
Note: For more information, contact your local authorized
engine service distributor.
Fault
SPN FMI SPN Description Description
Code
Engine Exhaust Gas EGR Valve Position - Data erratic, intermittent or

27 2 1228
Recirculation 1 Valve Position incorrect
Engine Exhaust Gas Recirculation 1 EGR Valve Position Circuit - Voltage below normal, or
27 4 2272
Valve Position shorted to low source
Engine Intake Throttle Actuator Position Sensor

Engine Intake Throttle Actuator
51 3 6497 Circuit- Voltage above normal, or shorted to high
Position Sensor Circuit
source
Engine Intake Throttle Actuator Position Sensor

Engine Intake Throttle Actuator
51 4 6498 Circuit- Voltage above normal, or shorted to low
Position Sensor Circuit
source
Engine Diesel Particulate Filter Intake Pressure - Data

Engine Diesel Particulate Filter Intake
81 16 2754 Valid But Above Normal Operating Range -
Pressure
Moderately Severe Level
Wheel-Based Vehicle Speed - Data erratic, intermittent

84 2 241 Wheel-Based Vehicle Speed
or incorrect
Wheel-Based Vehicle Speed Sensor Circuit tampering

has been detected - Abnormal rate of change
Wheel-Based Vehicle Speed - Received Network Data

In Error
84 9 3526 Wheel-Based Vehicle Speed Wheel-Based Vehicle Speed - Abnormal update rate
Accelerator Pedal or Lever Position Sensor 1 Circuit -

91 3 131 Accelerator Pedal Position 1
Voltage above normal, or shorted to high source

Voltage below normal, or shorted to low source
Accelerator Pedal or Lever Position 1 Sensor Circuit

91 1 147 Accelerator Pedal Position 1 Frequency - Data valid but below normal operating
Range
Accelerator Pedal or Lever Position Sensor 1 - Data

91 0 148 Accelerator Pedal Position 1 valid but above normal operational range - Most
Severe Level
Accelerator Pedal or Lever Position Sensor 1 - Data

erratic, intermittent or incorrect
9-54 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
Fault
Code


SAE J1939 Multiplexed Accelerator Pedal or Lever

Sensor System - Received Network Data In Error
SAE J1939 Multiplexed Accelerator Pedal or Lever

Sensor System - Abnormal update rate
Auxiliary Alternate Torque Validation Switch - Data

93 2 528 Engine Net Brake Torque
Fuel Delivery Pressure Sensor Circuit - Voltage above

94 3 546 Engine Fuel Delivery Pressure
normal, or shorted to high source
Fuel Delivery Pressure Sensor Circuit - Voltage below

normal, or shorted to low source
Fuel Pump Delivery Pressure - Data Valid But Below

Normal Operating Range - Moderately Severe Level
Fuel Pump Delivery Pressure - Data Valid But Above

Normal Operating Range - Least Severe Level
Fuel Pump Delivery Pressure - Data Valid But Below

Engine Fuel Delivery Pressure - Data Valid but Above

Normal Operational Range - Most Severe Level
Fuel Filter Differential Pressure - Data Valid But Above

95 16 2372 Engine Fuel Filter Differential Pressure
Water in Fuel Indicator - Data Valid But Above Normal

97 15 418 Water In Fuel Indicator
Operating Range - Least Severe Level
Water in Fuel Indicator Sensor Circuit - Voltage above

Water in Fuel Indicator Sensor Circuit - Voltage below

Water in Fuel Indicator - Data Valid But Above Normal

Operating Range - Moderately Severe Level
Engine Oil Level - Data valid but below normal

98 1 253 Engine Oil Level
operational range - Most Severe Level
6036, 6042, 8042, 10042, 10054 31211015 9-55

Electrical System
Fault
Code
Engine Oil Level - Data Valid But Below Normal

Engine Oil Level - Data valid but above normal

Engine Oil Rifle Pressure 1 Sensor Circuit - Voltage

100 3 135 Engine Oil Pressure
above normal, or shorted to high source
Engine Oil Rifle Pressure 1 Sensor Circuit - Voltage

below normal, or shorted to low source
Engine Oil Rifle Pressure - Data Valid But Below Normal

Engine Oil Rifle Pressure - Data valid but below normal

Engine Oil Rifle Pressure - Data erratic, intermittent or

incorrect
Crankcase Pressure - Data Valid But Above Normal

101 16 555 Engine Crankcase Pressure
Crankcase Pressure - Data valid but above normal

Crankcase Pressure Circuit - Voltage above normal, or

shorted to high source
Crankcase Pressure Circuit - Voltage below normal, or

shorted to low source
Crankcase Pressure - Data erratic, intermittent or

incorrect
Crankcase Pressure - Data Valid But Above Normal

Engine Intake Manifold #1 Intake Manifold 1 Pressure Sensor Circuit - Voltage

102 3 122
Pressure above normal, or shorted to high source
Engine Intake Manifold #1 Intake Manifold 1 Pressure Sensor Circuit - Voltage

102 4 123
Pressure below normal, or shorted to low source
Engine Intake Manifold #1 Intake Manifold 1 Pressure - Data Valid But Above
102 16 124
Pressure Normal Operating Range - Moderately Severe Level
Engine Intake Manifold #1 Intake Manifold 1 Pressure - Data Valid But Below
102 18 125
Pressure Normal Operating Range - Moderately Severe Level
9-56 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
Fault
Code
Intake Manifold 1 Pressure - Data erratic, intermittent

102 2 2973 Engine Intake Manifold #1 Pressure
or incorrect
102 10 3361 Engine Intake Manifold #1 Pressure Intake Manifold 1 Pressure - Abnormal rate of change
Turbocharger 1 Speed - Data Valid But Above Normal

103 16 595 Engine Turbocharger 1 Speed
Turbocharger 1 Speed - Data erratic, intermittent or

incorrect
Turbocharger 1 Speed - Data Valid But Below Normal

Turbocharger 1 Speed - Data Valid But Above Normal

Engine Turbocharger Lube Oil Pressure - Data Valid

Engine Turbocharger Lube Oil
104 18 3917 But Below Normal Operating Range - Moderately
Pressure 1
Severe Level
Engine Intake Manifold 1 Intake Manifold 1 Temperature Sensor Circuit -

105 3 153
Temperature Voltage above normal, or shorted to high source
Intake Manifold 1 Temperature Sensor Circuit -

105 4 154 Engine Intake Manifold 1Temperature
Intake Manifold 1 Temperature - Data valid but above

105 0 155 Engine Intake Manifold 1 Temperature
normal operational range - Most Severe Level
Intake Manifold 1 Temperature - Data erratic,

intermittent or incorrect
Intake Manifold 1 Temperature - Data Valid But Above

105 16 488 Engine Intake Manifold Temperature
Engine Intake Manifold #1 Intake Manifold 1 Temperature - Data Valid But Above
105 15 2964
Temperature Normal Operating Range - Least Severe Level
Intake Manifold 1 Temperature - Data Valid But Below

Engine Air Filter Differential Pressure - Data Valid But

107 16 3341 Engine Air Filter 1 Differential Pressure Above Normal Operating Range - Moderately Severe
Level
Engine Air Filter Differential Pressure - Data Valid But

107 15 5576 Engine Air Filter 1 Differential Pressure
Above Normal Operating Range - Least Severe Level
Barometric Pressure Sensor Circuit - Voltage above

108 3 221 Barometric Pressure
6036, 6042, 8042, 10042, 10054 31211015 9-57

Electrical System
Fault
Code
Barometric Pressure Sensor Circuit - Voltage above

Barometric Pressure - Data erratic, intermittent or

incorrect
Coolant Pressure Sensor Circuit - Voltage above

109 3 231 Engine Coolant Pressure
Coolant Pressure Sensor Circuit - Voltage below

Coolant Pressure - Data Valid But Below Normal

Engine Coolant Temperature 1 Sensor Circuit - Voltage

110 3 144 Engine Coolant Temperature
Engine Coolant Temperature 1 Sensor Circuit - Voltage

Engine Coolant Temperature - Data Valid But Above

Engine Coolant Temperature - Data valid but above

110 0 151 Temperature
Engine Coolant Temperature - Data erratic,

110 14 1847 Engine Coolant Temperature Engine Coolant Temperature - Special Instructions
110 31 2646 Engine Coolant Temperature Engine Coolant Temperature - Condition Exists
110 31 2659 Engine Coolant Temperature Engine Coolant Temperature - Condition Exists
Engine Coolant Temperature - Data Valid But Below

Engine Coolant Temperature - Data Valid But Above

Coolant Level Sensor 1 Circuit - Voltage above normal,

111 3 195 Engine Coolant Level
or shorted to high source
Coolant Level Sensor 1 Circuit - Voltage below normal,

or shorted to low source
9-58 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
Fault
Code
Coolant Level - Data Valid But Below Normal

Coolant Level - Data valid but below normal

111 2 422 Engine Coolant Level Coolant Level - Data erratic, intermittent or incorrect


SAE J1939 Multiplexing PGN Timeout Error - Abnormal

111 9 3613 SAE J1939 Multiplexing PGN Timeout
update rate
111 19 3614 SAE J1939 Multiplexing PGN Timeout Coolant Level Sensor - Received Network Data in Error

Coolant Level Sensor 1 Circuit - Voltage above normal,

Coolant Level Sensor 1 Circuit - Voltage below normal,

Engine Injector Metering Rail 1 Injector Metering Rail 1 Pressure - Data valid but above
157 0 449
Pressure normal operational range - Most Severe Level
Engine Injector Metering Rail 1 Injector Metering Rail 1 Pressure Sensor Circuit -
157 3 451
Pressure Voltage above normal, or shorted to high source
157 4 452
Pressure Voltage below normal, or shorted to low source
Injector Metering Rail 1 Pressure - Data Valid But

Engine Injector Metering Rail 1
157 16 553 Above Normal Operating Range - Moderately Severe
Pressure
Level
Engine Injector Metering Rail 1 Injector Metering Rail 1 Pressure - Data erratic,
157 2 554
Pressure intermittent or incorrect
Injector Metering Rail 1 Pressure - Data Valid But

Engine Injector Metering Rail 1
157 18 559 Below Normal Operating Range - Moderately Severe
Pressure
Level
Engine Injector Metering Rail 1 Injector Metering Rail 1 Pressure - Mechanical system
157 7 755
Pressure not responding or out of adjustment
6036, 6042, 8042, 10042, 10054 31211015 9-59

Electrical System
Fault
Code
Engine Injector Metering Rail 1 Injector Metering Rail 1 Pressure - Data valid but below
157 1 2249
Pressure normal operational range - Most Severe Level
Engine Injector Metering Rail 1 Injector Metering Rail 1 Pressure - Data Valid But
157 15 4727
Pressure Above Normal Operating Range - Least Severe Level
Battery 1 Voltage - Data Valid But Below Normal

168 18 441 Battery Potential / Power Input 1
Battery 1 Voltage - Data Valid But Above Normal


Battery 1 Voltage - Data Valid But Above Normal


Ambient Air Temperature Sensor 1 Circuit - Voltage

171 3 249 Ambient Air Temperature
Ambient Air Temperature Sensor 1 Circuit - Voltage

Ambient Air Temperature - Data erratic, intermittent

or incorrect
171 9 3531 Ambient Air Temperature Ambient Air Temperature - Abnormal update rate
Ambient Air Temperature - Received Network Data In

Error
Engine Fuel Temperature - Data Valid But Above

174 16 261 Engine Fuel Temperature 1
Engine Fuel Temperature Sensor 1 Circuit - Voltage

Engine Fuel Temperature Sensor 1 Circuit - Voltage

Engine Fuel Temperature - Data valid but above

Engine Fuel Temperature - Data erratic, intermittent or

incorrect
9-60 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
Fault
Code
Engine Oil Temperature Sensor 1 Circuit - Voltage

175 3 212 Engine Oil Temperature 1

Engine Oil Temperature - Data valid but above normal

Engine Oil Temperature - Data Valid But Above Normal

Engine Oil Temperature - Data erratic, intermittent or

incorrect


Engine Speed At Idle, Point 1 (Engine Engine Speed At Idle - Data Valid But Above Normal
188 16 3715
Configuration) Operating Range - Moderately Severe Level
Engine Speed At Idle, Point 1 (Engine Engine Speed At Idle - Data Valid But Below Normal
188 18 3716
Configuration) Operating Range - Moderately Severe Level
Engine Crankshaft Speed/Position - Data valid but

190 0 234 Engine Speed
above normal operational range - Most Severe Level
Engine Crankshaft Speed/Position - Data erratic,

Engine Crankshaft Speed/Position - Data Valid But

190 16 1992 Engine Speed Above Normal Operating Range - Moderately Severe
Level
Engine Crankshaft Speed/Position - Data erratic,

Engine Crankshaft Speed/Position - Data Valid But

190 16 2468 Engine Speed Above Normal Operating Range - Moderately Severe
Level
Transmission Output Shaft Speed - Data Valid But

191 16 349 Transmission Output Shaft Speed Above Normal Operating Range - Moderately Severe
Level
Transmission Output Shaft Speed - Data Valid But

191 18 489 Transmission Output Shaft Speed Below Normal Operating Range - Moderately Severe
Level
6036, 6042, 8042, 10042, 10054 31211015 9-61

Electrical System
Fault
Code
Transmission Output Shaft Speed - Abnormal update

191 9 3328 Transmission Output Shaft
rate
Transmission Output Shaft Speed - Received Network

191 19 3418 Transmission Output Shaft Speed
Data In Error
237 13 4517 Vehicle Identification Number Vehicle Identification Number - Out of Calibration
237 31 4721 Vehicle Identification Number Vehicle Identification Number - Condition Exists
Vehicle Identification Number - Data erratic,

237 2 4722 Vehicle Identification Number
251 2 319 Real Time Clock Real Time Clock - Data erratic, intermittent or incorrect
Engine Exhaust Gas

Exhaust Gas Recirculation Differential Pressure - Data
411 2 1866 Recirculation 1 Differential
Pressure
Exhaust Gas Recirculation Differential Pressure Sensor

Engine Exhaust Gas Recirculation 1
411 3 2273 Circuit - Voltage above normal, or shorted to high
Differential Pressure
source
Exhaust Gas Recirculation Differential Pressure Sensor

411 4 2274 Circuit - Voltage below normal, or shorted to low
Differential Pressure
source
Engine Exhaust Gas Recirculation 1 Exhaust Gas Recirculation Temperature - Data erratic,
412 2 1867
Temperature intermittent or incorrect
Engine Exhaust Gas Exhaust Gas Recirculation Temperature Sensor Circuit

412 3 2375
Recirculation 1 Valve Position - Voltage above normal, or shorted to high source
Engine Exhaust Gas Exhaust Gas Recirculation Temperature Sensor Circuit

412 4 2376
Recirculation 1 Temperature - Voltage below normal, or shorted to low source
Exhaust Gas Recirculation Temperature - Data Valid

412 15 2961 But Above Normal Operating Range - Least Severe
Temperature
Level
Exhaust Gas Recirculation Temperature - Data Valid

412 16 2962 But Above Normal Operating Range - Moderately
Temperature
Severe Level
Auxiliary Temperature Sensor Input 1 - Special

441 14 292 Auxiliary Temperature 1
Instructions
Auxiliary Temperature Sensor Input 1 Circuit - Voltage

9-62 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
Fault
Code

Auxiliary Temperature Sensor Input 1 - Special

Instructions


Brake Pedal Position - Data erratic, intermittent or

521 2 4526 Brake Pedal Position
incorrect
Accelerator Pedal or Lever Idle Validation Switch -

558 2 431 Accelerator Pedal 1 Low Idle Switch
Data erratic, intermittent or incorrect
Accelerator Pedal or Lever Idle Validation Switch

Circuit - Out of Calibration

Received Network Data In Error

Abnormal update rate
Anti-Lock Braking (ABS) Controller - Abnormal update

563 9 3488 Anti-Lock Braking (ABS) Active
rate
563 31 4215 Anti-Lock Braking (ABS) Active Anti-Lock Braking (ABS) Active - Condition Exists
Cruise Control Enable Switch - Mechanical system not

596 7 3839 Cruise Control Enable Switch
responding or out of adjustment
Cruise Control Enable Switch - Data erratic,

596 2 3841 Cruise Control Enable Switch
596 13 3842 Cruise Control Enable Switch Cruise Control Enable Switch - Out of Calibration
Brake Switch Circuit - Voltage above normal, or

597 3 769 Brake Switch
Brake Switch Circuit - Voltage below normal, or

597 4 771 Brake Switch
Cruise Control Set Switch - Data erratic, intermittent or

599 2 2721 Cruise Control Set Switch
incorrect
6036, 6042, 8042, 10042, 10054 31211015 9-63

Electrical System
Fault
Code
Auxiliary Intermediate (PTO) Speed Switch Validation -

611 2 523 System Diagnostic Code #1
Engine Magnetic Speed/Position Lost Both of Two

612 2 115 System Diagnostic Code #2
Signals - Data erratic, intermittent or incorrect
Proprietary Datalink Error (OEM/Vehicle Datalink) -

625 9 291 Proprietary Datalink
Start Enable Device 1 Canister Empty (Ether Injection) -

626 18 487 Engine Start Enable Device 1
Data Valid But Below Normal Operating Range
Start Enable Device 1 Circuit (Ether Injection) - Voltage

Start Enable Device 1Circuit (Ether Injection) - Voltage

Engine Control Module Critical Internal Failure - Bad

629 12 111 Controller #1
intelligent device or component
Engine Control Module Warning Internal Hardware

Failure - Bad intelligent device or component
At Least One Unacknowledged Most Severe Fault -

Condition Exists
At Least One Unacknowledged Moderately Severe

Fault - Condition Exists
Engine Control Module Calibration Engine Control Module Calibration Memory - Bad
630 12 3697
Memory intelligent device or component
Engine Fuel Actuator 1 Control Electronic Fuel Injection Control Valve Circuit -
633 31 2311
Command Condition Exists
J1939 Network #1, Primary Vehicle

SAE J1939 Multiplexing PGN Timeout Error - Abnormal
639 9 285 Network (previously SAE J1939 Data
update rate
Link)

SAE J1939 Multiplexing Configuration Error - Out of
Calibration
Link)

J1939 Network #1 - Data erratic, intermittent or
incorrect
Link)

639 9 427 Network (previously SAE J1939 Data SAE J1939 Datalink - Abnormal update rate
Link)
9-64 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
Fault
Code
Auxiliary Commanded Dual Output Shutdown -

640 14 599 Engine External Protection Input
Special Instructions
Engine Variable Geometry

641 9 1894 VGT Actuator Driver Circuit - Abnormal update rate
Turbocharger Actuator #1

641 13 1898 VGT Actuator Controller - Out of Calibration
VGT Actuator Driver Over Temperature (Calculated) -

641 15 1962 Data Valid But Above Normal Operating Range - Least
Severe Level
VGT Actuator Driver Over Temperature (Calculated) -

641 15 1976 Data Valid But Above Normal Operating Range - Least
Severe Level

641 11 2198 VGT Actuator Driver Circuit - Root Cause Not Known
Engine Variable Geometry VGT Actuator Driver Circuit (Motor) - Mechanical

641 7 2387
Turbocharger Actuator #1 system not responding or out of adjustment

641 13 2449 VGT Actuator Controller - Out of Calibration
Engine Variable Geometry VGT Actuator Controller - Bad intelligent device or

641 12 2634
Turbocharger Actuator #1 component

641 31 2635 VGT Actuator Driver Circuit - Condition Exists

641 9 2636 VGT Actuator Driver Circuit - Abnormal update rate
External Speed Command Input (Multiple Unit

Engine External Speed Command
644 2 237 Synchronization) - Data erratic, intermittent or
Input
incorrect
Engine Fan Clutch 1 Output Device Fan Control Circuit - Voltage below normal, or shorted
647 4 245
Driver to low source
Engine Fan Clutch 1 Output Device Fan Control Circuit - Voltage above normal, or shorted
647 3 2377
Driver to high source
Engine Fan Clutch 1 Output Device Fan Control Circuit - Voltage above normal, or shorted
647 3 6263
Driver to high source
Engine Fan Clutch 1 Output Device Fan Control Circuit - Voltage below normal, or shorted
647 4 6264
Driver to low source
6036, 6042, 8042, 10042, 10054 31211015 9-65

Electrical System
Fault
Code
Engine Exhaust Back Pressure Regulator Control
Engine Exhaust Back Pressure
649 3 5271 Circuit - Voltage Above Normal, or Shorted to High
Regulator Control Circuit
Source
Engine Exhaust Back Pressure Regulator Control

649 4 5272 Circuit - Voltage Below Normal, or Shorted to Low
Regulator Control Circuit
Source
Engine Exhaust Back Pressure Engine Exhaust Back Pressure Regulator Control
649 5 5273
Regulator Control Circuit Circuit - Current Below Normal or Open Circuit
Injector Solenoid Driver Cylinder 1 Circuit - Current

651 5 322 Engine Injector Cylinder #01
below normal or open circuit
Injector Solenoid Driver Cylinder 1 - Mechanical

system not responding or out of adjustment












9-66 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
Fault
Code








Starter Relay Driver Circuit - Voltage above normal, or

677 3 584 Engine Starter Motor Relay
Starter Relay Driver Circuit - Voltage below normal, or

677 4 585 Engine Starter Motor Relay
Auxiliary PWM Driver 1 Circuit - Voltage above normal,

697 3 2557 Auxiliary PWM Driver #1
Auxiliary PWM Driver 1 Circuit - Voltage below normal,

697 4 2558 Auxiliary PWM Driver #1
701 14 4734 Auxiliary I/O #01 Auxiliary Input/Output 1 - Special Instructions
Auxiliary Input/Output 2 Circuit - Voltage above

702 3 527 Auxiliary I/O #02
Auxiliary Input/Output 2 Circuit - Current below

702 5 4724 Auxiliary I/O #02
normal or open circuit
Auxiliary Input/Output 2 Circuit - Current above

702 6 4725 Auxiliary I/O #02
normal or grounded circuit
Auxiliary Input/Output 3 Circuit - Voltage above

703 3 529 Auxiliary I/O #03
6036, 6042, 8042, 10042, 10054 31211015 9-67

Electrical System
Fault
Code
Engine Speed / Position Camshaft and Crankshaft
723 7 731 Engine Speed 2 Misalignment - Mechanical system not responding or
out of adjustment
Engine Camshaft Speed / Position Sensor - Data

723 2 778 Engine Speed 2
Engine Camshaft Speed / Position Sensor - Data

723 2 2322 Engine Speed 2
Engine Intake Air Heater 1 Circuit - Voltage above

729 3 2555 Engine Intake Air Heater Driver #1
Engine Intake Air Heater 1 Circuit - Voltage below

Engine Intake Air Heater 1 Circuit - Voltage above

Engine Intake Air Heater 1 Circuit - Voltage below

748 9 3641 Transmission Output Retarder Transmission Output Retarder - Abnormal update rate
Crankcase Breather Filter Heater Circuit - Voltage

862 3 3733 Crankcase breather Heater Circuit



Remote Accelerator Pedal or Lever Position Sensor 1

974 3 133 Remote Accelerator Pedal Position Circuit - Voltage above normal, or shorted to high
source
Remote Accelerator Pedal or Lever Position Sensor 1

974 4 134 Remote Accelerator Pedal Position Circuit - Voltage below normal, or shorted to low
source
SAE J1939 Multiplexing Remote Accelerator Pedal or

974 19 288 Remote Accelerator Pedal Position Lever Position Sensor System - Received Network Data
In Error
Auxiliary Intermediate (PTO) Speed Switch Validation -

976 2 6563 PTO Governor State
9-68 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
Fault
Code
Engine (Compression) Brake Output Engine Brake Actuator Driver 1 Circuit - Voltage above
1072 3 2182
#1 normal, or shorted to high source
Engine (Compression) Brake Output Engine Brake Actuator Driver 1 Circuit - Voltage below
1072 4 2183
#1 normal, or shorted to low source
1072 3 6418
Engine (Compression) Brake Output Engine Brake Actuator Driver 1 Circuit - Voltage below
1072 4 6419
#1 normal, or shorted to low source
Engine (Compression) Brake Output Engine Brake Actuator Driver Output 2 Circuit -
1073 4 2363
#2 Voltage below normal, or shorted to low source
1073 3 2367
#2 Voltage above normal, or shorted to high source
1073 3 6421
#2 Voltage above normal, or shorted to high source
1073 4 6422
Engine Electric Lift Pump for Engine Electric Lift Pump for Engine Fuel Supply Circuit -
1075 3 2265
Fuel Supply Voltage above normal, or shorted to high source
1075 4 2266
Fuel Supply Voltage below normal, or shorted to low source
1075 3 6258
Fuel Supply Voltage above normal, or shorted to high source
1075 4 6259
Fuel Supply Voltage below normal, or shorted to low source
Engine Wait to Start Lamp - Mechanical system not

1081 7 3494 Engine Wait to Start Lamp
1081 9 3555 Engine Wait to Start Lamp Engine Wait to Start Lamp - Abnormal update rate
Engine Wait to Start Lamp - Received Network Data In

1081 19 3556 Engine Wait to Start Lamp
Error
1081 31 4252 Engine Wait to Start Lamp Engine Wait to Start Lamp - Condition Exists
Engine Protection System Engine Protection System Approaching Shutdown -

1109 0 3931
Approaching Shutdown Data valid but above normal operational range - Most
6036, 6042, 8042, 10042, 10054 31211015 9-69

Electrical System
Fault
Code
1112 4 2365
1112 3 2368
Engine Turbocharger 1 Boost Pressure - Mechanical

1127 7 3683 Engine Turbocharger 1 Boost Pressure
Engine ECU Temperature Sensor Circuit - Voltage

1136 3 697 Engine ECU Temperature
Engine ECU Temperature Sensor Circuit - Voltage

Engine ECU Temperature - Data erratic, intermittent or

incorrect
Turbocharger 1 Compressor Intake Temperature

Engine Turbocharger 1 Compressor
Intake Temperature
source
Turbocharger 1 Compressor Intake Temperature

Intake Temperature
source
Engine Turbocharger 1 Compressor Turbocharger 1 Compressor Intake Temperature -

1172 2 693
Intake Temperature Data erratic, intermittent or incorrect
Engine Turbocharger 1 Compressor Turbocharger 1 Compressor Intake Temperature

1172 9 3369
Intake Temperature Sensor - Abnormal update rate
Engine Turbocharger 1 Compressor Turbocharger 1 Compressor Intake Temperature

1172 19 3371
Intake Temperature Sensor - Received Network Data In Error
Engine Turbocharger 1 Compressor Turbocharger 1 Compressor Intake Pressure - Data

1176 18 629
Intake Pressure Valid But Below Normal Operating Range - Moderately
Engine Turbocharger 1 Compressor Turbocharger 1 Compressor Intake Pressure Circuit -

1176 3 741
Intake Pressure Voltage above normal, or shorted to high source
Engine Turbocharger 1 Compressor Turbocharger 1 Compressor Intake Pressure Circuit -

1176 4 742
Intake Pressure Voltage below normal, or shorted to low source
Engine Turbocharger 1 Compressor Turbocharger 1 Compressor Intake Pressure - Data

1176 2 743
Intake Pressure erratic, intermittent or incorrect
Turbocharger 1 Compressor Intake Pressure - Data

1176 1 3348 valid but below normal operational range - Most
Intake Pressure
Severe Level
9-70 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
Fault
Code
Engine Turbocharger 1 Compressor Turbocharger 1 Compressor Intake Pressure -

1176 9 3372
Intake Pressure Abnormal update rate
Engine Turbocharger 1 Compressor Turbocharger 1 Compressor Intake Pressure - Received

1176 19 3373
Intake Pressure Network Data In Error
Anti-theft Encryption Seed Present

1194 13 3298 Anti-theft Encryption Seed - Out of Calibration
Indicator
Antitheft Password Valid Indicator - Data erratic,

1195 2 269 Anti-theft Password Valid Indicator
Exhaust Gas Pressure Sensor 1 Circuit - Voltage above

1209 3 2373 Engine Exhaust Gas Pressure 1
Exhaust Gas Pressure Sensor 1 Circuit - Voltage below

Exhaust Gas Pressure 1 - Data erratic, intermittent or

incorrect
Exhaust Gas Pressure 1 - Data Valid But Above Normal

1213 9 3535 Malfunction Indicator Lamp Malfunction Indicator Lamp - Abnormal update rate

1231 2 3329 J1939 Network #2
incorrect

1235 2 3331 J1939 Network #3
incorrect
Engine Fuel Leakage - Data Valid But Above Normal

1239 16 4726 Engine Fuel Leakage 1
Idle Shutdown Vehicle Accessories Idle Shutdown Vehicle Accessories Relay Driver Circuit
1267 3 338
Relay Driver Circuit - Voltage above normal, or shorted to high source
Idle Shutdown Vehicle Accessories Idle Shutdown Vehicle Accessories Relay Driver Circuit
1267 4 339
Relay Driver Circuit - Voltage below normal, or shorted to low source
1322 31 1718 Engine Misfire for Multiple Cylinders Engine Misfire for Multiple Cylinders - Condition Exists
1323 31 1654 Engine Misfire Cylinder #1 Engine Misfire Cylinder 1 - Condition Exists
6036, 6042, 8042, 10042, 10054 31211015 9-71

Electrical System
Fault
Code
Engine Fuel Pump Pressurizing Engine Fuel Pump Pressurizing Assembly 1 Circuit -
1347 4 271
Assembly #1 Voltage below normal, or shorted to low source
Engine Fuel Pump Pressurizing Engine Fuel Pump Pressurizing Assembly 1 Circuit -
1347 3 272
Assembly #2 Voltage above normal, or shorted to high source
Engine Fuel Pump Pressurizing Assembly 1 -

Engine Fuel Pump Pressurizing
1347 7 281 Mechanical system not responding or out of
Assembly #3
adjustment
1349 3 483
Pressure Voltage above normal, or shorted to high source
1349 4 484
Pressure Voltage below normal, or shorted to low source
Multiple Unit Synchronization Switch - Data erratic,

1377 2 497 Engine Synchronization Switch
1378 31 649 Engine Oil Change Interval Engine Oil Change Interval - Condition Exists
1383 31 611 Engine was Shut Down Hot Engine Shut Down Hot - Condition Exists
Auxiliary Pressure Sensor Input 1 Circuit - Voltage

1387 3 1539 Auxiliary Pressure #1

1388 14 296 Auxiliary Pressure #2 Auxiliary Pressure Sensor Input 2 - Special Instructions


9-72 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
Fault
Code
1388 14 6584 Auxiliary Pressure #2 Auxiliary Pressure Sensor Input 2 - Special Instructions
Control Module Identification Input State Error - Data

1563 2 1256 Incompatible Monitor/Controller
Control Module Identification Input State Error - Data

1563 2 1257 Incompatible Monitor/Controller
1569 31 3714 Engine Protection Torque Derate Engine Protection Torque Derate - Condition Exists
Adaptive Cruise Control Mode - Data erratic,

1590 2 784 Adaptive Cruise Control Mode
Tachograph Output Shaft Speed - Abnormal update

1623 9 3186 Tachograph output shaft speed
rate
Tachograph Output Shaft Speed - Received Network

1623 19 3213 Tachograph output shaft speed
Data In Error
1623 13 5248 Tachograph Output Shaft Speed Tachograph Output Shaft Speed - Out of Calibration
1632 14 2998 Engine Torque Limit Feature Engine Torque Limit Feature - Special Instructions
1632 31 5193 Engine Torque Limit Feature Engine Torque Limit Feature - Condition Exists
Fan Speed - Data Valid but Above Normal Operational

1639 0 4789 Fan Speed
Range - Most Severe Level
Fan Speed - Data Valid but Below Normal Operational

1639 1 4791 Fan Speed
Fan Speed - Data Valid but Above Normal Operational

1639 15 6467 Fan Speed
Fan Speed - Data Valid but Below Normal Operational

1639 17 6468 Fan Speed
1639 2 6469 Fan Speed Fan Speed – Data Erratic, Intermittent, or Incorrect

1668 2 4437 J1939 Network #4 - Data erratic
incorrect
Engine Starter Mode Overcrank Protection - Condition

1675 31 3737 Engine Starter Mode
Exists
6036, 6042, 8042, 10042, 10054 31211015 9-73

Electrical System
Fault
Code
Aftertreatment 1 Diesel Exhaust Fluid Tank Level
Aftertreatment 1 Diesel Exhaust Fluid
1761 4 1668 Sensor Circuit - Voltage below normal, or shorted to
Tank Level
low source

1761 3 1669 Sensor Circuit - Voltage above normal, or shorted to
Tank Level
high source
Aftertreatment 1 Diesel Exhaust Fluid Tank Level -

1761 1 1673 Data valid but below normal operational range -Most
Tank Level
Severe Level
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment 1 Diesel Exhaust Fluid Tank Level
1761 2 1699
Tank Level Sensor - Data erratic, intermittent or incorrect

1761 17 3497 Data Valid But Below Normal Operating Range - Least
Tank Level
Severe Level

1761 18 3498 Data Valid But Below Normal Operating Range -
Tank Level
Aftertreatment 1 Diesel Exhaust Fluid SAE J1939 Multiplexing PGN Timeout Error - Abnormal
1761 9 4677
Tank Level update rate
1761 5 4679
Tank Level Sensor Circuit - Current below normal or open circuit
1761 13 4732
Tank Temperature Sensor - Out of Calibration

1761 6 4738 Sensor Circuit - Current above normal or grounded
Tank Level
circuit
1761 11 4739
Tank Level Sensor - Root Cause Not Known
1761 10 4769
Tank Level Sensor - Abnormal Rate of Change
1761 13 6526
Tank Temperature Sensor - Out of Calibration
1761 11 6562
Tank Level Sensor - Root Cause Not Known
Battery Temperature - Data Valid But Above Normal

1800 16 2263 Battery 1 Temperature
Battery Temperature - Data Valid But Below Normal

1800 18 2264 Battery 1 Temperature
9-74 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
Fault
Code
Roll Over Protection Brake Control Active - Condition

1818 31 3374 ROP Brake Control active
Exists
2006 9 5133 Source Address 6 Source Address 6 - Abnormal Update Rate

2623 3 1239 Accelerator Pedal #1 Channel 2

2623 4 1241 Accelerator Pedal #1 Channel 2
Turbocharger Compressor Outlet Temperature

2629 15 2347 (Calculated) - Data Valid But Above Normal Operating
Outlet Temperature
Range
Engine Charge Air Cooler 1 Outlet Engine Charge Air Cooler Outlet Temperature -
2630 3 2571
Temperature Voltage above normal, or shorted to high source
Engine Charge Air Cooler 1 Outlet Engine Charge Air Cooler Outlet Temperature -
2630 4 2572
Temperature Voltage below normal, or shorted to low source
Engine Charge Air Cooler 1 Outlet Engine Charge Air Cooler Outlet Temperature - Data
2630 2 3478
Temperature erratic, intermittent or incorrect
Engine Variable Geometry Engine VGT Nozzle Position - Mechanical system not
2633 7 3616
Turbocharger (VGT) 1 Nozzle Position responding or out of adjustment
Power Relay Driver Circuit - Voltage above normal, or

2634 3 1776 Power Relay
Power Relay Driver Circuit - Voltage below normal, or

2634 4 1777 Power Relay
Engine Turbocharger 1 Calculated Turbocharger Turbine Intake Temperature - Data Valid

2789 15 2346
Turbine Intake Temperature But Above Normal Operating Range - Least Severe
Turbocharger Turbine Intake Temperature - Data Valid

Engine Turbocharger 1 Calculated
Turbine Intake Temperature
Severe Level

2791 9 1893 EGR Valve Control Circuit - Abnormal update rate
(EGR1) Valve Control

2791 13 1896 EGR Valve Controller - Out of Calibration
EGR Valve Control Circuit Over Temperature - Data

2791 15 1961 Valid But Above Normal Operating Range - Least
Severe Level
6036, 6042, 8042, 10042, 10054 31211015 9-75

Electrical System
Fault
Code
Engine Exhaust Gas Recirculation 1 EGR Valve Control Circuit - Current below normal or
2791 5 2349
(EGR1) Valve Control open circuit
Engine Exhaust Gas Recirculation 1 EGR Valve Control Circuit - Current above normal or
2791 6 2353
(EGR1) Valve Control grounded circuit
Engine Exhaust Gas Recirculation 1 EGR Valve Control Circuit - Mechanical system not
2791 7 2357
(EGR1) Valve Control responding or out of adjustment
Engine Exhaust Gas Recirculation 1 EGR Valve Control Circuit - Mechanical system not
2791 7 6555
(EGR1) Valve Control responding or out of adjustment
2797 13 2765 Engine Injector Group 1 Engine Injector Bank 1 Barcodes - Out of Calibration
Engine Auxiliary Governor Switch - Abnormal update

2884 9 3735 Engine Auxiliary Governor Switch
rate
Estimated Engine Parasitic Losses - Estimated Engine Parasitic Losses - Percent Torque -
2978 9 3838
Percent Torque Abnormal update rate
Aftertreatment 1 Diesel Exhaust Fluid Tank

3031 4 1677 Temperature Sensor - Voltage below normal, or
Tank Temperature

3031 3 1678 Temperature Sensor - Voltage above normal, or
Tank Temperature
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment 1 Diesel Exhaust Fluid Tank

3031 2 1679
Tank Temperature Temperature - Data erratic, intermittent or incorrect

3031 9 4572
Tank Temperature Temperature - Abnormal Update Rate

3031 5 4682 Temperature Sensor Circuit - Current below normal or
Tank Temperature
open circuit

3031 13 4731
Tank Temperature Temperature Sensor - Out of Calibration

3031 6 4736 Temperature Sensor Circuit - Current above normal or
Tank Temperature
grounded circuit

3031 11 4737
Tank Temperature Temperature - Root Cause Not Known

Tank Temperature
9-76 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
Fault
Code
Engine Cooling System Monitor - Data Valid But Below

3060 18 3243 Engine Cooling System Monitor
Aftertreatment 1 Intake NOx Sensor Circuit - Voltage

3216 4 1885 Aftertreatment 1 Intake NOx
Aftertreatment 1 Intake NOx Sensor - Data erratic,

Aftertreatment 1 Intake NOx Sensor - Abnormal

update rate
3216 13 3718 Aftertreatment 1 Intake NOx Aftertreatment 1 Intake NOx - Out of Calibration
Aftertreatment 1 Intake NOx Sensor - Abnormal rate of

change
Aftertreatment 1 Intake NOx - Data Valid But Above

Aftertreatment 1 Intake NOx Sensor - Data not

Rational - Drifted High


Aftertreatment 1 Intake NOx Sensor - Abnormal rate of

change
Aftertreatment Intake Oxygen Sensor - Data erratic,

3217 2 1861 Aftertreatment 1 Intake O2
Aftertreatment 1 Intake Gas Sensor Aftertreatment 1 Intake NOx Sensor Power Supply -
3218 2 3682
Power Status Data erratic, intermittent or incorrect
Aftertreatment 1 Outlet NOx Sensor - Data erratic,

3226 2 1694 Aftertreatment 1 Outlet NOx
Aftertreatment 1 Outlet NOx Sensor Circuit - Voltage

Aftertreatment 1 Outlet NOx Sensor - Abnormal

update rate
Aftertreatment 1 Outlet NOx Sensor - Abnormal rate of

change
6036, 6042, 8042, 10042, 10054 31211015 9-77

Electrical System
Fault
Code
Aftertreatment 1 Outlet NOx Sensor - Out of

Calibration
Aftertreatment 1 Outlet NOx Sensor - Data not




Aftertreatment Outlet NOx Sensor Aftertreatment Outlet NOx Sensor Circuit- Voltage
3226 4 6521
Circuits below normal or shorted to low source
Aftertreatment 1 Outlet NOx Sensor - Abnormal rate of

change
Aftertreatment Outlet Oxygen Sensor Circuit -

3227 9 2683 Aftertreatment 1 Outlet O2
Aftertreatment 1 Outlet Gas Sensor Aftertreatment 1 Outlet NOx Sensor Power Supply -
3228 2 3681
Aftertreatment 1 Outlet Gas Sensor Aftertreatment 1 Outlet NOx Sensor Power Supply -
3228 2 6582
Aftertreatment 1 Diesel Particulate Filter Intake

Aftertreatment 1 Diesel Particulate
3242 16 3253 Temperature - Data Valid But Above Normal Operating
Filter Intake Gas Temperature
Range

Range
Aftertreatment 1 Diesel Particulate Aftertreatment 1 Diesel Particulate Filter Intake

3242 0 3311
Filter Intake Gas Temperature Temperature - Data valid but above normal operation

3242 4 3316 Temperature Sensor Circuit - Voltage below normal, or

3242 3 3317 Temperature Sensor Circuit - Voltage above normal, or
Aftertreatment 1 Diesel Particulate Aftertreatment 1 Diesel Particulate Filter Intake

3242 2 3318
Filter Intake Gas Temperature Temperature - Data erratic, intermittent or incorrect
9-78 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
Fault
Code
Aftertreatment 1 Diesel Particulate Filter Outlet
Filter Outlet Gas Temperature
Range

Range
Aftertreatment 1 Diesel Particulate Aftertreatment 1 Diesel Particulate Filter Outlet

3246 0 3312
Filter Outlet Gas Temperature Temperature - Data valid but above normal operation


Aftertreatment 1 Diesel Particulate Aftertreatment 1 Diesel Particulate Filter Outlet

3246 2 3322
Filter Outlet Gas Temperature Temperature - Data erratic, intermittent or incorrect
Aftertreatment Exhaust Gas Temperature 2 - Data

Aftertreatment 1 Exhaust Gas
3249 17 2742 Valid But Below Normal Operating Range - Least
Temperature 2
Severe Level
Aftertreatment Exhaust Gas Temperature 2 - Data

Aftertreatment 1 Exhaust Gas
3249 18 2743 Valid But Below Normal Operating Range - Moderately
Temperature 2
Severe Level
Aftertreatment 1 Diesel Particulate Aftertreatment Diesel Particulate Filter Differential

3251 3 1879
Filter Differential Pressure Pressure Sensor Circuit - Voltage above normal

3251 4 1881
Filter Differential Pressure Pressure Sensor Circuit - Voltage below normal

3251 2 1883
Filter Differential Pressure Pressure Sensor - Data erratic, intermittent or incorrect
Aftertreatment Diesel Particulate Filter Differential

3251 16 1921 Pressure - Data Valid But Above Normal Operating
Filter Differential Pressure
Range

3251 0 1922 Pressure - Data valid but above normal Operating
Range

3251 15 2639 Pressure - Data valid but above normal Operating
Range
Aftertreatment 2 Intake NOx Sensor - Abnormal

update rate
3265 9 3988 Aftertreatment 2 Outlet NOx Aftertreatment 2 Outlet NOx - Abnormal Update Rate
6036, 6042, 8042, 10042, 10054 31211015 9-79

Electrical System
Fault
Code
Alternator 1 Status - Voltage Above Normal, or

3353 3 4953 Alternator 1 Status
Shorted to High Source
Alternator 1 Status - Voltage Below Normal, or Shorted

3353 4 4954 Alternator 1 Status
to Low Source
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit
3361 2 2976
Dosing Unit Temperature - Data erratic, intermittent or incorrect
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit -
3361 3 3558
Dosing Unit Voltage above normal, or shorted to high source
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit -
3361 4 3559
Dosing Unit Voltage below normal, or shorted to low source
3362 31 1682
Dosing Unit Input Lines Input Lines - Condition Exists
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment 1 Diesel Exhaust Fluid Tank Heater -
3363 3 1683
Tank 1 Heater Voltage above normal, or shorted to high source
3363 4 1684
Tank 1 Heater Voltage below normal, or shorted to low source
Aftertreatment 1 Diesel Exhaust Fluid Tank Heater -

Tank 1 Heater

3363 16 1713 Data Valid But Above Normal Operating Range -
Tank 1 Heater

Tank 1 Heater
adjustment

Tank 1 Heater
adjustment

Tank 1 Heater
3363 3 6479
Tank 1 Heater Voltage above normal, or shorted to high source
3363 4 6481
Tank 1 Heater Voltage below normal, or shorted to low source
Aftertreatment Diesel Exhaust Fluid Quality Sensor

Tank 1 Quality
source
9-80 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
Fault
Code
Aftertreatment Diesel Exhaust Fluid Quality Sensor
Tank 1 Quality
source
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment Diesel Exhaust Fluid Quality - Out of
3364 13 1714
Tank 1 Quality Calibration
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment Diesel Exhaust Fluid Quality - Root
3364 11 1715
Tank 1 Quality Cause Not Known
Aftertreatment Diesel Exhaust Fluid Quality - Data

3364 1 3866 valid but below normal operational range - Most
Tank 1 Quality
Severe Level

3364 18 3867 Valid But Below Normal Operating Range - Moderate
Tank 1 Quality
Severe Level
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment Diesel Exhaust Fluid Quality -

3364 9 3868
Tank 1 Quality Abnormal update rate
Aftertreatment Diesel Exhaust Fluid Quality Sensor -

Tank 1 Quality
adjustment
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment Diesel Exhaust Fluid Quality Sensor -
3364 12 3877
Tank 1 Quality Bad intelligent device or component
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment Diesel Exhaust Fluid Quality - Data
3364 2 3878
Tank 1 Quality erratic, intermittent or incorrect
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment Diesel Exhaust Fluid Quality - Received
3364 19 4241
Tank 1 Quality Network Data In Error
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment Diesel Exhaust Fluid Quality -

3364 10 4277
Tank 1 Quality Abnormal Rate of Change
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment Diesel Exhaust Fluid Quality Sensor
3364 5 4741
Tank 1 Quality Circuit - Current below normal or open circuit
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment Diesel Exhaust Fluid Quality Sensor
3364 6 4742
Tank 1 Quality Circuit - Current above normal or grounded circuit

Aftertreatment Diesel Exhaust Fluid
3364 15 4842 Valid But Above Normal Operating Range - Least
Quality
Severe Level

3364 18 6752 Valid But Below Normal Operating Range - Moderate
Tank 1 Quality
Severe Level
Electronic Throttle Control Actuator Electronic Throttle Control Actuator Driver Circuit-
3464 3 6493
Driver Circuit Voltage above normal, or shorted to high source
6036, 6042, 8042, 10042, 10054 31211015 9-81

Electrical System
Fault
Code
3464 4 6494
Driver Circuit Voltage above normal, or shorted to low source
3464 5 6496
Driver Circuit Voltage above normal, or shorted to high source
Aftertreatment Fuel Pressure Sensor - Data erratic,

3480 2 1926 Aftertreatment Fuel Pressure
Aftertreatment Fuel Pressure Sensor Circuit - Voltage

Aftertreatment Fuel Pressure Sensor Circuit - Voltage

Aftertreatment Fuel Pressure Sensor - Data Valid But

Below Normal Operating Range - Least Severe Level
Aftertreatment Fuel Rate - Data Valid But Above

3481 16 2778 Aftertreatment 1 Fuel Rate
Aftertreatment Fuel Shutoff Valve Circuit - Voltage

3482 3 1923 Aftertreatment 1 Fuel Enable Actuator
Aftertreatment Fuel Shutoff Valve Circuit - Voltage

Aftertreatment Fuel Shutoff Valve - Data erratic,

Aftertreatment Fuel Shutoff Valve - Mechanical system

not responding or out of adjustment
Aftertreatment Fuel Shutoff Valve Swapped - Out of

Calibration
Aftertreatment Fuel Shutoff Valve - Data Valid But

Above Normal Operating Range - Moderately Severe
Aftertreatment Purge Air Actuator Circuit - Voltage

3490 4 3223 Aftertreatment 1 Purge Air Actuator
Aftertreatment Purge Air Actuator Circuit - Voltage

Aftertreatment Purge Air Actuator - Mechanical

Sensor Supply 1 Circuit - Voltage below normal, or

3509 4 352 Sensor supply voltage 1
9-82 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
Fault
Code
Sensor Supply 1 Circuit - Voltage above normal, or







Sensor Supply 5 - Voltage above normal, or shorted to

high source
Sensor Supply 5 - Voltage below normal, or shorted to

low source


Aftertreatment 1 Diesel Exhaust Fluid Temperature 2

Temperature 2
high source
Aftertreatment 1 Diesel Exhaust Fluid Temperature 2

Temperature 2
low source
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment 1 Diesel Exhaust Fluid Temperature 2 -

3515 2 4242
Temperature 2 Data erratic, intermittent or incorrect

3515 10 4243
Temperature 2 Abnormal Rate of Change
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment 1 Diesel Exhaust Fluid Temperature 2

3515 5 4743
Temperature 2 Sensor Circuit - Current below normal or open circuit
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment 1 Diesel Exhaust Fluid Temperature 2

3515 6 4744
Temperature 2 Sensor Circuit - Current above normal or grounded
6036, 6042, 8042, 10042, 10054 31211015 9-83

Electrical System
Fault
Code

3515 11 4745
Temperature 2 Root Cause Not Known

3515 10 6619
Temperature 2 Abnormal Rate of Change
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment 1 Diesel Exhaust Fluid Property -

3521 31 4235
Property Condition Exists
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment 1 Diesel Exhaust Fluid Property - Root
3521 11 4768
Property Cause Not Known
Ambient Air Density - Data Valid But Below Normal

3555 17 1943 Ambient Air Density
Aftertreatment Doser - Data erratic, intermittent or

3556 2 1932 Aftertreatment Hydrocarbon Doser
incorrect
Aftertreatment Doser - Mechanical system not

Aftertreatment Doser Circuit - Current below normal

or open circuit.
Aftertreatment Doser - Data Valid But Below Normal

Injector Power Supply - Bad intelligent device or

3597 12 351 ECU Power Output Supply Voltage #1
component
Power Supply Lost With Ignition On - Data erratic,

ECU Power Output Supply Voltage 1 - Data Valid But

3597 18 1938 ECU Power Output Supply Voltage #1 Below Normal Operating Range - Moderately Severe
Level
ECU Power Output Supply Voltage 1 - Voltage above

ECU Power Output Supply Voltage 1 - Voltage below

ECU Power Output Supply Voltage 1 - Data Valid But

3597 17 6499 ECU Power Output Supply Voltage #1 Below Normal Operating Range - Moderately Severe
Level

Aftertreatment Diesel Particulate
3610 3 3133 Pressure Sensor Circuit - Voltage above normal, or
Filter Outlet Pressure
9-84 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
Fault
Code
3610 4 3134 Pressure Sensor Circuit - Voltage below normal, or
Aftertreatment Diesel Particulate Aftertreatment 1 Diesel Particulate Filter Outlet

3610 2 3135
Filter Outlet Pressure Pressure - Data erratic, intermittent or incorrect

3610 3 6551 Pressure Sensor Circuit - Voltage above normal, or

3610 4 6552 Pressure Sensor Circuit - Voltage below normal, or
Aftertreatment Diesel Particulate Aftertreatment 1 Diesel Particulate Filter Outlet

3610 2 6553
Filter Outlet Pressure Pressure - Data erratic, intermittent or incorrect
Engine Air Shutoff Circuit - Voltage above normal, or

3667 3 3139 Engine Air Shutoff Status
Engine Air Shutoff Circuit - Voltage below normal, or

Engine Air Shutoff - Mechanical System Not

3667 7 4484 Engine Air Shutoff
Responding or Out of Adjustment
Engine Air Shutoff Status - Data erratic, intermittent or

incorrect
Aftertreatment Regeneration Inhibit Aftertreatment Regeneration Inhibit Switch - Data

3695 2 4213
Switch erratic, intermittent or incorrect
Aftertreatment Regeneration Inhibit Aftertreatment Regeneration Inhibit Switch - Data

3695 2 6568
Switch erratic, intermittent or incorrect
Diesel Particulate Filter Active

Particulate Trap Active Regeneration Inhibited Due to
3703 31 2777 Regeneration Inhibited Due to Inhibit
Inhibit Switch - Condition Exists
Switch

Diesel Particulate Filter Active Regeneration Inhibited
3713 31 3753 Regeneration Inhibited Due to System
Due to System Timeout - Condition Exists
Timeout

Diesel Particulate Filter Active Regeneration Inhibited
3713 31 6596 Regeneration Inhibited Due to System
Due to System Timeout - Condition Exists
Timeout
Diesel Particulate Filter 1 Conditions Diesel Particulate Filter 1 Conditions Not Met for
3750 31 3396
Not Met for Active Regeneration Active Regeneration - Condition Exists
6036, 6042, 8042, 10042, 10054 31211015 9-85

Electrical System
Fault
Code
3750 14 5938
Not Met for Active Regeneration Active Regeneration – Condition Exists
Aftertreatment 1 Diesel Exhaust Fluid Average

3826 18 4573 Consumption - Data Valid But Below Normal
Average Consumption
Operating Range
Aftertreatment Diesel Particulate Aftertreatment 1 Diesel Particulate Filter System - Data

3936 15 1981
Filter System Valid But Above Normal Operating Range - Level
Aftertreatment 1 Diesel Particulate Filter System -

Filter System
adjustment
Aftertreatment Diesel Particulate Aftertreatment Diesel Particulate Filter System -

3936 14 4584
Filter System Special Instructions
Aftertreatment 1 Diesel Particulate Filter System -

Filter System
adjustment
NOx limits exceeded due to

NOx limits exceeded due to Insufficient Reagent
4094 31 3543 Insufficient Diesel Exhaust Fluid
Quality - Condition Exists
Quality
NOx limits exceeded due to Empty Aftertreatment Diesel Exhaust Fluid Tank Empty -
4096 31 3547
Diesel Exhaust Fluid Tank Condition Exists
Aftertreatment Fuel Drain Valve Circuit - Voltage

4097 3 2732 Aftertreatment 1 Fuel Drain Actuator
Aftertreatment Fuel Drain Valve Circuit - Voltage

Aftertreatment Fuel Drain Valve - Mechanical system

not responding or out of adjustment
Generator Output Frequency Adjust Potentiometer

Generator Output Frequency Adjust
Potentiometer Circuit
source
Droop Adjust Potentiometer Circuit - Voltage below

4183 4 3696 Droop Adjust Potentiometer Circuit
Gain Adjust Potentiometer Circuit - Voltage below

4184 4 3694 Gain Adjust Potentiometer Circuit
Overspeed Shutdown Relay Driver Diagnostic has

4185 31 1427 Overspeed Shutdown Relay Driver
detected an error - Condition Exists
9-86 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
Fault
Code
Low Oil Pressure Shutdown Relay Low Oil Pressure (LOP) Shutdown Relay Driver
4186 31 1428
Driver Diagnostic has detected an error - Condition Exists
High Engine Temperature (HET) Shutdown Relay

High Engine Temperature Shutdown
4187 31 1429 Driver Diagnostic has detected an error - Condition
Relay Driver
Exists
Pre-Low Oil Pressure Indicator Relay Pre-Low Oil Pressure Warning Relay Driver Diagnostic
4188 31 1431
Driver has detected an error - Condition Exists
Pre-High Engine Temperature Pre-High Engine Temperature Warning Relay Driver

4223 31 1432
Warning Relay Driver Diagnostic has detected an error - Condition Exists
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment SCR Actual Dosing Reagent Quantity -
4331 18 4658
Actual Dosing Quantity Data Valid But Below Normal Operating Range - Mo
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment 1 Diesel Exhaust Fluid Pressure Sensor
4334 3 3571
Doser Absolute Pressure - Voltage above normal, or shorted to high source
4334 4 3572
Doser Absolute Pressure - Voltage below normal, or shorted to low source
4334 18 3574
Doser Absolute Pressure - Data Valid But Below Normal Operating Range
4334 16 3575
Doser Absolute Pressure - Data Valid But Above Normal Operating Range
4334 2 3596
Doser Absolute Pressure - Data erratic, intermittent or incorrect
Aftertreatment 1 Diesel Exhaust Fluid Dosing

4337 3 4174 Temperature Sensor - Voltage Above Normal, or
Dosing Temperature Sensor
Aftertreatment 1 Diesel Exhaust Fluid Dosing

Dosing Temperature Sensor
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment 1 Diesel Exhaust Fluid Dosing

4337 2 4244
Dosing Temperature Temperature - Data erratic, intermittent or incorrect
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment 1 Diesel Exhaust Fluid Dosing

4337 10 4249
Dosing Temperature Temperature - Abnormal Rate of Change
Aftertreatment 1 SCR Feedback Aftertreatment 1 SCR Feedback Control Status -

4339 31 4586
Control Status Condition Exists
6036, 6042, 8042, 10042, 10054 31211015 9-87

Electrical System
Fault
Code
Aftertreatment 1 Diesel Exhaust Fluid Line Heater 1
Line Heater 1 State
source

Line Heater 1 State
source
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment 1 Diesel Exhaust Fluid Line Heater 1
4340 5 3258
Line Heater 1 State Circuit - Current below normal or open circuit
4340 5 6482

Line Heater 1 State
source

Line Heater 1 State
source

Line Heater 2 State
source

Line Heater 2 State
source
4342 5 3261
4342 5 6483

Line Heater 2 State
source

Line Heater 2 State
source
Aftertreatment Diesel Exhaust Fluid Line Heater 3

Line Heater 3 State
source

Line Heater 3 State
source
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment Diesel Exhaust Fluid Line Heater 3
4344 5 3425
9-88 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
Fault
Code
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment Diesel Exhaust Fluid Line Heater 3
4344 5 6484

Line Heater 3 State
source

Line Heater 3 State
source
Aftertreatment 1 SCR Intake Temperature Sensor

Aftertreatment 1 SCR Catalyst Intake
Gas Temperature
source
Aftertreatment 1 SCR Intake Temperature Sensor

Gas Temperature
source
Aftertreatment 1 SCR Catalyst Intake Aftertreatment 1 SCR Intake Temperature Sensor -

4360 2 3144
Gas Temperature Data erratic, intermittent or incorrect
Aftertreatment 1 SCR Catalyst Intake Aftertreatment 1 SCR Intake Temperature - Data Valid
4360 15 3164
Gas Temperature But Above Normal Operating Range - Least Severe
Aftertreatment 1 SCR Intake Temperature - Data valid

4360 0 3229 but above normal operational range - Most Severe
Gas Temperature
Level
Aftertreatment 1 SCR Intake Temperature - Data Valid

Gas Temperature
Severe Level
Aftertreatment 1 SCR Intake Temperature - Data Valid

Aftertreatment 1 SCR Intake
Temperature
Severe Level
Aftertreatment 1 SCR Outlet Temperature Sensor

Aftertreatment 1 SCR Catalyst Outlet
Gas Temperature
source

Gas Temperature
source
Aftertreatment 1 SCR Catalyst Outlet Aftertreatment 1 SCR Outlet Temperature Sensor -

4363 2 3148
Gas Temperature Data erratic, intermittent or incorrect
Aftertreatment 1 SCR Catalyst Outlet Aftertreatment 1 SCR Outlet Temperature - Data valid
4363 0 3165
Gas Temperature but above normal operational range - Most Severe
Aftertreatment 1 SCR Outlet Temperature - Data Valid

Gas Temperature
Severe Level
6036, 6042, 8042, 10042, 10054 31211015 9-89

Electrical System
Fault
Code
Gas Temperature
source

Gas Temperature
source
Aftertreatment SCR Catalyst Conversion Efficiency -

Aftertreatment 1 SCR Conversion
Efficiency
Aftertreatment SCR Catalyst Conversion Efficiency -

Aftertreatment 1 SCR Conversion
Efficiency
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment Diesel Exhaust Fluid Return Valve -
4376 3 3577
Return Valve Voltage above normal, or shorted to high source
4376 4 3578
Return Valve Voltage below normal, or shorted to low source
4376 7 4157
Return Valve Mechanical system not responding or out of adjust
4376 7 6527
Return Valve Mechanical system not responding or out of adjust
4490 9 3367 Specific Humidity Specific Humidity Sensor - Abnormal update rate
Specific Humidity Sensor - Received Network Data In

4490 19 3368 Specific Humidity
Error
Aftertreatment 1 Diesel Oxidation Catalyst Intake

Aftertreatment Diesel Oxidation
Catalyst Intake Temperature
Range


Aftertreatment Diesel Oxidation Aftertreatment 1 Diesel Oxidation Catalyst Intake

4765 2 3315
Catalyst Intake Temperature Temperature - Data erratic, intermittent or incorrect

4765 13 3325
Catalyst Intake Temperature Temperature Swapped - Out of Calibration
9-90 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
Fault
Code

4765 2 6539
Catalyst Intake Temperature Temperature - Data erratic, intermittent or incorrect
Aftertreatment 1 Diesel Oxidation Aftertreatment 1 Diesel Oxidation Catalyst Outlet Gas

4766 3 4533 Catalyst Outlet Gas Temperature Temperature Sensor Circuit - Voltage above normal, or
Sensor Circuit shorted to high source

4766 4 4534 Catalyst Outlet Gas Temperature Temperature Sensor Circuit - Voltage below normal, or
Sensor Circuit shorted to low source

4766 2 5386
Catalyst Outlet Gas Temperature Temperature - Data Erratic, Intermittent, or Incorrect
Aftertreatment 1 Diesel Oxidation Catalyst Outlet Gas

Aftertreatment 1 Diesel Oxidation
Catalyst Outlet Gas Temperature

Range - Moderately Severe Level

Range - Least Severe Level
Aftertreatment SCR Catalyst System - Mechanical

4792 7 3751 Aftertreatment SCR Catalyst System
Aftertreatment 1 SCR Catalyst System - Special

4792 14 4585 Aftertreatment 1 SCR Catalyst System
Instructions
Aftertreatment Warm Up Diesel Aftertreatment Warm Up Diesel Oxidation Catalyst

4793 31 3158
Oxidation Catalyst Missing - Condition Exists
Aftertreatment 1 SCR Catalyst System Missing -

4794 31 3151 Aftertreatment 1 SCR Catalyst System
Condition Exists
Aftertreatment 1 Diesel Particulate Aftertreatment 1 Diesel Particulate Filter Missing -

4795 31 1993
Filter Missing Condition Exists
Aftertreatment 1 Diesel Oxidation Aftertreatment 1 Diesel Oxidation Catalyst Missing -

4796 31 1664
Catalyst Missing Condition Exists
Aftertreatment 1 Diesel Oxidation Aftertreatment 1 Diesel Oxidation Catalyst Missing -

4796 31 6726
Catalyst Missing Condition Exists

4809 3 3152 Oxidation Catalyst Intake Intake Temperature Sensor Circuit - Voltage above
Temperature normal
6036, 6042, 8042, 10042, 10054 31211015 9-91

Electrical System
Fault
Code
4809 4 3153 Oxidation Catalyst Intake Intake Temperature Sensor Circuit - Voltage below
Temperature normal

4809 2 3154 Oxidation Catalyst Intake Intake Temperature - Data erratic, intermittent or
Temperature incorrect

4809 13 3166 Oxidation Catalyst Intake Intake Temperature Sensor Swapped - Out of
Temperature Calibration

4809 16 3247 Oxidation Catalyst Intake Intake Temperature - Data Valid But Above Normal
Temperature Operating Range

4810 3 3155 Oxidation Catalyst Outlet Outlet Temperature Sensor Circuit - Voltage above
Temperature normal

4810 4 3156 Oxidation Catalyst Outlet Outlet Temperature Sensor Circuit - Voltage below
Temperature normal

4810 2 3157 Oxidation Catalyst Outlet Outlet Temperature - Data erratic, intermittent or
Temperature incorrect

4810 0 3162 Oxidation Catalyst Outlet Outlet Temperature - Data valid but above normal
Temperature operating Range –Most Severe level

4810 16 3169 Oxidation Catalyst Outlet Outlet Temperature - Data Valid But Above Normal

4810 15 3249 Oxidation Catalyst Outlet Outlet Temperature - Data Valid But Above Normal
Aftertreatment Diesel Oxidation Aftertreatment 1 Diesel Oxidation Catalyst Face

5018 11 2637
Catalyst Plugged - Root Cause Not Known
Engine Exhaust Gas Recirculation Outlet Pressure

Outlet Pressure
high source
Engine Exhaust Gas Recirculation Outlet Pressure

Outlet Pressure
low source
Engine Exhaust Gas Recirculation 1 Engine Exhaust Gas Recirculation Outlet Pressure -
5019 2 3138
Outlet Pressure Data erratic, intermittent or incorrect
Aftertreatment 1 Intake Gas NOx Aftertreatment 1 Intake NOx Sensor Heater - Abnormal
5024 10 3649
Sensor Heater Ratio rate of change
9-92 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
Fault
Code
Aftertreatment 1 Outlet Gas NOx Aftertreatment 1 Outlet NOx Sensor Heater -

5031 10 3583
Sensor Heater Ratio Abnormal rate of change
Aftertreatment 1 Outlet Gas NOx Aftertreatment 1 Outlet NOx Sensor Heater -

5031 10 6581
Sensor Heater Ratio Abnormal rate of change
Engine Brake Active Lamp - Voltage Above Normal, or

5097 3 4293 Engine Brake Active Lamp Data
Engine Brake Active Lamp - Voltage below normal, or

5097 4 4294 Engine Brake Active Lamp Data


Aftertreatment Selective Catalytic

Aftertreatment Diesel Exhaust Fluid Tank Low Level
5245 31 4863 Reduction Operator Inducement
Indicator
Active
Aftertreatment SCR Operator Inducement - Data valid

Aftertreatment SCR Operator
5246 0 3712 but above normal operational range - Most Severe
Inducement Severity
level
Aftertreatment 1 Diesel Oxidation Catalyst Conversion

5298 18 1691 Efficiency - Data Valid But Below Normal Operating
Catalyst Conversion Efficiency
Aftertreatment 1 Diesel Oxidation Catalyst Conversion

5298 17 2638 Efficiency - Data Valid But Below Normal Operating
Catalyst Conversion Efficiency
Aftertreatment 1 Diesel Particulate Aftertreatment Diesel Particulate Filter Incomplete

5319 31 3376
Filter Incomplete Regeneration Regeneration - Condition Exists
Engine Fuel Injection Quantity Error Engine Fuel Injection Quantity Error for Multiple
5357 31 4713
for Multiple Cylinders Cylinders - Condition Exists
5380 11 4936 Engine Fuel Valve 1 Engine Fuel Valve 1 - Root Cause Not Known
5380 13 4937 Engine Fuel Valve 1 Engine Fuel Valve 1 - Out of Calibration
Aftertreatment Diesel Exhaust Fluid Aftertreatment Diesel Exhaust Fluid Dosing Valve -
5394 5 3567
Dosing Valve Current below normal or open circuit
6036, 6042, 8042, 10042, 10054 31211015 9-93

Electrical System
Fault
Code
Aftertreatment Diesel Exhaust Fluid Dosing Valve -
Aftertreatment Diesel Exhaust Fluid
Dosing Valve
adjustment
Aftertreatment Diesel Exhaust Fluid Aftertreatment Diesel Exhaust Fluid Dosing Valve -
5394 2 3755
Dosing Valve Data erratic, intermittent or incorrect
Engine Idle Fuel Quantity - Data Valid But Above

5395 16 3337 Engine Idle Fuel Quantity
Engine Idle Fuel Quantity - Data Valid But Below

5395 18 3338 Engine Idle Fuel Quantity
Engine Crankcase Ventilation Hose Engine Crankcase Ventilation Hose Disconnected -

5396 31 3377
Disconnected Condition Exists
Aftertreatment 1 Diesel Particulate Aftertreatment Diesel Particulate Filter Regeneration

5397 31 3375
Filter Regeneration too Frequent too Frequent - Condition Exists
Engine Fan Clutch 2 Output Device Engine Fan Clutch 2 Control Circuit - Voltage above
5484 3 3633
Driver normal, or shorted to high source
Engine Fan Clutch 2 Output Device Engine Fan Clutch 2 Control Circuit - Voltage below
5484 4 3634
Driver normal, or shorted to low source
Engine Fan Clutch 2 Output Device Engine Fan Clutch 2 Control Circuit - Voltage above
5484 3 6456
Driver normal, or shorted to high source
Engine Fan Clutch 2 Output Device Engine Fan Clutch 2 Control Circuit - Voltage below
5484 4 6457
Driver normal, or shorted to low source
Aftertreatment 1 Diesel Exhaust Fluid Aftertreatment Diesel Exhaust Fluid Line Heater Relay
5491 3 3562
Line Heater Relay - Voltage above normal, or shorted to high source
5491 4 3563
Line Heater Relay - Voltage below normal, or shorted to low source
Aftertreatment 1 Diesel Exhaust Fluid Line Heater

5491 7 3713 Relay - Mechanical system not responding or out of
Line Heater Relay
adjustment
5491 3 6477
Line Heater Relay - Voltage above normal, or shorted to high source
5491 4 6478
Line Heater Relay - Voltage below normal, or shorted to low source
9-94 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
Fault
Code
Aftertreatment 1 Diesel Exhaust Fluid Line Heater
5491 7 6537 Relay - Mechanical system not responding or out of
Line Heater Relay
adjustment
High Pressure Common Rail Fuel Pressure Relief Valve

High Pressure Common Rail Fuel
5571 7 3727 - Mechanical system not responding or out of
Pressure Relief Valve
adjustment
High Pressure Common Rail Fuel High Pressure Common Rail Fuel Pressure Relief Valve
5571 0 3741
Pressure Relief Valve - Data valid but above normal operational range
5571 3 4262
Pressure Relief Valve - Voltage Above Normal, or Shorted to High Source
5571 4 4263
Pressure Relief Valve - Voltage below normal, or shorted to low source
5571 11 4265
Pressure Relief Valve - Root Cause Not Known
5571 31 4867
Pressure Relief Valve - Condition Exists
High Pressure Common Rail Fuel Pressure Relief Valve

High Pressure Common Rail Fuel
5571 15 5585 - Data Valid But Above Normal Operating Range -
Pressure Relief Valve
Least Severe Level
Engine Injector Metering Rail 1 Engine Injector Metering Rail 1 Cranking Pressure -
5585 18 4691
Cranking Pressure Data Valid But Below Normal Operating Range - Mo
Cruise Control Disable Command - Abnormal update

5603 9 3843 Cruise Control Disable Command
rate
5603 31 3845 Cruise Control Disable Command Cruise Control Disable Command - Condition Exists
5605 31 3844 Cruise Control Pause Command Cruise Control Pause Command - Condition Exists
Engine Exhaust Back Pressure Engine Exhaust Back Pressure Regulator Position -
5625 2 5274
Regulator Position Data Erratic, Intermittent or Incorrect
Engine Exhaust Back Pressure Regulator Position

5625 3 5275 Sensor Circuit - Voltage Above Normal, or Shorted to
Regulator Position Sensor Circuit
High Source
Engine Exhaust Back Pressure Regulator Position

5625 4 5276 Sensor Circuit - Voltage Below Normal, or Shorted to
Regulator Position Sensor Circuit
Low Source
6036, 6042, 8042, 10042, 10054 31211015 9-95

Electrical System
Fault
Code
Engine Exhaust Back Pressure Engine Exhaust Back Pressure Regulator - Out of
5626 13 5277
Regulator Calibration
Aftertreatment 1 Outlet Soot Sensor - Voltage Above

5741 3 4143 Aftertreatment 1 Outlet Soot Sensor
Normal, or Shorted to High Source
Aftertreatment 1 Outlet Soot Sensor - Voltage below

5741 4 4144 Aftertreatment 1 Outlet Soot Sensor
Aftertreatment 1 Outlet Soot - Data erratic,

5741 2 4451 Aftertreatment 1 Outlet Soot
Aftertreatment Diesel Particulate Aftertreatment Diesel Particulate Filter Temperature

5742 9 4151
Filter Temperature Sensor Module Sensor Module - Abnormal update rate

5742 12 4158
Filter Temperature Sensor Module Sensor Module - Bad intelligent device or component
Aftertreatment Diesel Particulate Filter Temperature

5742 3 4161 Sensor Module - Voltage Above Normal, or Shorted to
Filter Temperature Sensor Module
high source

5742 4 4162 Sensor Module - Voltage below normal, or shorted to
low source

5742 16 4163 Sensor Module- Data Valid But Above Normal
Operating Range

5742 11 4259
Filter Temperature Sensor Module Sensor Module - Root Cause Not Known

Aftertreatment Selective Catalytic Reduction
5743 9 4152 Reduction Temperature Sensor
Temperature Sensor Module - Abnormal update rate
Module
Aftertreatment Selective Catalytic Aftertreatment Selective Catalytic Reduction

5743 12 4159 Reduction Temperature Sensor Temperature Sensor Module - Bad intelligent device or
Module component

5743 3 4164 Reduction Temperature Sensor Temperature Sensor Module - Voltage Above Normal,
Module or Shorted to high source

5743 4 4165 Reduction Temperature Sensor Temperature Sensor Module - Voltage below normal,
Module or Shorted to low source

5743 16 4166 Reduction Temperature Sensor Temperature Sensor Module - Data Valid But Above
Module Normal
9-96 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
Fault
Code
Aftertreatment Selective Catalytic Reduction
5743 11 4261 Reduction Temperature Sensor
Temperature Sensor Module - Root Cause Not Known
Module
5745 3 4168
Dosing Unit Heater Heater - Voltage Above Normal, or Shorted to High
Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit

5745 4 4169 Heater - Voltage below normal, or shorted to low
Dosing Unit Heater
source

5745 18 4171 Heater - Data Valid But Below Normal Operating
Dosing Unit Heater
Range

5745 17 6513 Heater - Data Valid But Below Normal Operating
Dosing Unit Heater
Range

5746 3 4155 Heater Relay - Voltage Above Normal, or Shorted to
Dosing Unit Heater Relay
high source

5746 4 4156 Heater Relay - Voltage below normal, or shorted to low
source

5746 3 6529 Heater Relay - Voltage Above Normal, or Shorted to
high source
Aftertreatment 1 Outlet Soot Sensor Aftertreatment 1 Outlet Soot Sensor Heater - Voltage
5747 3 4153
Heater Above Normal, or Shorted to High Source
Aftertreatment 1 Outlet Soot Sensor Aftertreatment 1 Outlet Soot Sensor Heater - Voltage
5747 4 4154
Heater below normal, or shorted to low source
Aftertreatment 1 Outlet Soot Sensor Aftertreatment 1 Outlet Soot Sensor Heater -

5747 10 4449
Heater Abnormal rate of change
5793 9 4284 Desired Engine Fueling State Desired Engine Fueling State - Abnormal Update Rate
Aftertreatment Warm Up Diesel

Aftertreatment Warm Up Diesel Oxidation Catalyst
5797 12 4253 Oxidation Catalyst Temperature
Temperature Sensor Module - Bad intelligent device
Sensor Module

5797 3 4254 Oxidation Catalyst Temperature Temperature Sensor Module - Voltage Above Normal,
Sensor Module or shorted to high source

5797 4 4255 Oxidation Catalyst Temperature Temperature Sensor Module - Voltage below normal,
Sensor Module or shorted to low source
6036, 6042, 8042, 10042, 10054 31211015 9-97

Electrical System
Fault
Code
5797 16 4256 Oxidation Catalyst Temperature Temperature Sensor Module - Data Valid But Above
Sensor Module Normal Operating Range – Moderately Severe Level
Aftertreatment Warm Up Diesel

Aftertreatment Warm Up Diesel Oxidation Catalyst
5797 11 4258 Oxidation Catalyst Temperature
Temperature Sensor Module - Root Cause Not Known
Sensor Module

5798 2 4245 Heater Temperature - Data erratic, intermittent or
Dosing Unit Heater Temperature
incorrect
5798 10 4251
Dosing Unit Heater Temperature Heater Temperature - Abnormal Rate of Change
5838 31 4485 EGR Valve Malfunction EGR Valve Malfunction - Condition Exists
Diesel Exhaust Fluid Consumption Diesel Exhaust Fluid Consumption Malfunction -

5839 31 4486
Malfunction Condition Exists
Diesel Exhaust Fluid Dosing Diesel Exhaust Fluid Dosing Malfunction - Condition
5840 31 4487
Malfunction Exists
Diesel Exhaust Fluid Quality Diesel Exhaust Fluid Quality Malfunction - Condition
5841 31 4488
Malfunction Exists
5842 31 4489 SCR Monitoring System Malfunction SCR Monitoring System Malfunction - Condition Exists
Water in Fuel Indicator 2 Sensor Water in Fuel Indicator 2 Sensor Circuit - Voltage
6301 3 4688
Circuit above normal, or shorted to high source
Water in Fuel Indicator 2 Sensor Water in Fuel Indicator 2 Sensor Circuit - Voltage
6301 4 4689
Circuit below normal, or shorted to low source
Cold Start Injector Metering Rail 1 Pressure - Data Valid

Cold Start Injector Metering Rail 1
6653 16 4841 But Above Normal Operating Range - Moderate
Pressure
Severe Level
Maintain ECU Power Lamp - Voltage Above Normal, or

6655 3 4951 ECU Power Lamp
Maintain ECU Power Lamp - Voltage Below Normal, or

Shorted to Low Source
Maintain ECU Power Lamp - Voltage Above Normal, or

9-98 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
Fault
Code
Maintain ECU Power Lamp - Voltage Below Normal, or

Shorted to Low Source
Variable Geometry Turbocharger Variable Geometry Turbocharger Actuator Software -

6713 13 4956
Actuator Out of Calibration
Variable Geometry Turbocharger Variable Geometry Turbocharger Actuator Software -

6713 31 4957
Actuator Condition Exists
6713 9 5177 VGT Actuator Driver Circuit VGT Actuator Driver Circuit - Abnormal update rate
Fan Blade Pitch Position Sensor Circuit - Voltage

6799 3 5183 Engine Fan Blade Pitch
Above Normal, or Shorted to High Source
Fan Blade Pitch Position Sensor Circuit - Voltage Below

Normal, or Shorted to Low Source
Fan Blade Pitch - Mechanical system not responding or

out of adjustment
Fan Blade Pitch Position Sensor Circuit - Voltage

Above Normal, or Shorted to High Source
Fan Blade Pitch Position Sensor Circuit - Voltage Below

Normal, or Shorted to Low Source
Fan Blade Pitch - Mechanical system not responding or

out of adjustment
Aftertreatment 1 Diesel Exhaust Fluid Dosing System

6802 31 5278
Frozen - Condition Exists
SCR Operator Inducement Override SCR Operator Inducement Override Switch - Abnormal
6881 9 5653
Switch Update Rate
SCR Operator Inducement Override SCR Operator Inducement Override Switch - Out of
6881 13 5654
Switch Calibration
Aftertreatment Diesel Oxidation Aftertreatment Diesel Oxidation Catalyst Temperature

6882 9 5391
Catalyst Temperature Sensor Module Sensor Module - Abnormal Update Rate

6882 12 5392
Catalyst Temperature Sensor Module Sensor Module - Bad Intelligent Device or Component
6036, 6042, 8042, 10042, 10054 31211015 9-99

Electrical System
Fault
Code
Aftertreatment Diesel Oxidation Catalyst Temperature
6882 3 5393 Sensor Module - Voltage Above Normal or Shorted to
Catalyst Temperature Sensor Module
High Source

6882 4 5394 Sensor Module - Voltage Below Normal or Shorted to
Low Source

6882 11 5395
Catalyst Temperature Sensor Module Sensor Module - Root Cause Not Known

6882 16 5396 Sensor Module - Data Valid But Above Normal
SCR System Cleaning Inhibited Due to SCR System Cleaning Inhibited Due to Inhibit Switch -
6918 31 5632
Inhibit Switch Condition Exists
SCR System Cleaning Inhibited Due to SCR System Cleaning Inhibited Due to System Timeout
6928 31 5631
System Timeout - Condition Exists
SCR System Cleaning Inhibited Due to SCR System Cleaning Inhibited Due to System Timeout
6928 31 6597
System Timeout - Condition Exists
7848 31 6634
Not Met for Active Regeneration Active Regeneration - Condition Exists
Cruise Control (Resistive) Signal Circuit - Voltage

520199 3 193 Cruise Control
Cruise Control (Resistive) Signal Circuit - Voltage

Crankcase Depression Valve - Mechanical system not

520320 7 2699 Crankcase Depression Valve
Cruise Control (Resistive) #2 Signal Circuit - Voltage

Cruise Control (Resistive) #2 Signal Circuit - Voltage

Glow Plug Module - Bad intelligent device or

520435 12 3222 Glow Plug Module
component
Closed Crankcase Ventilation System Closed Crankcase Ventilation System Pressure Sensor -
520595 3 4286
Pressure Sensor Voltage Above Normal, or Shorted to High Source
9-100 31211015 6036, 6042, 8042, 10042, 10054

Electrical System
Fault
Code
Closed Crankcase Ventilation System Closed Crankcase Ventilation System Pressure Sensor -
520595 4 4287
Pressure Sensor Voltage below normal, or shorted to low source
Closed Crankcase Ventilation System Closed Crankcase Ventilation System Pressure - Data
520595 2 4288
Pressure erratic, intermittent or incorrect
Aftertreatment 1 Outlet NOx Sensor Aftertreatment 1 Outlet NOx Sensor Closed Loop
520668 31 4452
Closed Loop Operation Operation - Condition Exists
Aftertreatment 1 Diesel Exhaust Fluid Dosing Valve 1

520716 3 4752 Heater - Voltage Above Normal, or Shorted to High
Dosing Valve 1 Heater
Source
Aftertreatment 1 Diesel Exhaust Fluid Dosing Valve 1

520716 4 4753 Heater - Voltage Below Normal, or Shorted to Low
Dosing Valve 1 Heater
Source
Engine Boost Curve Selection - Data erratic,

520791 2 5215 Engine Boost Curve Selection
Engine Emergency Shutdown Switch Engine Emergency Shutdown Switch Actived -

520808 31 5291
Actived Condition Exists
Excessive Time Since Last Engine Air Excessive Time Since Last Engine Air Shutoff
520809 31 5292
Shutoff Maintenance Test Maintenance Test - Condition Exists
Aftertreatment Diesel Exhaust Fluid Dosing Unit Relay

520953 3 5866 Feedback- Voltage Above Normal or Shorted to High
Source.
Aftertreatment Diesel Exhaust Fluid Dosing Unit Relay

520953 4 5867 Feedback- Voltage Below Normal or Shorted to Low
Source.
Machine Constrained Operation- Abnormal Update

Rate. No Communication or an invalid data transfer
520968 9 5939 rate has been detected on the J1939 data link
between the ECM and the machine electronic control
unit.
Machine Constrained Operation- Received Network

520968 19 5941 Data in Error. The received J1939 datalink message
was not valid.
Aftertreatment 1 Diesel Oxidation Aftertreatment 1 Diesel Oxidation Catalyst System-

524286 31 5617
Catalyst System Special Instruction
524286 31 9491 Reserved for temporary use - Condition Exists
524286 31 9999 Reserved for temporary use - Condition Exists
6036, 6042, 8042, 10042, 10054 31211015 9-101

Electrical System
9-102 31211015 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
10.5 Boom Extend Interlock System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
10.6 Boom Extend Interlock System Operation (10054 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
10.6.1 Extend Interlock Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
10.6.2 Outrigger Interlock Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
10.7 Stabil-TRAK™ System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
10.7.1 Stabil-TRAK™ System Test Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
10.7.2 Stabil-TRAK™ System Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
10.8 Stabil-TRAK™ Electrical Circuit Operation and Troubleshooting (6042/8042/10042) 10-15
10.9 Stabil-TRAK™ and Boom Interlock Electrical Circuit Operation and Troubleshooting (10054)
10-19
10.10 Boom/Outrigger Interlock System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
10.10.1 System Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
6036, 6042, 8042, 10042, 10054 31211015 10-1

10.11 Stabil-TRAK™ Hydraulic Circuit Operation and Troubleshooting . . . . . . . . . . . . . . . . . . 10-26

10.11.1 Stabil-TRAK™ Cylinder Oil Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
10.11.2 Hydraulic Circuit Operation - FREE PIVOT Mode, Rod Oil Out . . . . . . . . . . . . . . . . . 10-30
10.11.3 Hydraulic Troubleshooting - FREE PIVOT Mode, Rod Oil Out. . . . . . . . . . . . . . . . . . 10-31
10.11.4 Hydraulic Circuit Operation - FREE PIVOT Mode, Base Oil Out . . . . . . . . . . . . . . . . 10-32
10.11.5 Hydraulic Troubleshooting - FREE PIVOT Mode, Base Oil Out . . . . . . . . . . . . . . . . . 10-33
10.11.6 Hydraulic Circuit Operation - SLOW PIVOT Mode, Rod Oil Out . . . . . . . . . . . . . . . . 10-34
10.11.7 Hydraulic Troubleshooting - SLOW PIVOT Mode, Rod Oil Out. . . . . . . . . . . . . . . . . 10-35
10.11.8 Hydraulic Circuit Operation - SLOW PIVOT Mode, Base Oil Out . . . . . . . . . . . . . . . 10-36
10.11.9 Hydraulic Troubleshooting - SLOW PIVOT Mode, Base Oil Out . . . . . . . . . . . . . . . . 10-37
10.11.10 Hydraulic Circuit Operation - LOCKED MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38
10.11.11 Hydraulic Circuit Operation - LOCKED MODE, Frame Level Right . . . . . . . . . . . . . 10-38
10.11.12 Hydraulic Troubleshooting - LOCKED MODE, Will Not Frame Level Right. . . . . . 10-39
10.11.13 Hydraulic Circuit Operation - LOCKED MODE, Frame Level Left . . . . . . . . . . . . . . . 10-40
10.11.14 Hydraulic Troubleshooting - LOCKED MODE, Will Not Frame Level Left . . . . . . . 10-41
10.12 Boom Extend System Hydraulic Circuit Operation and Troubleshooting. . . . . . . . . . . 10-42
10.12.1 Troubleshooting Symptom Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
10.12.2 Hydraulic Circuit Operation - Extend Interlock Mode. . . . . . . . . . . . . . . . . . . . . . . . . 10-44
10.12.3 Hydraulic Troubleshooting - Extend Interlock Mode . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
10.12.4 Hydraulic Circuit Operation - Outrigger Interlock Mode . . . . . . . . . . . . . . . . . . . . . . 10-46
10.12.5 Hydraulic Troubleshooting - Outrigger Interlock Mode . . . . . . . . . . . . . . . . . . . . . . 10-46
10-2 31211015 6036, 6042, 8042, 10042, 10054

10.1 STABIL-TRAK™ SYSTEM COMPONENT

TERMINOLOGY
of the major assemblies of the Stabil-TRAK system. The
following illustration identifies the components that are
BOOM PROXIMITY SWITCH

(RIGHT REAR CORNER OF BOOM)
STABIL-TRAK
MANIFOLD
FRAME LEVEL STABIL-TRAK
CYLINDER CYLINDER
Model 10054 Shown
6036, 6042, 8042, 10042, 10054 31211015 10-3

10.2 BOOM EXTEND INTERLOCK SYSTEM

COMPONENT TERMINOLOGY (10054
ONLY)
of the major assemblies of the boom extend interlock system.
The following illustration identifies the components that are
BOOM EXTEND SENSOR
BOOM LOCKOUT
VALVE
OUTRIGGER CYLINDER
PRESSURE SWITCH (2)
10-4 31211015 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 machine 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 • Transmission in (N) NEUTRAL,
compartment located in the cab. • Hydraulic circuits,
. • Electrical circuits and
• Five solenoid-operated valves on
Stabil-TRAK manifold (3)
~
1
MAQ1061
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
and Stabil-TRAK manifold to accommodate
2
Stabil-TRAK system operation.
The Stabil-TRAK lock mode 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
3 • Placing the Transmission in (N) NEUTRAL
• 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 free
pivot mode is active and none of these functions will affect
the Stabil-TRAK system.
MH2980
MH2980
6036, 6042, 8042, 10042, 10054 31211015 10-5

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 machine may operate in any one of
5 D
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 beyond a
a. Free Pivot Mode point between “E” and “F” boom extend letters
Boom below 40° (5), Stabil-TRAK system is in FREE PIVOT (approximately 40 ft (12 m), unless both outriggers have
MODE (6). Rear axle is allowed to pivot freely. Frame level been lowered onto solid terrain.
control will function normally with or without outriggers Once this system has been activated, machine will
down. Stabil-TRAK indicator will be OFF (7). automatically place Stabil-TRAK system in LOCKED MODE.
System will remain in LOCKED MODE, until boom has been
b. Slow Pivot Mode retracted. (Refer to Section 10.6, “Boom Extend Interlock
Boom above 40° (5), Stabil-TRAK system is now in SLOW System Operation (10054 Only)”, for more information).
PIVOT MODE (8). In this mode, rear axle is UNLOCKED and is Frame level control will function slower than normal in this
allowed to pivot, but will respond SLOWLY to changes in mode with or without the outriggers down.
terrain. Stabil-TRAK indicator (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 in (N) NEUTRAL
• Depressing and holding service brake pedal
10-6 31211015 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 Stabil- The Model 10054 uses an additional logic wiring harness,
TRAK manifold, attached to the stabilizer cylinder above the that includes all wiring, fuses and relays needed for the
left side of the rear axle. operation of the boom interlock, Stabil-TRAK and outrigger
If a solenoid valve is suspected of malfunctioning, disconnect systems.
the coil wiring lead and test the coil for proper resistance (7- The logic harness has a fuse panel (1) that is attached to the
9 ohms) and for proper voltage from the harness (12 VDC). fuse panel (2) from cab harness. The logic harness includes all
Replace the solenoid coil if open or shorted to ground. the additional relays (R14 through R20) and fuses (24 and
Also inspect the valve cartridge, o-rings, and the other 25) required for the operation of the boom interlock, Stabil-
hydraulic and electrical components in the circuit to accurately TRAK and outrigger systems.
determine the cause of the problem. Refer to Section 10.9, “Stabil-TRAK Boom Interlock Electrical
All solenoid coils are identical and can be interchanged for Circuit Operation and Troubleshooting (10054),” for
diagnostic purposes. electrical troubleshooting information.
R1
24
R16
2
4
R17
16
R18
18
14
R19 25
15
R20
17
R21
MT3131 R22 1
Note: DO NOT interchange solenoid valves 4A (14), 4B (15), MAQ1911
12A (16) or 12B (17) with solenoid valve 3 (18). These valves will
No. Amp Circuit
fit into the other locations, but are configured differently
internally and will not operate properly if interchanged. 4 10 Amp Boom Switch
R1 35 Amp Boom Switch
Cartridge valves 4A (14), 4B (15), 12A (16) and
R16 35 Amp Stabilizer Interlock
12B (17) are identical and can be interchanged for diagnostic
proposes. R17 35 Amp Stabilizer Lockup
R18 35 Amp Boom Extend Interlock Relay
Note: Make sure 0.060 orifices are in place when installing
R19 35 Amp Right Outrigger Lock Out
solenoid valves 4A (14) and 4B (15).
R20 35 Amp Left Outrigger Lock Out
In general, if there is a problem with the Stabil-TRAK system R21 35 Amp Park Brake Interlock Relay
beyond common electrical troubles, the involved electrical
R22 35 Amp Boom Extension Lock Out
and hydraulic circuits should each be checked and the exact
source of the problem diagnosed before any parts are 24 7.5 Amp Outrigger 1 (Mini-Fuse)
replaced. 25 7.5 Amp Outrigger 2 (Mini-Fuse)
6036, 6042, 8042, 10042, 10054 31211015 10-7

10.4.4 Relay Testing 8. When reassembling right side console access panel (3),
torque screws (4) to 3–5 lb-ft (13–22 Nm).
If after checking the electrical system, a relay is suspect, test
the relay as follows: 9. Properly connect the battery. Refer Section 9.8,
machine, fully retract the boom, lower the boom, place 10. Close and secure rear engine compartment door.
the transmission in (N) NEUTRAL, engage the parking 11. Remove the Do Not Operate Tags from both the ignition
brake, straighten all wheels and shut the engine OFF. key switch and the steering wheel.
3 MAQ1890
5. Fuse block relays are located in fuse block and is

mounted behind right side console access panel (3). To
gain access, remove screws (4) that secure right side
panel in place.
5
30 86
6
85 87a 87
MAQ2110
6. Remove suspect relay from fuse panel.

7. Apply proper voltage to relay coil at terminal 86 (5) and
attach the ground (-) probe to terminal 85 (6), ground.
An audible click should be heard indicating that relay is
functioning properly.
10-8 31211015 6036, 6042, 8042, 10042, 10054

10.4.5 Outrigger Pressure Switches b. Removal

(10054 Only) 1. Park the machine on a firm, level surface, level the
a. Testing the transmission in (N) NEUTRAL, engage the parking
If after checking the electrical system, a pressure switch is brake, straighten all wheels.
suspect, test the switch as follows: 2. Lower the outriggers onto firm terrain, and shut the engine
OFF.
machine, fully retract the boom, lower the boom, place 3. Place a Do Not Operate Tag on both the ignition key
the transmission in (N) NEUTRAL, engage the parking switch and steering wheel, stating that the machine
brake, straighten all wheels. should not be operated.
2. Lower the outriggers onto firm terrain, and shut the engine
OFF.
3. Place a Do Not Operate Tag on both the ignition key “Battery”, for procedure.
6. Disconnect the pressure switch wiring connector (18)
from the harness connector (19).
19 20
18
MH4131
MH4121 7. Remove the outrigger pressure switch (20) from the

4. Disconnect the pressure switch wiring connector (18) outrigger cylinder.
from the harness connector (19). 8. Wipe up any spilled hydraulic oil.
5. Check for continuity across the red and black wires at the
c. Installation
pressure switch wiring connector (18). If there is no
continuity across the red and black wires, replace the 1. Install pressure switch (20), and torque to 25–38 lb-ft
switch. (34–41 Nm).
6. Remove Do Not Operate Tags from both ignition key 2. Connect the pressure switch wiring connector (18) to
switch and steering wheel when done. the harness connector (19).
4. Close and secure rear engine compartment door.
6036, 6042, 8042, 10042, 10054 31211015 10-9


DESCRIPTION
Note: The boom interlock system is used only on the Model
10054.
Boom extend interlock system is designed to provide
additional stability, allowing boom to be extended to its
maximum limits. Appropriate Operation and Safety Manual
contains boom extend interlock basic information. A copy of
Operation and Safety Manual should always be available in
storage compartment located in cab.
MH2950
MH4100
The interlock system operates via an interface between the

outrigger pressure switches (1), boom extend sensor (2),
boom lockout valve (3) and the logic wiring harness.
Boom extend interlock system can only be activated when
both outriggers are lowered onto firm terrain. Once boom
extend interlock system has been activated, machine will
automatically place Stabil-TRAK system in LOCKED MODE.
The Stabil-TRAK system will remain in LOCKED MODE, until
boom has been retracted. (Refer to Section 10.4, “Stabil-TRAK
Operation,” for more information.)
10-10 31211015 6036, 6042, 8042, 10042, 10054


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 its E
maximum limits. The boom extend interlock system may D
operate in one of the two following modes: C
B
10.6.1 Extend Interlock Mode A
EXTEND INTERLOCK MODE, limits boom extension (4) to a

7
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, approximately
40 ft (12m) until outriggers have been lowered onto firm
terrain.
Retract function will still operate normally in this mode. MAQ1900
H 10.6.2 Outrigger Interlock Mode

G OUTRIGGER INTERLOCK MODE, allows for full boom
F extension (6) only as long as both outriggers (7) have been
lowered onto firm terrain (outriggers DOWN). Once this
4 E
condition is met, the boom is allowed to extend to its full
D limits.
C
As the boom is extended past the “F” boom extend letter, the
B machine will automatically place the Stabil-TRAK system in
A the LOCKED MODE. It will remain in this mode until the boom
has been retracted to a point where the boom extend sensor
is activated.
5 With outrigger interlock engaged additional systems are
automatically activated that enhance stability of machine:
• Stabil-TRAK is in the LOCKED Mode.
• Transmission has been DECLUTCHED.
• Parking brake is ENGAGED.
OH0633
• Outrigger RAISE function is inoperable.
With the outriggers RAISED (5) and the boom inside of the • Stabil-TRAK light will be ON (8).
extension limit (4) the machine will function normally. The Other effects you will experience while the outrigger
Stabil-TRAK system will perform as designed. interlock is engaged:
Note: As an added measure of safety, ALWAYS remember to • With Stabil-TRAK active, frame level will be slower than
shift the Transmission to (N) NEUTRAL, move the neutral lock normal.
lever to 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.
6036, 6042, 8042, 10042, 10054 31211015 10-11

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

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

• Test the Stabil-TRAK system with the machine on a
level surface.
• Remove any attachment from the quick coupler
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.
10-12 31211015 6036, 6042, 8042, 10042, 10054

Stabil-TRAK System Test Procedures
Step 1
a. Place the machine 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 machine.
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 transmission to (1) FIRST gear.
d. Move the transmission to the (F) FORWARD position.
e. Drive the machine up on the block and stop by applying service brake with left foot.
f. Use the frame level control to level the machine back to 0°.
Step 3
a. Place the transmission in(N) NEUTRAL.

b. Raise the boom to approximately 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. Continue using your left foot to depress the service brake pedal.
b. With transmission 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 machine off
the block. While backing off the block, the front left tire should remain off the ground.
LOCKED MODE
IMPORTANT: Perform Steps 5 thru 9 with the engine rpm at idle.

Step 5
a. Keep the service brake pedal depressed.
b. Place the transmission in (N) NEUTRAL.
c. Take your foot off the service brake pedal. The Stabil-TRAK light should remain ON and the front left tire
Neutral Test
should remain off the ground.

Step 6
a. With the transmission in (N) NEUTRAL, engage the parking brake switch.
b. Move the transmission to the (F) FORWARD position. The Stabil-TRAK light should remain ON and the front
Park Brake Test
left tire should remain off the ground.
6036, 6042, 8042, 10042, 10054 31211015 10-13

Stabil-TRAK System Test Procedures
Step 7
a. With the parking brake switch ON, place the transmission in(N) NEUTRAL.
b. Lower the boom no lower than 45°.
c. Frame level the machine no more than 5° to the left.
d. Frame level the machine back to 0°.
e. Frame level the machine 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 machine 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 transmission 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.
e. The Stabil-TRAK light should go OFF.
SLOW
PIVO
f. The front left tire should return to the ground while the machine travels in reverse.
g. Depress the service brake pedal to stop the machine.
Step 9
LOCKED
MODE
a. With the service brake pedal depressed and the boom angle exactly 45° move the transmission 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 machine forward against the block to stop the machine from moving forward.
e. With the front left tire against the block, frame level the machine 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 leveling to
left, but tire should immediately lower when frame level function is stopped.
g. Frame level the machine back to 0° and pause briefly.
SLOW PIVOT MODE
h. Frame level the machine 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 machine back to 0°.
k. Depress the service brake pedal.
l. Place the transmission in(N) NEUTRAL.
m. Lower the boom.
10-14 31211015 6036, 6042, 8042, 10042, 10054

10.8 STABIL-TRAK™ 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 and Refer to Section , “6042, 8042 and Refer to Section , “6042, 8042 and
10042 Stabil-TRAK Electrical Cir- 10042 Stabil-TRAK Electrical Cir- 10042 Stabil-TRAK Electrical Cir-
cuit FREE PIVOT Mode.” cuit SLOW PIVOT Mode.” cuit LOCKED MODE.”
Machine Ignition On Ignition On Ignition On
Conditions Boom Below 40° Boom Above 40° Boom Above 40°
Switch/ Boom Retracted Boom Retracted Boom Retracted
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 DE
Definitions:
PB = Park Brake
SB = Service Brake
DE = De-energized
E = Energized
C = Closed
O = Open
6036, 6042, 8042, 10042, 10054 31211015 10-15

FREE PIVOT MODE 1. Ignition “ON” 4. PB & SB Released

6042, 8042 and 10042 Stabil-TRAK 2. Boom Below 40° 5. Transmission in Fwd. or Rev.
Electrical Circuit Conditions 3. Boom Retracted
FREE PIVOT Mode
Lock Relay
Stabilizer
Switch Relay
Start Relay
Park Brake
Disengage
Neutral
Boom
Relay
MAQ1920
10-16 31211015 6036, 6042, 8042, 10042, 10054

SLOW PIVOT MODE 1. Ignition “ON” 4. PB & SB Released

2. Boom Above 40° 5. Transmission in Fwd. or Rev. 6042, 8042 and 10042 Stabil-TRAK
Electrical Circuit
Conditions 3. Boom Retracted SLOW PIVOT Mode
Lock Relay
Stabilizer
Switch Relay
Start Relay
Park Brake
Disengage
Neutral
Boom
Relay
MAQ1930
6036, 6042, 8042, 10042, 10054 31211015 10-17

LOCKED MODE 1. Ignition “ON” 4. PB & SB Applied

6042, 8042 and 10042 Stabil-TRAK 2. Boom Above 40° 5. Transmission in Neutral
Electrical Circuit Conditions 3. Boom Retracted
LOCKED MODE
Lock Relay
Stabilizer
Switch Relay
Start Relay
Park Brake
Disengage
Neutral
Boom
Relay
MAQ1940
10-18 31211015 6036, 6042, 8042, 10042, 10054

10.9 STABIL-TRAK™ AND 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 Sta-
“10054 Stabil-TRAK “10054 Stabil-TRAK
bil-TRAK Electrical Circuit Boom
Electrical Circuit Boom Electrical Circuit 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
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
Note: If an outrigger is raised or a pressure switch is defective, boom on the 10054 will not extend beyond the 42 Series extension
limit.
Definitions:
Boom Retracted = Less than 42 Series extension limit
6036, 6042, 8042, 10042, 10054 31211015 10-19

Boom Extended = Boom at 42 Series extension limit or

greater (See Figure at Right). H
PB = Park Brake G
DE = De-energized F
E = Energized E
it D
C = Closed
m
O = Open Li C
B
n
io
A
ns
42 Series Exte
MH6110
10-20 31211015 6036, 6042, 8042, 10042, 10054

MODE 1 1. Ignition “ON” 4. PB Released

10054 Stabil-TRAK Electrical Circuit 2. Boom Below 40° 5. Transmission in Fwd. or Rev.
Boom Extend Mode 1 Conditions 3. Boom Retracted 6. Outriggers Raised
Park Brake
Stabilizer
Interlock
Stabilizer
Interlock
Lockup
Outrigger
Relay
Outrigger
Lockout
Relay
Interlock
Lockout
Extend
Lockout
Boom
Extend
Boom
Right
Left
Lock Relay
Stabilizer
Switch Relay
Park Brake
Start Relay
Disengage
Neutral
Boom
Relay
4
Start Relay
Neutral
45A1
MAQ1951
6036, 6042, 8042, 10042, 10054 31211015 10-21

MODE 2 1. Ignition “ON” 4. PB Released

2. Boom Below 40° 5. Transmission in Fwd. or Rev. 10054 Stabil-TRAK Electrical Circuit
Conditions Boom Extend Mode 2
3. Boom Ext. To 42 Foot Ext. Limit 6. Outriggers Raised
Park Brake
Stabilizer
Interlock
Stabilizer
Interlock
Lockup
Outrigger
Relay
Outrigger
Lockout
Relay
Interlock
Lockout
Extend
Lockout
Boom
Extend
Boom
Right
Left
Lock Relay
Stabilizer
Switch Relay
Park Brake
Start Relay
Disengage
Neutral
Boom
Relay
4
Start Relay
Neutral
45A1
MAQ1961
10-22 31211015 6036, 6042, 8042, 10042, 10054

MODE 3 1. Ignition “ON” 4. PB Applied By Interlock Sys.

10054 Stabil-TRAK Electrical Circuit 2. Boom Below 40° 5. Trans. in Neutral By Interlock Sys.
Boom Extend Mode 3 Conditions 3. Boom Ext. Beyond 42 Foot Ext. Limit 6. Outriggers Lowered
Park Brake
Stabilizer
Interlock
Stabilizer
Interlock
Lockup
Outrigger
Relay
Outrigger
Lockout
Relay
Interlock
Lockout
Extend
Lockout
Boom
Extend
Boom
Right
Left
Lock Relay
Stabilizer
Switch Relay
Park Brake
Start Relay
Disengage
Neutral
Boom
Relay
4
Start Relay
Neutral
45A1
MAQ1971
6036, 6042, 8042, 10042, 10054 31211015 10-23

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 machine
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.
10-24 31211015 6036, 6042, 8042, 10042, 10054

Boom/Outrigger Interlock System Test Procedures
Step 1
a. Place the machine with no load on a hard, level surface such as blacktop or concrete.
EXTEND
MODE 1
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 machine again.
b. Attempt to frame level the machine to the right and left; it should frame level normally.
EXTEND
MODE 2
BOOM
Step 3
a. Lower both outriggers to the ground. DO NOT lift the front wheels of the machine 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 beyond the letter "F".
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 machine 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 machine; the machine should not move.
c. If the machine attempts to move, STOP and have the system repaired before using the machine 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 machine 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 machine to a level position.
Step 6
a. Place the transmission in (N) NEUTRAL, move the neutral lock lever to the NEUTRAL LOCK position.
b. Fully retract the boom.
c. Raise the outriggers.
d. Engage the parking brake switch, shut the engine OFF and remove the key.
EXTEND
MODE 1
BOOM
e. Exit the machine using both handholds.
6036, 6042, 8042, 10042, 10054 31211015 10-25

10.11 STABIL-TRAK™ HYDRAULIC CIRCUIT

OPERATION AND TROUBLESHOOTING
The function of the Stabil-TRAK system varies under different
operating conditions. The basic modes include the FREE The hydraulic operation and troubleshooting information
PIVOT MODE, SLOW PIVOT MODE and LOCKED MODE. for each of these modes will be described on the
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 Boom angle is below 40° Operation - FREE PIVOT Mode, Rod Oil
front 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 Boom angle is below 40° Operation - FREE PIVOT Mode, Base Oil
front 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
Transmission is in (N) NEUTRAL, or Park
Troubleshooting - LOCKED MODE, Will
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 Boom angle is above 40° Circuit Operation - LOCKED MODE,
front tire comes off the ground. Frame Level Right,” and Section
10.11.12, “Hydraulic Troubleshooting -
LOCKED MODE, Will Not Frame
Level Right.”
10-26 31211015 6036, 6042, 8042, 10042, 10054

Troubleshooting Symptom Chart
With the boom above 40°, when Ignition ON, engine running Refer to Section 10.11.13, “Hydraulic
leveling the frame to left, right Boom angle is above 40° Circuit Operation - LOCKED MODE,
front tire comes off the ground. Frame Level Left,” and Section
10.11.14, “Hydraulic Troubleshooting -
LOCKED MODE, Will Not Frame Level
Left.”
6036, 6042, 8042, 10042, 10054 31211015 10-27

10.11.1 Stabil-TRAK™ Cylinder Oil Flow

In the FREE PIVOT and SLOW PIVOT MODES, oil flow from the
stabilizer cylinder will be in one of two directions; ROD OIL 1
OUT or BASE OIL OUT.
ROD OIL OUT flow will occur when the left side of the rear
axle is lower than the right side (left wheel in a pothole, or the
2
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
10-28 31211015 6036, 6042, 8042, 10042, 10054

6036, 6042, 8042, 10042, 10054 31211015 10-29

10.11.2 Hydraulic Circuit Operation - FREE PIVOT Mode, Rod Oil Out
FRAME
LEVEL MAIN CONTROL
FRAME SWAY
ATTACH TILT
LIFT/LOWER
CYLINDER VALVE
EXT/RET
P
AUX
T T3
BYPASS
CHECK
TM
VALVE
STABIL-TRAK
CYLINDER G3
G2 FTR V
3 DE
2A
T
PBG PVG PB
2B
JS
HYDRAULIC
.030 DIA. 3 P BV
RESERVOIR
1 SECONDARY
12B 4B 4A 12A FUNCTION
MANIFOLD
E DE DE E
.060 DIA. .060 DIA.

2 100 PSI
T HYDRAULIC
STABIL-TRAK TM G1 P OIL COOLER
MANIFOLD
Pressure SOLENOID COIL 4
STATE
Return
Suction DE DE-ENERGIZED
E ENERGIZED
Load Sense MAQ1980
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 of the
• Travel select lever in (F) FORWARD or (R) REVERSE Stabil-TRAK cylinder (1). The oil then flows through the
position solenoid-operated valves 12B (2) and 12A (3), to the base
• Park brake OFF 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.
10-30 31211015 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 Boom
engine running Interlock Electrical Circuit Operation and
Troubleshooting (6042/8042/10042),” or
• Boom angle is Check electrical wiring. Not Section 10.9,
below 40° “Stabil-TRAK Boom Interlock Electrical
Circuit Operation and Troubleshooting
• Travel select lever (10054).”
in (F) FORWARD or
(R) REVERSE If OK
• Park brake OFF

• Service brake Check solenoid coils 12A and 12B on the
Stabil-TRAK manifold for correct resistance Not Replace solenoid(s).
DISENGAGED
(7-9 ohms).
If OK
Remove solenoid cartridges 12A and 12B

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

frame level cylinder.
6036, 6042, 8042, 10042, 10054 31211015 10-31

10.11.4 Hydraulic Circuit Operation - FREE PIVOT Mode, Base Oil Out
FRAME
LEVEL MAIN CONTROL
FRAME SWAY
ATTACH TILT
LIFT/LOWER
CYLINDER VALVE
EXT/RET
P
AUX
T T3
BYPASS
CHECK
STABIL-TRAK
TM
VALVE
CYLINDER G3
G2 FTR V
3 DE
2A
T
PBG PVG PB
2B
JS
.030 DIA.
2 P BV HYDRAULIC
RESERVOIR
1 12B 4B 4A 12A
SECONDARY
FUNCTION
MANIFOLD
E DE DE E
.060 DIA. .060 DIA.

100 PSI
3
T HYDRAULIC
MANIFOLD
STATE
Return
E ENERGIZED
Load Sense MAQ1990
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 end
• Travel select lever in (F) FORWARD or (R) REVERSE of the Stabil-TRAK cylinder (1). The oil then flows through the
position solenoid-operated valves 12A (2) and 12B (3), to the rod side
• Park brake OFF 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.
10-32 31211015 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 comes
• Ignition ON, off the ground.
engine running
• Boom angle is Refer to Section 10.8, “Stabil-TRAK Boom
below 40° Interlock Electrical Circuit Operation and
Troubleshooting (6042/8042/10042),” or
• Travel select lever Check electrical wiring. Not Section 10.9,
in (F) FORWARD or “Stabil-TRAK Boom Interlock Electrical
(R) REVERSE Circuit Operation and Troubleshooting
(10054).”
• Park brake ON If OK
• Service brake
DISENGAGED Check solenoid coils 12A and 12B on the
(7-9 ohms).
If OK
Remove solenoid cartridges 12A

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

6036, 6042, 8042, 10042, 10054 31211015 10-33

10.11.6 Hydraulic Circuit Operation - SLOW PIVOT Mode, Rod Oil Out
FRAME
LEVEL MAIN CONTROL
FRAME SWAY
ATTACH TILT
LIFT/LOWER
CYLINDER VALVE
EXT/RET
P
AUX
T T3
BYPASS
CHECK
STABIL-TRAK
TM
VALVE
CYLINDER G3
G2 FTR V
3 DE
2A
T
PBG PVG PB
2B
JS
P BV HYDRAULIC
.030 DIA.
RESERVOIR
1 12B 4B 4A
SECONDARY
12A FUNCTION
MANIFOLD
DE E E DE
.060 DIA. 2 5 .060 DIA. 100 PSI

3 4
T HYDRAULIC
STABIL-TRAK TM P OIL COOLER
G1
MANIFOLD
Pressure SOLENOID COIL
Return STATE 6
E ENERGIZED
Load Sense MAQ2000
Conditions: The 0.060 inch orifices (3 and 4) in solenoid-operated valves

• Boom angle is above 40° 4A (5) and 4B (2) 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 required, extra oil is required
• Travel select lever in (F) FORWARD or (R) REVERSE from system through the 100 psi (7 bar) reducing cartridge (6)
position in the Stabil-TRAK manifold. Restrictions produce the slow
Operation: 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.
10-34 31211015 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
• Boom angle is Interlock Electrical Circuit Operation and
above 40° Troubleshooting (6042/8042/10042),” or
Check electrical wiring. Not Section 10.9,
• Travel select “Stabil-TRAK Boom Interlock Electrical
lever in (F) Circuit Operation and Troubleshooting
FORWARD or (R) (10054).”
If OK
REVERSE
• Park brake OFF
• Service brake Check solenoid coils 4A and 4B on the
DISENGAGED
(7-9 ohms).
If OK
Remove solenoid cartridges 4A and 4B from

Stabil-TRAK manifold and inspect for debris Not Clean passages or replace cartridge(s).
or damage.
If OK
Inspect check valves on frame level cylinder. Not Replace check valve(s).
6036, 6042, 8042, 10042, 10054 31211015 10-35

10.11.8 Hydraulic Circuit Operation - SLOW PIVOT Mode, Base Oil Out
FRAME
LEVEL MAIN CONTROL
FRAME SWAY
ATTACH TILT
LIFT/LOWER
CYLINDER VALVE
EXT/RET
P
AUX
T T3
BYPASS
CHECK
STABIL-TRAK
TM
VALVE
CYLINDER G3
G2 FTR V
3 DE
2A
T
PBG PVG PB
2B
JS
P BV HYDRAULIC
.030 DIA.
RESERVOIR
1 SECONDARY
MANIFOLD
DE E E DE
.060 DIA. 5 2 .060 DIA.

100 PSI
4
3
T HYDRAULIC
STABIL-TRAK TM P OIL COOLER
G1
MANIFOLD
Pressure 6
SOLENOID COIL
STATE
Return
E ENERGIZED
Load Sense MAQ2010
Conditions: The 0.060 inch orifices (3 and 4) in solenoid-operated valves

• Boom angle is above 40° 4A and 4B will slow the movement of the rear axle in reaction
to terrain changes. The frame level will react normally in this
• Park brake OFF mode.
• Service brake DISENGAGED Because of greater volume of oil in base end, extra oil is
• Travel select lever in (F) FORWARD or (R) REVERSE returned to the tank through the 100 psi (7 bar) reducing
position cartridge (6) in the Stabil-TRAK manifold. Restrictions produce
Operation: 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.
10-36 31211015 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
• Travel select “Stabil-TRAK Boom Interlock Electrical
lever in (F) Circuit Operation and Troubleshooting
FORWARD or (R) If OK (10054).”
REVERSE
• Park brake OFF
Check solenoid coils 4A and 4B in the
• Service brake Stabil-TRAK manifold for correct resistance Not Replace solenoid(s).
DISENGAGED (7-9 ohms).
If OK
Remove solenoid coils 4A and 4B from Stabil-

TRAK manifold and inspect for debris or Not Clean passages or replace cartridge(s).
damage.
If OK

6036, 6042, 8042, 10042, 10054 31211015 10-37

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, cables
a. Conditions:
activate the frame level valve in the main control valve
• Boom angle is above 40° assembly. As the joystick is moved to the right, the frame level
• Park brake ON, or service brake ENGAGED, or spool valve is shifted, allowing oil to flow through the valve, to
transmission in (N) NEUTRAL the Stabil-TRAK manifold, port V.
Oil entering the Stabil-TRAK manifold at port V flows through
b. Operation: solenoid cartridge valve 3 (5), through a 0.030 inch orifice (6)
and check valve 2A (7), to the base end of the Stabil-TRAK
When the conditions are met, solenoids 4A, 4B, 12A
cylinder (8). The orifice slows the movement of the frame
and 12B are de-energized and solenoid 3 is energized.
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 2B
in solenoid-operated valves 4A (1), 4B (2), 12A (3), (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.
10-38 31211015 6036, 6042, 8042, 10042, 10054

10.11.12 Hydraulic Troubleshooting - LOCKED MODE, Will Not Frame Level Right
12
FRAME
LEVEL MAIN CONTROL
FRAME SWAY
ATTACH TILT
LIFT/LOWER
CYLINDER VALVE
EXT/RET
P
AUX
11 T T3
BYPASS
CHECK
STABIL-TRAK
TM
10 VALVE
CYLINDER G3
G2 FTR V
7
E
3
2A
9 5 T
2B
6 PBG PVG PB
JS
P BV HYDRAULIC
.030 DIA.
8 3 RESERVOIR
SECONDARY
MANIFOLD
DE DE DE DE
1
.060 DIA. 2 .060 DIA.
100 PSI
4
T HYDRAULIC
MANIFOLD
STATE 13
Return
E ENERGIZED
Load Sense MAQ2020
Conditions: With boom above 40°, when frame

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

on the Stabil-TRAK cylinder.
6036, 6042, 8042, 10042, 10054 31211015 10-39

10.11.13 Hydraulic Circuit Operation - Oil from rod end of the frame level cylinder flows through the
LOCKED MODE, Frame Level Left 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 pilot line of
• Park brake ON, or service brake ENGAGED, or
check valve 2A (7), opening the valve.
transmission 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. The oil
When the joystick control is placed in the frame level mode, then flows through solenoid-operated valve 3 (4), through
cables activate the frame level valve in the main control valve port V, to the frame level spool valve in the main control
assembly. As the joystick is moved to the right, the frame level valve. Oil flows through the valve, dumping the returned oil
spool valve is shifted, allowing oil to flow through the valve, to the reservoir.
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 (9),
Some of this oil is diverted to the pilot line of the check valve 4B (10), 12A (11), and 12B (12). At this time pilot pressure will
(3) on the return side of the frame level cylinder, opening the cause the 100 psi relief valve (13) to change position,
valve. allowing the excess oil to vent to the reservoir.
10-40 31211015 6036, 6042, 8042, 10042, 10054

10.11.14 Hydraulic Troubleshooting - LOCKED MODE, Will Not Frame Level Left
FRAME
LEVEL MAIN CONTROL
FRAME SWAY
1
ATTACH TILT
LIFT/LOWER
CYLINDER VALVE
EXT/RET
P
AUX
2 T T3
BYPASS
CHECK
STABIL-TRAK
TM 3 4 VALVE
CYLINDER G3
G2 FTR V
7
E
3
2A
5 8 T
PBG PVG PB
2B
JS
P BV HYDRAULIC
.030 DIA.
6 11 RESERVOIR
SECONDARY
MANIFOLD
DE DE DE DE
9
.060 DIA. .060 DIA.
12 10 100 PSI
T HYDRAULIC
MANIFOLD
STATE
Return
E ENERGIZED
Load Sense MAQ2030
Conditions: With boom above 40°, when frame

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

on the Stabil-TRAK cylinder.
6036, 6042, 8042, 10042, 10054 31211015 10-41

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
Refer to Section 10.12.2, “Hydraulic

Ignition ON, engine running Circuit Operation - Extend Interlock
With both outriggers RAISED, the
Mode” and Section 10.12.3, “Hydraulic
boom will not extend. Both outriggers RAISED Troubleshooting - Extend Interlock
Mode”.
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 Mode” and Section 10.12.5, “Hydraulic
extend to its full limits. Both outriggers lowered onto firm terrain Troubleshooting - Outrigger Interlock
Mode”.
10-42 31211015 6036, 6042, 8042, 10042, 10054

6036, 6042, 8042, 10042, 10054 31211015 10-43

10.12.2 Hydraulic Circuit Operation - to the piston side of the pilot-operated valve (5), causing it to
Extend Interlock Mode close. This prevents oil flow to the extend/retract cylinder (6),
preventing the boom from being extended further.
Operation:
Retract function is still allowed, as oil flow through MCV (8)
When the outriggers in the RAISED position, the outrigger
reversed, forcing the counterbalance valve (9) to open.The
pressure switches (1 and 2) are open.
oil flow will cause the pilot-operated valve (5) to open,
As the boom is extended past the boom extend switch, the returning oil to the main control valve (8) and reservoir (10).
switch opens, de-energizing the boom lockout solenoid (3).
This allows pressurized oil to flow through the valve body (4)
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 Interlock Electrical Circuit Operation and
(F) FORWARD or (R) Troubleshooting (10054),”
REVERSE
• Park brake OFF If OK
• Service brake
DISENGAGED Check solenoid coil from the boom lockout
valve for correct resistance (7-9 ohms). Not Replace solenoid.
If OK
Remove solenoid cartridge from boom

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

on extend/retract cylinder.
10-44 31211015 6036, 6042, 8042, 10042, 10054

EXTEND/RETRACT CYLINDER BOOM LOCKOUT VALVE
7
5
6
C1
9 3
4
DE
T
V1
OUTRIGGER
VALVE
MAIN CONTROL
VALVE 8
FRAME SWAY
ATTACH TILT
LIFT/LOWER
P
EXT/RET
BYPASS
AUX
LS
CHECK
T T3 VALVE
0.156 DIA.
0.156 DIA.
HYDRAULIC
RESERVOIR
10
LS
1.2 DIA.
B1 A1 B2 A2
E R E R
PUMP
HYDRAULIC
OIL COOLER
1 2
L.H. R.H.
OUTRIGGER
CYLINDER

Return STATE
E ENERGIZED
LoadSense
MAQ2040
6036, 6042, 8042, 10042, 10054 31211015 10-45

10.12.4 Hydraulic Circuit Operation - Outrigger As the boom extends past the boom extend switch, the
Interlock Mode switch opens. The boom extend lockout solenoid valve (3),
remains energized by the circuit provided by the outrigger
Operation:
pressure switches.
When the outriggers are lowered onto firm terrain, pressure
Pressurized oil flows over the free-flow check valve (4), into
within the outrigger cylinders close the outrigger pressure
the base of the extend/retract cylinder (5) allowing the
switches (1 and 2), energizing the boom extend lockout
cylinder to extend.
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 Interlock
Note: When the outrigger interlock Check electrical wiring. Not Electrical Circuit Operation and
mode is engaged, the following Troubleshooting (10054),”
systems are automatically activated: If OK
• Stabil-TRAK system is in LOCKED
MODE.
(Refer to Section 10.4,
“Stabil-TRAK Operation,”
Check outrigger pressure switches for Not Replace switch(es).
for more information.) proper operation.
• Transmission has
been DECLUTCHED.
If OK
• Park brake ENGAGED.
• Outrigger RAISE function has
Check solenoid coil from the boom lockout
been DISABLED. However, the valve for correct resistance (7-9 ohms). Not Replace solenoid.
LOWER function is still active, to
allow for any changes in
outrigger footing. If OK
Remove solenoid cartridge from boom

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

Not Replace check valve(s).
10-46 31211015 6036, 6042, 8042, 10042, 10054

EXTEND/RETRACT CYLINDER BOOM LOCKOUT VALVE
5 4
C1
E
3
T
V1
OUTRIGGER
VALVE
MAIN CONTROL
VALVE
FRAME SWAY
ATTACH TILT
LIFT/LOWER
P
EXT/RET
BYPASS
AUX
LS
CHECK
T T3 VALVE
0.156 DIA.
0.156 DIA.
HYDRAULIC
RESERVOIR
LS
1.2 DIA.
B1 A1 B2 A2
E R E R
PUMP
HYDRAULIC
OIL COOLER
1 2
L.H. R.H.
OUTRIGGER
CYLINDER

Return STATE
E ENERGIZED
LoadSense
MAQ2050
6036, 6042, 8042, 10042, 10054 31211015 10-47

10-48 31211015 6036, 6042, 8042, 10042, 10054

31211015
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161(Corporate)
(800) 554-5438(Service)
(717) 485-6417
JLG Worldwide Locations

JLG Industries JLG Ground Support Oude JLG Latino Americana LTDA Oshkosh-JLG (Tianjin)
358 Park Road Bunders 1034 Rua Antonia Martins Luiz, 580 Equipment Technology LTD
Regents Park Breitwaterstraat 12A Distrito Industrial Joao Narezzi Shanghai Branch
NSW 2143 3630 Maasmechelen Indaiatuba-SP 13347-404 No 465 Xiao Nan Road
Sydney 2143 Belgium Brasil Feng Xian District
Australia +32 (0) 89 84 82 26 +55 (19) 3936 7664 (Parts) Shanghai 201204
+6 (12) 87186300 Email: [email protected] +55(19)3936 9049 (Service) China
+6 (12) 65813058 Email: [email protected] +86 (21) 800 819 0050
Email: [email protected] Email: [email protected]
JLG Industries Dubai JLG France SAS JLG Deutschland GmbH JLG Equipment Services Ltd.
Jafza View Z.I. Guillaume Mon Amy Max Planck Str. 21 Rm 1107 Landmark North
PO Box 262728, LB 19 30204 Fauillet 27721 Ritterhude - Ihlpohl 39 Lung Sum Avenue
20th Floor, Office 05 47400 Tonniens Germany Sheung Shui N. T.
Jebel Ali, Dubai France +49 (0) 421 69350-0 Hong Kong
+971 (0) 4 884 1131 +33 (0) 553 84 85 86 +49 (0) 421 69350-45 +(852) 2639 5783
+971 (0) 4 884 7683 +33 (0) 553 84 85 74 Email:[email protected] +(852) 2639 5797
Email: [email protected] Email: [email protected]
JLG Industries (Italia) S.R.L. JLG EMEA B.V. JLG NZ Access Equipment & JLG Industries
Via Po. 22 Polaris Avenue 63 Services Vahutinskoe shosse 24b.
20010 Pregnana Milanese (MI) 2132 JH Hoofdorf 2B Fisher Cresent Khimki
Italy The Netherlands Mt Wellington 1060 Moscow Region 141400
+39 (0) 2 9359 5210 +31 (0) 23 565 5665 Auckland, New Zealand Russia Federation
+39 (0) 2 9359 5211 Email: [email protected] +6 (12) 87186300 +7 (499) 922 06 99
Email: [email protected] +6 (12) 65813058 +7 (499) 922 06 99
Email:[email protected]
Oshkosh-JLG Singapore JLG Iberica S.L. JLG Sverige AB JLG Industries (UK) Ltd.
Technology Equipment Pte Ltd. Trapadella, 2 Enkopingsvagen 150 Bentley House
35 Tuas Avenue 2 Pol. Ind. Castellbisbal Sur 176 27 Jarfalla Bentley Avenue
Jurong Industrial Estate 08755 Castellbisbal Sweden Middleton, Greater Manchester
Singapore 639454 Barcelona +46 (0) 8 506 595 00 M24 2GP
+65 6591 9030 Spain +46 (0) 8 506 595 27 United Kingdom
+65 6591 9045 +34 (0) 93 772 47 00 Email: [email protected] +44 (0) 161 654 1000
Email: [email protected] +34 (0) 93 771 1762 +44 (0) 161 654 1003
Email:[email protected] Email: [email protected]
www.jlg.com

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Service Manual

An Oshkosh Corporation Company

DATE REVISION DESCRIPTION

6036, 6042, 8042, 10042, 10054 31211015 i

(8042, 10042, 10054)

XXXhp (XXkW) @ XXXX RPM 2

ii 31211015 6036, 6042, 8042, 10042, 10054

6036, 6042, 8042, 10042, 10054 31211015 i

ii 31211015 6036, 6042, 8042, 10042, 10054

6036, 6042, 8042, 10042, 10054 31211015 iii

iv 31211015 6036, 6042, 8042, 10042, 10054

PARAGRAPH TITLE PAGE

6036, 6042, 8042, 10042, 10054 31211015 1-1

1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS

1.2 DISCLAIMER WARNING indicates a potentially hazardous situation which,

1-2 31211015 6036, 6042, 8042, 10042, 10054

1.6 SAFETY INSTRUCTIONS 1.6.3 General Hazards

6036, 6042, 8042, 10042, 10054 31211015 1-3

1-4 31211015 6036, 6042, 8042, 10042, 10054

PARAGRAPH TITLE PAGE

6036, 6042, 8042, 10042, 10054 31211015 2-1

2.9 Hydraulic Connection Assembly and Torque Specification . . . . . . . . . . . . . . . . . . . . . . . 2-31

2-2 31211015 6036, 6042, 8042, 10042, 10054

2.1 REPLACEMENT PARTS AND WARRANTY

Maximum Weight Without Attachments (lbs/kg)

Before ordering parts or initiating service inquiries, make

6036, 6042, 8042, 10042, 10054 31211015 2-3

2.2.1 Travel Speeds

TRANSMISSION 6036 6042 8042 10042 /10054

2.2.2 Hydraulic Cylinder Performance

APPROXIMATE TIMES (seconds)

2-4 31211015 6036, 6042, 8042, 10042, 10054

2.2.3 Electrical System

2.2.4 Engine Performance Specifications

6036, 6042, 8042, 10042, 10054 31211015 2-5

Size Tire Type Minimum Ply/ Fill Type Pressure

Size Tire Type Minimum Ply/ Fill Type Pressure

Size Tire Type Minimum Ply/ Fill Type Pressure

d. 10042 & 10054

Size Tire Type Minimum Ply/ Fill Type Pressure

2-6 31211015 6036, 6042, 8042, 10042, 10054

2.3 FLUID SPECIFICATIONS

6036, 6042, 8042, 10042, 10054 31211015 2-7

2-8 31211015 6036, 6042, 8042, 10042, 10054

2.4 FLUID AND LUBRICANT CAPACITIES

Engine Crankcase Oil

6036, 6042, 8042, 10042, 10054 31211015 2-9

2.5 SERVICE AND MAINTENANCE

2.5.1 Every 10 Hours

OC0960 OC0970 OC0910 OC0920 OC0930 OC0890

OC0950 OC0880 OC0940 OC0900

2.5.2 First 50 Hours

Check Boom Chain Check Wheel Lug

2.5.3 Every 50 Hours

Check Washer Lubrication

2.5.4 First 250 Hours

OC1040 OC1050 OC1070

Change Axle Oil Change Wheel End Change

2-10 31211015 6036, 6042, 8042, 10042, 10054