SkyTrak 6036 Service Manual

Service Manual

Model

6036

S/N 9B0499 & Before

8990151

Revised February 11, 2005

Effectivity Page

January, 1997 - 001 - Original Issue.

February 11, 2005 - B - Replaced all branding with JLG.

Model 6036 S/N 9B0499 and Before

A

Effectivity Page

B	Model 6036 S/N 9B0499 and Before

SECTION CONTENTS

Section	Subject	Page

Section 1	Safety Practices ................................................................................	1-1
Section 2	General Instructions ..........................................................................	2-1
Section 3	Boom .................................................................................................	3-1
Section 4	Operator's Cab ..................................................................................	4-1
Section 5	Wheel Assembly, Tires, and Axle ......................................................	5-1
Section 6	Drive Shafts and Drop Box ................................................................	6-1
Section 7	Transmission, Clark Series 18000.....................................................	7-1
Section 8	Engine, Perkins Series 4.236 and T4.236 .........................................	8-1
Section 9	Hydraulic System ..............................................................................	9-1
Section 10	Electrical System .............................................................................	10-1

Model 6036 S\N 9B0499 and Before Model 6036 S\N 9B0499 and Before

This Page Left Blank Intentionally

Section 1. Safety Practices

				SECTION 1
		SAFETY PRACTICES
		CONTENTS
						Danger !
Par.		Title		Page
1.1		INTRODUCTION		1-1		The signal word “DANGER” signifies that an
1.2		SIGNAL WORDS		1-1
						imminently hazardous situation to a person
1.3		PERSONAL CONSIDERATIONS		1-2
						on or near the forklift exists. This danger to
1.4		EQUIPMENT CONSIDERATIONS		1-2		persons is such that it will result in a high
1.5		GENERAL CONSIDERATIONS		1-3		likelihood of death or permanent injury if the
1.6		OPERATIONAL CONSIDERATIONS		1-3		recommended precautions or practices are not
						taken.
1.7		FINAL WORD		1-4

1.1 INTRODUCTION

Practically all SERVICE work involves the need to drive the forklift. The Owners/Operators Manual, supplied with each forklift, contains detailed safety practices relating to driving and operating. These practices apply to the service technician and should be read, understood, and practiced.

Prior to performing any service on the forklift, consideration should be given to factors that may have an effect upon safety; not only on the mechanic, but also the bystanders.

1.2 SIGNAL WORDS

This symbol means “ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED !” The symbol is used in conjunction with the following signal words to attract your attention to safety messages found throughout this manual. The message that follows the symbol contains important information about SAFETY. To avoid injury and possible death, carefully read and thoroughly understand each message.

Warning !

The signal word “WARNING” signifies that a potentially hazardous situation to a person on or near the forklift exists, which could result in death or serious injury if the recommended precautions or practices are not taken.

Caution !

The signal word “Caution” signifies that a potentially hazardous situation to a person on or near the forklift exists, which may result in minor or moderate injury if the recommended precautions or practices are not taken.

IMPORTANT: The information in this manual does not replace any safety rules used in your area. Before operating this forklift, learn the rules and laws for your area. Make sure the machine has the correct equipment according to these rules and laws.

Your safety and the safety of others in the work area depend on your knowledge of correct operating procedures for the machine.

Model 6036 S\N 9B0499 and Before

1-1

Section 1. Safety Practices

1.3 PERSONAL CONSIDERATIONS

Item	What to do	Why
Clothing	Do not wear loose clothing or jewelry.	Improper clothing can catch on controls
		or moving parts and cause accidents
		and/or injury.
Eye Protection	Always wear appropriate eye protection	Permanent eye damage can be caused
	when chiseling, grinding, discing, welding,	if foreign matter enters the eye.
	painting, when repairing hydraulic sys-
	tems, or checking, testing or charging the
	battery.
Breathing	Wear respiratory protection if grinding or	Fumes, dust or paint spray are harmful
Protection	painting.	when inhaled.
Hearing	Always wear ear protection if noise is	Continuous loud noise can damage your
Protection	excessive.	hearing.
Foot Protection	Wear protective footwear with reinforced	To protect feet from falling objects and
	toe caps and oil-resistant soles.	to prevent slipping.
Lifting	Make sure you are capable of lifting an	To avoid injury through incorrect han-
	object. Get help or use a sling on large	dling of heavy components.
	components.

1.4 EQUIPMENT CONSIDERATIONS

Item		What to do	Why
Operator’s Cab		Before using the forklift, be sure the	The cab protects the operator from
		operator’s cab and rear window are	possible serious injury or death.
		secure and serviceable.
Lifting		Check all lifting equipment (chains,	To prevent serious injury or death due to
Equipment		brackets, hooks, etc.), before use. Be	falling objects.
		sure equipment is the proper capacity.
		Never stand under a suspended load or	To prevent serious injury or death.
		raised implement.
Compressed Air		Always use a general purpose nozzle to	To prevent serious injury to operator
		blow dust, filings, dirt, etc., from work	and/or co-workers.
		area. Always wear eye protection when
		using compressed air to clean a work
		area.
			To prevent injury to other personnel in
		Look around before using an air hose.	the work area.

1-2	Model 6036 S\N 9B0499 and Before

Section 1. Safety Practices

1.4EQUIPMENT CONSIDERATIONS (cont.)

Item		What to do	Why
Hand Tools		Always use the proper tool for the job.	Many cuts, abrasions, and/or injuries
			are caused by defective or improper
			tools.
		Always keep tools clean and in good	Well maintained tools work better and
		working order.	may prevent injury.
		Always use the Special Service Tools	These tools will reduce the work, labor
		recommended.	and costs.

1.5 GENERAL CONSIDERATIONS

Item		What to do	Why
Solvents		Use only approved cleaning fluids and	Certain types of fluid cause damage to
		solvents that are known to be safe.	components and may cause skin
			irritation.
Housekeeping		Clean and remove all hazards from the	To prevent accidents and injuries.
		area.
First Aid		Do not overlook any cut, abrasion, or	What appears at first trivial, could
		burn. Have it cleaned and dressed	become painful and injurious.
		properly.
		Make sure you know the location of the	Quick application of first aid procedures.
		First Aid Box.
Cleanliness		Plug all hose ends and connections when	To prevent dirt and foreign material from
		removing components. Clean exterior of	entering the system. Dirt and abrasive
		all parts before repairing. A high pres-	dust can reduce the efficiency and
		sure or steam cleaner is recommended.	working life of a component and lead to
		Always wear eye protection when steam	costly replacement. Permanent eye
		cleaning.	damage can be caused if foreign matter
			enters the eye.

1.6 OPERATIONAL CONSIDERATIONS

Item		What to do	Why
Engine		Stop the engine if at all possible before	To prevent serious injury and/or death.
		performing any service.
Dangerous		Place a warning sign on forklifts that are	To prevent serious injury and/or death.
Start		dangerous to start. Disconnect battery
		leads if leaving the unit unattended.

Model 6036 S\N 9B0499 and Before

1-3

Section 1. Safety Practices

1.6 OPERATIONAL CONSIDERATIONS (cont.)

Item	What to do	Why
Ventilation	Avoid prolonged running of the engine in	Exhaust fumes are highly toxic and
	a closed area with inadequate ventilation.	can kill.
Radiator Cap	Always turn the radiator cap slowly to the	Escaping coolant can burn you seri-
	first stop to relieve pressure.	ously.
Soft Ground	Never work on a forklift on soft ground.	To prevent serious injury and/or death.
	Check for additional ballast. Seek
	assistance and install suitable supports if
	necessary.
Supports and	Make sure safe and stable supports or	To prevent serious injury and/or death.
Straps	straps are installed beneath or around a
	component or structural member that may
	fall before commencing work.
Oil Pressure	Before loosening hoses or tubes, turn off	A pressure explosion will cause
	the engine and operate the controls	serious injury.
	several times to relieve pressure.
Pressure	Make sure all test equipment is in good	To prevent damage to the system or
Testing	condition.	the equipment, and to eliminate the
		possibility of personal injury.
	Use only gauges specified.
	Comply with test procedure specified.
Leaving Forklift	Lower carriage to the ground.	To prevent accidental injury.
Parking	Do not park or attempt to service forklift	To prevent serious injury and/or death.
	on an incline. If unavoidable, block all
	wheels.
Wheels and	Keep tires inflated to correct pressure.	To prevent dangerous travel and load
Tires		handling.
	Do not over-inflate tires.	Over-inflation can cause tires to burst
		and result in personal injury.

The safety precautions and practices in this manual 1.7 FINAL WORD are extremely important. Not following them can

cause personal injury or death. Read this section carefully and be sure you understand all the precautions and practices noted before attempting to service the forklift.

1-4	Model 6036 S\N 9B0499 and Before

This Page Left Blank Intentionally

Section 2 General Instructions

SECTION 2

GENERAL INSTRUCTIONS

CONTENTS

Par.	Title	Page		Par.	Title	Page
2.1	INTRODUCTION	2-2	2.9		AFTER SERVICE STARTUP
2.2	CLEANING	2-2			AND CHECKS	2-5
2.3	REPLACEMENT	2-2	2.9.1		Starting After Servicing	2-5
2.4	HOSES AND TUBES	2-2	2.9.2		After Hydraulic Component
2.4.1	Inspection	2-2			Servicing	2-5
2.4.2	Installation	2-2	2.9.3		After Brake System Servicing	2-5
2.5	BEARINGS	2-3	2.9.4		After Fuel System Servicing	2.5
2.5.1	Removal	2-3	2.9.5		After Replacing Transmission	2.5
2.5.2	Cleaning	2-3	2.9.6		After Tire Servicing	2-5
2.5.3	Installation	2-3	2.9.7		After Engine Servicing	2-5
2.6	PRESSURE TESTING AND		2.9.8		After Boom Servicing	2-5
	ADJUSTMENT	2-3	2.9.9		After Axle Servicing	2-5
2.7.	TORQUES	2-3	2.10		FLUID LEVELS AND
2.7.1	Fasteners	2-3			LUBRICATION	2-5
2.7.2	Bolts and Nuts	2-3	2.10.1		Wheel Ends	2-5
2.7.3	Flared Fittings (37°, steel)	2-3	2.10.2		Hydraulic Reservoir	2-6
2.7.4	Straight Thread O-ring Fitting		2.10.3		Engine Oil	2-6
	(non-adjustable)	2-4	2.10.4		Cooling System	2-6
2.7.5	Straight Thread O-ring Fitting		2.10.5		Splines	2-6
	(adjustable)	2-4	2.10.6		Drop Box	2-6
2.8	PAINTING	2-4	2.10.7		Grease Fittings	2-6
2.8.1	Orange Paint	2-4
2.8.2	Black Paint	2-4
2.8.3	White Paint	2-4

2-1	Model 6036 S/N 9B0499 and Before

Section 2 General Instructions

2.1INTRODUCTION

Appropriate service methods and proper repair procedures are essential for safe, reliable operation of the forklift and safety of the individual doing the work. This Maintenance Manual provides general directions for accomplishing service and repair work with tested, effective techniques. Following them will assure reliability.

There are many variations in procedures, techniques, tools, and parts for servicing vehicles, as well as work skills. This Manual cannot possibly anticipate all such variations and provide advice or cautions for each one. Accordingly, anyone who intends to depart from the instructions in this Manual must first consider his safety and the vehicle integrity.

2.2CLEANING

Clean the exterior of all parts before repairing. Dirt and abrasive dust reduce the efficient work life of the part and lead to costly replacement.

Use cleaning fluids and solvents which are suitable for cleaning parts and do not risk the safety of the user. Certain types of fluids damage rubber parts and/or cause skin irritation.

The following precautions must be observed to insure hydraulic cleanliness:

1.Flush hose and tube assemblies with a solvent compatible with hose assemblies. Blow out excess solvent with shop air.

2.Cap hydraulic fittings and protect threads until installation.

3.Cap hoses and tube assemblies until installation

4.Flush hydraulic reservoir, fuel tank, and gear housing with a suitable solvent to remove paint, metal chips, welding shot, etc.

5.Protect system components from airborne contaminants. Plug all cylinder, valve, reservoir, tank, and pump openings until installation.

6.Use clean, filtered oil when filling the system.

7.System cleanliness level must be a minimum ISO code 18/15 particle ratio count.

2.3REPLACEMENT

Replace O-rings, seals, and gaskets whenever they are disturbed. Never mix new and old seals or O-rings regardless of condition. Always lubricate new seals and O-rings with hydraulic oil before installation.

When replacing parts, use the correct tool.

2.4HOSES AND TUBES

2.4.1Inspection

1.If the hose end fittings are damaged, always replace hoses and tubes . Damaged, dented, crushed, or leaking hose fittings restrict oil flow and the operation of the parts being served. Fittings showing signs of movement from their original position have failed and must be replaced.

2.Be sure hoses are in good condition. If in doubt, replace them.

3.Replace hoses if the following occur:

•chafed outer cover

•concealed corrosion of wire reinforcement.

•ballooning (replace immediately !)

•kinked, crushed, stretched, or deformed.

2.4.2 Installation

1.When installing a new hose, loosely connect each end and make sure the hose takes up the designed position before tightening the connection. Clamps should be tightened sufficiently to hold the hose without crushing and to prevent chafing.

2.If a hose is replaced on a moving part, be sure it does not foul by moving the part through its complete range of travel.

3.Be sure any hose which has been installed is not kinked or twisted.

4.Free moving, unsupported hoses must never touch each other or related work surfaces. This causes chafing reducing hose life.

Model 6036 S/N 9B0499 and Before

2-2

2.5BEARINGS

2.5.1Removal

1.Bearings should never be removed unless absolutely necessary. Always use the recommended puller to reduce the risk of bearing or related component damage.

2.When bearings or bushings are removed, check that the bearing is free from discoloration, nicks, scuffing, and signs of overheating. If in doubt, replace the bearing or bushing.

2.5.2 Cleaning

Bearings acceptable for service should be cleaned in a suitable solvent and immersed in clean lubricating oil until needed.

2.5.3 Installation

1.Be sure bearings are installed with care during servicing, maintenance and repair.

2.Install bearings in either of the following two ways:

•press fit on rotating parts such as shafts and gears, and

•push fit into static locations such as reduction gear housings.

3.When possible, always install the bearing into the rotating part first.

4.Use the proper tools or a press when installing a bearing or bushing.

5.In the absence of the proper tools or press, heat the bearings and/or casing in hot oil to assist in the installation.

2.6PRESSURE TESTING AND ADJUSTMENT

Prior to pressure testing or adjustment, be sure all hoses are in good condition and all fittings tight.

Use a pressure gauge with a range that is large enough to measuring the specified pressure.

Comply with the correct procedure to prevent damage to the system or the equipment and to eliminate the possibility of injury.

Section 2 General Instructions

Be sure that hydraulic oil is at operating temperature (80 to 120 °F) before adjusting relief valves, pressure reducing valve or sequence valve. If necessary, operate the machine to raise the oil temperature. The oil temperature can be checked by placing a hand against the side or the bottom of the reservoir. If your hand feels too hot to keep against the reservoir, the oil temperature is acceptable.

2.7TORQUES

2.7.1Fasteners

All fasteners are plated and equal to SAE grade 5 (PC8.8) unless otherwise specified.

2.7.2 Bolts and Nuts

Unless otherwise specified the following grade 5 (PC8.8) torque values (±10%) apply:

	Torque				Torque
Inch	lb-ft	N m		mm	N m	lb-ft
1/4	9	12		6.0	10	7
5/16	18	24		8.0	25	18
3/8	31	42		10.0	50	37
7/16	50	68		---	---	---
1/2	75	105		12.0	80	59
9/16	110	150		14.0	130	95
5/8	150	200		16.0	200	146
3/4	250	340		20.0	360	263
7/8	380	515		22.0	510	372
1.0	585	790		24.0	650	475

2.7.3 Flared Fittings (37o, steel)

1.Align tube and fitting

2.Tighten nut to the following torque:

SAE		Torque
Size	lb-ft		N m
4	8-12		11-16
6	19-23		26-31
8	38-46		52-63
10	50-58		68-79
12	84-92		114-125
14	100-108		136-147
16	117-129		159-175
20	176-200		239-271
24	251-283		340-384

2-3	Model 6036 S/N 9B0499 and Before

Section 2 General Instructions

2.7.4Straight Thread O-ring Fitting (non-adjustable)

1.Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material.

2.Lubricate O-ring with light coating of oil.

3.Torque as follows:

SAE		Torque
Size	lb-ft		N m
4	22-26		30-35
6	46-54		63-73
8	95-105		129-143
10	125-135		170-183
12	165-175		224-237
16	245-255		332-346
20	270-290		366-393
24	365-385		495-522

2.7.5Straight Thread O-ring Fitting (adjustable)

1.Inspect and correct both mating parts for burrs, nicks, scratches, or any foreign particles.

2.Lubricate O-ring with light coat of oil.

3.Back off locknut as far as possible.

4.Screw fitting into the port by hand until the backup washer contacts the face of the port and is pushed all the way towards the locknut.

5.To position the fitting, unscrew by the required amount, but not more than one full turn.

6.Hold the fitting in the desired position and torque the locknut as follows:

SAE		Torque
Size	lb-ft		N m
4	14.5-17.5		20-24
6	37-43		50-58
8	75-85		102-115
10	115-125		156-170
12	155-165		210-224
16	225-235		305-319
20	260-280		353-380
24	340-360		461-488

2.8PAINTING

Unless otherwise specified, paint all components as follows:

2.8.1 Orange Paint

Use orange paint on all components except as specified in paragraphs 2.8.2 and 2.8.3.

P/N 8528033 ..................1 gallon service paint P/N 8528034 ......................... 16 oz Spray can

2.8.2 Black Paint

Use P/N 8528036 ................... 16 oz spray can Boom Angle Indicator Pointer

Wheels

Brake Pedal

Radiator

Seat Adaptor Plate

Radiator Shroud

Transmission Oil Cooler

Axles

Drive Shafts

Drop Box

Forks

Mirrors and their Brackets

Dash Panels

Instrument Mounting Plate

Air Cleaner

Steering Column

Joystick Panel

Cab Door Handle

2.8.3 White Paint

Use P/N 8528040 ................... 16 oz spray can Boom Extend Cylinder

Model 6036 S/N 9B0499 and Before

2-4

2.9AFTER SERVICE STARTUP AND CHECKS

2.9.1Starting After Servicing

NOTE: Refer to Owners/Operators Manual for engine cold start procedure.

1.Check fluid levels.

2.Start engine at idle. Check for leaks from hydraulic components, engine, axles, transmission, brakes and reservoirs.

3.Purge systems of air by operating functions.

4.Check for proper operation.

5.Retract all cylinders. Shutdown and check reservoir levels. Recheck levels when oil is cold.

6.Replace hydraulic filter if required.

2.9.2After Hydraulic Component Servicing

1.Check torque on fastening hardware of components being replaced.

2.Check that hoses are in place and tightly connected.

3.Check hydraulic fluid level and replenish as required.

4.Start forklift and bleed systems of air.

5.Check operation.

2.9.3 After Brake System Servicing

1.Check level of TRAK wet disc brake oil in wheel ends and replenish as required.

2.Bleed brakes.

3.Check wheel end brake pressure.

4.Check operation.

2.9.4 After Fuel System Servicing

1.Bleed fuel system.

2.Fill tank with clean fuel as required.

Section 2 General Instructions

2.9.5 After Replacing Transmission

1.Check transmission fluid level and replenish as required.

2.Replace transmission filter.

3.Check torque on drive shaft yoke hardware.

4.Refer to the Clark Maintenance Manual for “Servicing Machine After Transmission Overhaul”.

2.9.6 After Tire Servicing

1.Check hydrofill mixture, air pressure and weight of tire (empty and full).

2.Check wheel nut torque.

2.9.7 After Engine Servicing

Consult the qualified service agent for proper procedure before startup.

2.9.8 After Boom Servicing

1.Check wear pads.

2.Check chain tension adjustment.

3.Lubricate all grease points.

2.9.9 After Axle Servicing

1.Check fluid levels.

2.Check torque of drive shaft yoke hardware.

3.Check wheel nut torque.

4.Check toe-in if required.

5.Lubricate all grease points.

6.Refer to Dana Service Manual for “SECTION 1 - General Information”.

2.10FLUID LEVELS AND LUBRICATION

2.10.1Wheel Ends

Use the following procedure to check fluid level on the wheel ends:

1.Level the forklift, ground the carriage, shut off engine, and engage the parking lock. Be sure that arrow on wheel end housing is pointing down.

2-5	Model 6036 S/N 9B0499 and Before

Section 2 General Instructions

2.Clean the area around the magnetic drain plug and remove the plug and check fluid level. Use only Special TRAK Wet Disc Brake Oil (P/ N 8522042) as required to bring level up even with the plug hole.

IMPORTANT: Other brake oils should not be used! You will lose braking force and brake squealing will occur.

3. Clean and install drain plug.

2.10.2 Hydraulic Reservoir

With the oil cold and the forklift on a level surface and all hydraulic cylinders retracted, check the sight gauge plug. If oil is visible in the sight gauge plug, the level is satisfactory. If oil level is not visible in the sight gauge, the level is unsatisfactory and hydraulic oil must be added.

2.10.3 Engine Oil

Oil level should be between the full and add mark on the dipstick.

2.10.4 Cooling System

Check level of coolant in overflow bottle. When coolant is hot, bottle should be 3/4 full to full. When coolant is cool, bottle should be 1/4 to 1/2 full. Add coolant as required through the overflow bottle (50/50 mixture of ethylene glycol and water).

2.10.5 Splines

Transmission input shaft splines must be coated with a molybdenum disulfide or Molykote compound.

2.10.6 Drop Box

Remove level plug in drop box and check level of oil. Add Tractor Hydraulic Fluid (THF) as required through the level plug hole with a squeeze bottle. Bring the oil level up even with the level plug hole and install the level plug.

2.10.7 Grease Fittings

1.Coat the following with a multi-purpose lithiumbased grease:

•Hydraulic cylinder pins (10 points)

•Drive shaft slip joints (3 points)

•Boom chain sheaves (2 points)

•Boom pivot pins (2 points)

•Carriage pivot pins (2 points)

•Axle pivot pins (4 points)

•Axle steer knuckles (8 points)

•Axle tie rod ball joints (4 points)

•Axle steer cylinder ball joints (8 points)

2.All excess grease must be removed.

Model 6036 S/N 9B0499 and Before

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This Page Left Blank Intentionally

Section 3. Boom

SECTION 3

BOOM

CONTENTS

Par.		Title	Page
3.1		BOOM ASSEMBLY	3-1
3.1.1		Inner Boom Replacement	3-1
3.1.2		Intermediate Boom Replacement	3-3
3.1.3		Outer Boom Replacement	3-5
3.1.4		ChainReplacement	3-9
3.1.5		Chain Lubrication	3-10
3.1.6		Chain Tension Check	3-10
3.1.7		Chain Tension Adjustment	3-11
3.1.8		Wear Pad Replacement	3-11
3.1.9		Hose Tensioning	3-12
3.1.10		Long Term Storage Preparation	3-13
3.1.11		Boom Lubrication Points	3-13
3.2		EMERGENCY
		BOOM LOWERING	3-13

3.2.1Loss of Engine Power

	or Hydraulic Pump Failure	3-13
3.2.2	Hydraulic Line Failure	3-14
3.3	QUICK ATTACH ASSEMBLY	3-15
3.4	TROUBLESHOOTING	3-16
3.5	SPECIFICATIONS	3-17

3.1BOOM ASSEMBLY

The boom assembly, Fig. 3.1, consists of inner, intermediate, and outer booms. The intermediate boom slides in the outer boom and the inner boom slides in the intermediate boom. As the boom extend/retract cylinder extends or retracts the intermediate boom, a pair of extend chains and one retract chain moves the inner boom in the same direction.

IMPORTANT: The inner, intermediate and outer boom replacement instructions in paragraphs 3.1.1 through 3.1.3 must be completed in sequence. Replacement of two or more booms as a unit requires special considerations that are not covered in these instructions.

3.1.1 Inner Boom Replacement

a. Removal

1.Park forklift on level surface, engage park lock and retract boom.

EXTEND CHAIN

INTERMEDIATE BOOM

OUTER BOOM

INNER BOOM

GOOSENECK

RETRACT CHAIN

BOOM EXTEND/RETRACT CYLINDER

REAR BOOM COVER

MA0011

Fig. 3.1 Boom Assembly

Model 6036 S/N 9B0499 and Before

3-1

Section 3. Boom

INNER

BOOM

QUICK ATTACH

PIVOT PIN GOOSENECK

WITH GREASE

FITTING

BASE END

PIN

	LOCK	GRILLE TILT
		CYLINDER
	PIN

QUICK ATTACH

ASSEMBLY

ROD END PIN

MA0021

Fig. 3.2 Gooseneck

2.Prepare to replace the inner boom, Fig. 3.2, by removing the grille tilt cylinder as described in paragraph 9.2.4.a.

3.Remove the quick attach pivot pin, Fig. 3.2, and quick attach assembly from the gooseneck.

4.Remove the rear boom cover, Fig. 3.1.

5.Pull the grille tilt cylinder hoses out the rear boom cover opening.

6.Working from the rear boom cover opening, record the number of shims beneath each wear pad as you remove the side and top wear pads from the inner boom, Fig. 3.3.

7.Refer to Fig. 3.1 and remove the locknuts and washers that attach the extend and retract chains to the inner boom.

8.Use a sling and a suitable hoist to slide the inner boom out the front of the intermediate boom.

9.Refer to Fig. 3.3 and remove bottom wear pad from the rear of the inner boom.

b. Inspection and Replacement

1.Inspect the boom and welds and contact JLGif structural damage is detected.

2.Inspect hoses and replace if damaged.

3.Inspect and replace wear pads as described in paragraph3.1.8.

c. Installation

1.Refer to Fig. 3.3 and install the bottom wear pad on the inner boom. Install a new pad if it is excessively worn (refer to paragraph 3.1.8). Apply Loctite® Removable Threadlocker 242 to the capscrews and torque them to 31 lb-ft (42 N m).

2.Connect the extend chains at the top rear of the inner boom; temporarily secure the other end of the chains to the top front of the inner boom

3.Use slings and a suitable hoist to slide the repaired or new inner boom and extend chains into the intermediate boom.

4.Working through the rear cover opening, temporarily install the top and side inner boom wear pads on the inner boom, Fig. 3.3. Replace pads that are excessively worn. Use the same amount of shimming as used when the pads were removed.

IMPORTANT: The ends of wear pad attaching capscrews must not protrude beyond the wear pad insert; the ends must range from flush to 0.19" (5 mm) recessed in the wear pad insert (refer to Fig. 3.3).

5.Check the wear pad gap between the inner boom side and top wear pads and the intermediate boom. The gap should be 0.07 to 0.13" (1,8 to 3,3 mm) and equal for all top and side wear pads. Install or remove shims as required.

6.Install the wear pads by applying Loctite 242 to the capscrews and torquing them to 31 lb-ft (42 N m).

7.Secure the retract chain to the inner boom with washers and locknuts. Make sure the chains are not twisted.

8.Tie the grille tilt cylinder hoses together and push them through the inner boom to the opening at the inner boom gooseneck.

9.Refer to Fig. 3.2 and install the quick attach assembly on the gooseneck with the quick attach pivot pin. Position pin with grease holes facing UP.

10.Using grease fittings at the ends of the pin, lubricate the quick attach pivot pin.

11.Install the grille tilt cylinder as described in paragraph 9.2.4.f.

12.Adjust hose tension as described in paragraphs 3.1.9.

3-2	Model 6036 S/N 9B0499 and Before

Section 3. Boom

CAPSCREW ENDS TO BE FLUSH TO 0.19" (5 mm) RECESSED IN WEAR PAD INSERT

GAP MUST BE 0.07 TO 0.13" (1,8 TO 3,3 mm)

GAP MUST BE 0.07 TO 0.13" (1,8 TO 3,3 mm)

INTERMEDIATE

BOOM

INNER BOOM

PAD, INSERT (1), LOCK WASHER (2), FLAT WASHER (2), 3/8-16 X 7/8" CAPSCREW (2)

PAD, SPACER, INSERT (2),

LOCK WASHER (6),

FLAT WASHER (6),

3/8-16 X 1-3/4"

CAPSCREW (6),

14 GA SHIM

CAPSCREW ENDS TO BE FLUSH

TO 0.19" (5 mm) RECESSED IN

WEAR PAD INSERT

PAD, #14 GA SHIM, INSERT (2),

LOCK WASHER (4),

FLAT WASHER (4),

3/8-16 X 3/4"

CAPSCREW (4)

MA0031

Fig. 3.3 Rear Wear Pads Attached to Inner Boom

13.Check and adjust chain tension as described in paragraphs 3.1.6 and 3.1.7.

14.Refer to Fig. 3.1 and install the rear boom cover.

3.1.2 Intermediate Boom Replacement

a Removal

1.Refer to paragraph 3.1.1.a and remove the inner boom.

2.Remove the rod end pin, Fig. 3.4, and retaining rings that attach the rod end of the boom extend/retract cylinder to the intermediate boom. Lower the rod end to the anti-buckle bar.

Model 6036 S/N 9B0499 and Before

3.Working from the rear boom cover opening, record the number of shims beneath each wear pad as you remove the side and top wear pads from intermediate boom, Fig. 3.6.

ANTI-BUCKLE BAR

OUTER BOOM

	ROD END PIN				BASE END PIN
	INTERMEDIATE			EXTEND/RETRACT
				CYLINDER
	BOOM						MA0041

Fig. 3.4 Extend/Retract Cylinder

3-3

Section 3. Boom

4.Use a sling and a suitable hoist to slide the intermediate boom out the front of the outer boom.

5.Record the number of shims beneath each wear pad as you remove the rear bottom, Fig. 3.6, and all front wear pads, Fig. 3.5, from the intermediate boom.

6.Examine the chain sheaves for wear and replace if necessary.

b. Inspection and Replacement

1.Inspect the boom and welds and contact JLG if structural damage is detected.

PAD, INSERT (2),

SPACER, #10 GA SHIM, FLAT WASHER (4), LOCK WASHER (4), 3/8-16 X 1-3/4" CAPSCREW (4)

INNER BOOM

GAP MUST BE 0.07 TO 0.13" (1,8 TO 3,3 mm)

PAD, #10 GA SHIM,

INSERT (4),

LOCK WASHER (8), FLAT WASHER (8), 3/8-16 X 3/4" CAPSCREW (8)

PAD, INSERT (2),

	LOCK WASHER (6),	INTERMEDIATE
		BOOM
	FLAT WASHER (6),
	3/8-16 X 7/8"
	CAPSCREW (2),
	3/8-16 X 1-3/4"
	CAPSCREW (4)	MA0051

Fig. 3.5 Front Wear Pads Attached to Intermediate Boom

3-4

2.Inspect hoses and replace if damaged.

3.Inspect and replace wear pads as described in paragraph3.1.8.

c. Installation

1.Refer to Fig. 3.6 and install the rear bottom wear pad, Fig. 3.6, on the intermediate boom. Install a new pad if it is excessively worn (refer

to paragraph 3.1.8). Apply Loctite® Removable Threadlocker 242 to the capscrews and torque them to 31 lb-ft (42 N m).

2.Using a sling and a suitable hoist, slide the repaired or new intermediate boom into the outer boom.

3.Working through the rear boom cover opening, refer to Fig. 3.6 and temporarily install the rear top and side wear pads on the intermediate boom. Replace pads that are excessively worn. Use the same amount of shimming as used when the pads were removed.

IMPORTANT: The ends of wear pad attaching capscrews must not protrude beyond the wear pad insert; the ends must range from flush to 0.19" (5 mm) recessed in the wear pad insert (refer to Fig. 3.3).

4.Refer to paragraph 3.1.1.c and install the inner boom.

5.Connect the extend chains at the front of the outer boom.

6.On the front of the intermediate boom, check the gap between the intermediate boom side and top wear pads and the inner boom, Fig.

3.5.The gap should be 0.07 to 0.13 inches (1,8 to 3,3 mm) and equal on all sides. Remove or install shims as required.

7.Working through the rear boom cover opening, refer to Fig. 3.6 and check the gap between the intermediate boom side and top wear pads and the outer boom. The gap should be 0.07 to

0.13inches (1,8 to 3,3 mm) and equal on all sides. Remove or install shims as required.

8.Install the wear pads by applying Loctite 242 to the capscrews and torquing them to 31 lb-ft (42 N m).

9.Refer to Fig. 3.4 and apply anti-seize compound to the rod end pin. Secure the rod end of the boom extend/retract cylinder to the intermediate boom with the rod end pin, Fig. 3.4 and retaining rings.

Model 6036 S/N 9B0499 and Before

PAD, INSERT (1),

LOCK WASHER (3),

FLAT WASHER (3),

3/8-16 X 7/8"

CAPSCREW (3)

GAP MUST BE 0.07 TO O.13" (1,8 TO 3,3 mm)

Section 3. Boom

PAD, INSERT (1), LOCK WASHER (3), FLAT WASHER (3), 3/8-16 X 7/8" CAPSCREW (3)

GAP MUST BE 0.07 TO O.13" (1,8 TO 3,3 mm)

PAD, #10 GA SHIM,

INSERT (2),

LOCK WASHER (4),

FLAT WASHER (4),

3/8-16 X 3/4"

CAPSCREW (4)

GAP MUST BE 0.07 TO O.13" (1,8 TO 3,3 mm)

PAD, SPACER, #10 GA
SHIM, INSERT (1),		INTERMEDIATE
LOCK WASHER (2),		BOOM
FLAT WASHER (2),		OUTER BOOM
3/8-16 X 2"
CAPSCREW (2)		MA0061

Fig. 3.6 Rear Wear Pads Attached to Intermediate Boom

3.1.3 Outer Boom Replacement

a. Removal

1.Refer to paragraphs 3.1.1.a and 3.1.2.a and remove the inner and intermediate booms.

2.Disconnect and remove the extend and retract chains from the outer boom. Check the condition of the chains and replace if worn or damaged.

3Refer to paragraph 9.2.2.a and remove the boom extend/retract cylinder.

4.Refer to Fig. 3.7 and remove the locknut and capscrew that secures the slave cylinder rod end pin. Remove the pin. Check the condition of the bearing in the cylinder rod end; replace bearing if worn or damaged.

5.Refer to Fig. 3.8 and disconnect the grille tilt cylinder hoses from the tubing at the hose guides and remove the hoses from the boom.

HOIST CYLINDER

ROD END PIN BOOM PIVOT

PIN

OUTER BOOM

	FRAME
EXTEND/RETRACT
CYLINDER BASE	SLAVE CYLINDER
END PIN	ROD END PIN
	MA0071

Fig. 3.7 Outer Boom Pivot Pins

Model 6036 S/N 9B0499 and Before

3-5

Section 3. Boom

OUTER BOOM INTERMEDIATE BOOM

INNER BOOM

HOSES

HOSE GUIDE

CLAMP

TUBING

SUPPORT PLATE

TO MAIN

CONTROL

CONNECTION

VALVE

GRILLE TILT

CYLINDER

MA0081

Fig. 3.8 Grille Tilt Cylinder Hoses

6.Disconnect and cap or plug the grille tilt cylinder tubing, extend cylinder tubes and bulkhead fittings in support plate, Fig. 3.8, below the rear opening of the boom.

7.Loosen clamps that hold the tubing to the bottom of the outer boom and remove the tubing from the outer boom.

8.Attach slings and a suitable hoist to the approximate center of gravity of the outer boom and remove all slack from hoist cable.

NOTE: The approximate center of gravity of the outer boom will be closer to the rear of the outer boom.

9.Refer to Fig. 3.7 and remove the locknut and capscrew that secures the hoist cylinder rod end pin. Remove the pin. Check the condition of the bearing in the cylinder rod end; replace bearing if worn or damaged.

10.Refer to Fig. 3.7 and remove the capscrews and lock washers securing boom pivot pins to the outer boom.

11.Remove both boom pivot pins and washer spacers from the outer boom and main frame.

12.Using the hoist, remove the outer boom from the main frame of the forklift.

13.Check the condition of both boom pivot main frame bearings; replace if worn or damaged.

14.If the front outer boom wear pads, Fig. 3.9, are excessively worn, temporarily replace them with new pads. Use the same amount of shimming as used when the pads were removed.

IMPORTANT: The ends of wear pad attaching capscrews must not protrude beyond the wear pad insert; the ends must range from flush to 0.19" (5 mm) recessed in the wear pad insert (refer to Fig. 3.3).

b. Inspection and Replacement

1.Inspect the boom and welds and contact JLGl if structural damage is detected.

2.Inspect hoses and replace if damaged.

3.Inspect and replace wear pads as described in paragraph3.1.8.

c. Installation

1.Using slings and a suitable hoist, align the outer boom pivot collars with the main frame bearings.

2.Install the boom pivot pins and washer spacers, placing the spacers on the inside of the frame bearing, Fig. 3.10. Using No. 10 and/or 14 gauge shims, shim to maintain a gap between the frame bearing and outer boom of 0.07 to 0.13" (1,8 to 3,3 mm).

3-6	Model 6036 S/N 9B0499 and Before

PAD, INSERT (1), LOCK WASHER (2), FLAT WASHER (2), 3/8-16 X 7/8" CAPSCREW (2)

GAP MUST BE 0.07 TO 0.13" (1,8 TO 3,3 mm)

Section 3. Boom

PAD, INSERT (1), LOCK WASHER (2), FLAT WASHER (2), 3/8-16 X 7/8" CAPSCREW (2)

	GAP MUST BE 0.07 TO		GAP MUST BE 0.07 TO
	0.13" (1,8 TO 3,3 mm)	PAD, #10 GA SHIM,	0.13" (1,8 TO 3,3 mm)
		INSERT (4),
		LOCK WASHER (8),
	INTERMEDIATE	FLAT WASHER (8),
		3/8-16 X 3/4"	OUTER BOOM
	BOOM	CAPSCREW (8)
	PAD, SPACER, #10 GA		PAD, SPACER, #10 GA
	SHIM, INSERT (1),		SHIM, INSERT (1),
	LOCK WASHER (3),		LOCK WASHER (3),
	FLAT WASHER (3),		FLAT WASHER (3),
	3/8-16 X 1-3/4"		3/8-16 X 1-3/4"
	CAPSCREW (3)		CAPSCREW (3)
			MA0091

Fig. 3.9 Front Wear Pads Attached to Outer Boom (Rear Wear Pads are Attached to Intermediate Boom)

3.Install the capscrews and lock washers locking the boom pivot pins to the outer boom.

4.Rest the front of the boom on cribbing so it is not solely supported by the hoist.

5.Install the grille tilt cylinder tubing in clamps on the bottom of the outer boom, (Fig. 3.8), and connect each tube, extend tubes and bulkhead fittings to fittings at the support plate. Connect main valve hoses. Tighten the tube clamps.

6.Refer to Fig. 3.8 and connect the grille tilt cylinder hoses to the tubing. Route the hoses around hose guide bracket and into the outer boom. Continue pushing the hoses until they come out the rear boom cover opening.

7.Install the base end of the boom extend/retract cylinder on the outer boom with a pivot pin, Fig. 3.7, and retaining rings. Coat the pin with antiseize compound.

8.Reattach tubes to extend cylinder ports.

10.Attach the rod end of each hoist cylinder to the outer boom with a pivot pin and lock the pin in place with a capscrew and locknut.

	SHIM HERE TO MAINTAIN 0.07
	TO 0.13" (1,8 TO 3,3 mm) GAP
CAPSCREW AND	USING #10 AND/OR 14 GA
LOCK NUT	WASHER SPACERS

FRAME

BEARING

FRAME

OUTER

BOOM

BOOM PIVOT

PIN

9.Attach the rod end of the slave cylinder to the outer boom with a pivot pin and lock the pin in place with a capscrew and locknut.

DO NOT GREASE FITTING

SHIM HERE

MA0101

Fig. 3.10 Boom Pivot Pin Shimming

Model 6036 S/N 9B0499 and Before

3-7

Section 3. Boom

INNER

BOOM

			SHOULDER
	1-1/2"	SCREW AND
		CLEVIS	LOCKNUT
	TO
	2-1/2"			YOKE
	(38 mm	CHAIN LINK
	TO
	63 mm)
		PIN AND		SHOULDER
				SCREW AND
		RETAINING		LOCKNUT
	INTERMEDIATE	RING
	BOOM

EXTEND CHAIN,

EXTEND CHAIN

LOCKNUT AND

FLAT WASHER

BLOCK

OUTER BOOM

	INNER BOOM
	INTERMEDIATE BOOM
			RETRACT	INNER BOOM
	OUTER BOOM			RETRACT CHAIN
		CHAIN	CHAIN
				LOCKNUT AND
	RETRACT CHAIN

	LOCKNUT AND	SUPPORT	FLAT WASHER
		PLATE
	FLAT WASHER
			MA0111
	Fig. 3.11 Chain Replacement

11.Attach the two extend chains at the chain yoke, Fig. 3.11, on top of the boom. Allow the remaining ends of the chains to hang free until the intermediate boom has been installed.

12.Attach the retract chain at the chain support plate, Fig. 3.11, and route it along the bottom of the outer boom to the rear boom cover opening.

13.Remove hoist and sling from outer boom.

14.Remove cribbing from front of boom.

15.Refer to paragraphs 3.1.2.b and 3.1.1.b and install the intermediate and inner booms.

16.Refer to Fig. 3.9 and check the wear pad gap between the front outer boom side and top wear

pads and the intermediate boom. The gap should be 0.07 to 0.13" (1,8 to 3,3 mm) and equal on all sides. Remove or install shims as required.

IMPORTANT: The ends of wear pad attaching capscrews must not protrude beyond the wear pad insert; the ends must range from flush to 0.19" (5 mm) recessed in the wear pad insert (refer to Fig. 3.3).

17.Install the wear pads by applying Loctite 242 to the capscrews and torquing them to 31 lb-ft (42 N m).

18.Lubricate the outer boom pivot pins, Fig. 3.7, with multi-purpose lithium based grease.

3-8	Model 6036 S/N 9B0499 and Before

3.1.4 Chain Replacement

Two chains extend the inner boom and one chain retracts it.

Extend Chains

IMPORTANT: Replace extend chains in pairs or sets ONLY.

a. Removal

1.Fully retract the boom.

2.Remove the rear boom cover.

3.Refer to Fig. 3.11 and remove the extend chain locknut and flat washer securing each chain clevis to a block at the upper rear of the inner boom.

4.Remove the locknut and shoulder screw that attaches each extend chain to the yoke at the front of the boom.

5.Pull the chains out the front of the boom.

6.Remove a chain clevis at both ends of each chain.

b. Installation

1.Be sure the boom is fully retracted.

2.Install a chain clevis on both ends of each chain.

3.Working from the rear boom cover opening, remove both top intermediate boom wear pads to gain access to rear boom chain connection.

4.Using a long rod or other suitable tool, route the chains between the upper plates of the inner and intermediate booms to the front boom opening. Make sure chains are not twisted.

5.Route the chains over the chain sheave and attach the chains to the front yoke with a shoulder screw and locknut. Tighten the locknut completely, then back off 1/4 turn.

6.Secure the rear of the chain to a block at the upper rear of the inner boom with a flat washer and locknut. The elastic collar on the locknut must engage the chain clevis by at least one full thread. Be sure locknuts are tightened equally.

7.Check the position of the chain yoke at the front of the outer boom. The front of the yoke must be parallel to the front face of the outer boom. If not, adjust the locknuts accordingly.

Section 3. Boom

8.Refer to paragraph 3.1.5 and lubricate the chain.

9.Refer to paragraphs 3.1.6 and 3.1.7 and check and adjust the chains.

RetractChain

a. Removal

1.Fully retract the boom.

2.Remove the rear boom cover.

3.Remove the inner boom retract chain locknut and flat washer, Fig. 3.11, securing the retract chain to a block at the lower rear of the inner boom.

4.Remove the outer boom retract chain locknut and flat washer attaching the retract chain clevis to a chain support plate at the bottom of the outer boom.

5.From the rear outer boom cover opening, pull the retract chain from the space between the outer and intermediate booms.

6.Remove a chain clevis from each end of the chain.

b. Installation

1.Be sure the boom is fully retracted.

2.Install a chain clevis on each end of the chain.

3.Secure the rear of the chain to a block at the lower rear of the inner boom with a flat washer and locknut. Route the chain around the chain sheave. The elastic collar on the locknut must engage the chain clevis by at least one full thread.

4.Using a long rod or other suitable tool, route the chain between the lower plates of the outer and intermediate booms to the chain support plate opening, Fig. 3.11, on the bottom of the outer boom.

5.Secure chain clevis to the chain support plate using a flat washer and locknut. Torque the locknuts to 35 to 40 lb-ft (47,5 to 54,2 N m).

6.Refer to paragraph 3.1.5 and lubricate the chain.

7.Refer to paragraphs 3.1.6 and 3.1.7 and check and adjust the chain.

Model 6036 S/N 9B0499 and Before

3-9

Section 3. Boom

3.1.5 Chain Lubrication

250 Hour Intervals

1.Remove the rear boom cover from the outer boom.

2.Extend and retract the boom several times applying multi-purpose lithium based grease to the entire retract chain with a brush or grease gun.

3.With the boom fully extended, apply multipurpose lithium based grease to the extend chain using a brush or grease gun.

4.Install the rear boom cover on the outer boom.

MAXIMUM CHAIN

SAG WITH BOOM

EXTENDED

IS 3/4" (19 mm)

CENTER SECTION

OF INTERMEDIATE

BOOM

OA0491

Fig. 3.12 Maximum Extend Chain Sag

3.1.6 Chain Tension Check

250 Hour Intervals

Check tension of boom extend chains after the first 50 hours of operation and at 250 hour intervals thereafter.

3-10

BOOM

EXTEND

CHAINS

EXTEND

CHAIN

SHEAVE

LUBE

FITTING

FRONT FACE

OF YOKE

MUST BE

PARALLEL

TO FRONT

FACE OF

OUTER

BOOM

OA0531

Fig. 3.13 Yoke and Extend Chains

Adjust the chains so that:

•the inner boom extends 1-1/2 to 2-1/2" (38 to 64 mm) from the front of the intermediate boom when the boom is retracted, Fig. 3.11, and

•the extend chains are no closer to the intermediate boom than 3/4" (19 mm) when the boom is extended, Fig. 3.12, and

•the front face of the yoke, Fig. 3.13, is parallel to the front face of the outer boom.

WEAR

EXTEND CHAIN

PADS WEAR LOCKNUTS

PADS

RETRACT CHAIN SHEAVE
LUBE FITTING	OA0521

Fig. 3.14 Rear Boom Cover Opening

Model 6036 S/N 9B0499 and Before

Adjustment is accomplished using extend chain adjustment locknuts, Fig. 3.14.

a. Chain Locknut Functions

Loosen extend chain locknuts to extend the inner boom and increase extend chain sag.

Tighten outer boom retract chain locknut to retract the inner boom and decrease extend chain sag.

b. Adjusting Procedure

1.Raise the boom to a horizontal (level) position. Fully extend the boom, then retract it 2" which is 1" per section (51 mm which is 25,5 mm per section).

2.Measure sag in the extend boom chains between the bottom of the chains and the top of the inner boom at their closest point, Fig. 3.12. Acceptable boom extend chain sag is between 3/4 and 1-3/4" (19 and 45 mm). If the measurement is less than 3/4" (19 mm), adjust the boom chains as described in the following steps.

RETRACT CHAIN

LOCKNUT

EXTEND CYLINDER

OA0511

Fig. 3.15 Retract Chain Adjustment Locknut

3.1.7 Chain Tension Adjustment

1.Retract the boom completely to check the position of the inner boom. If the distance between the front edges of the intermediate and inner booms is between 1-1/2 and 2-1/2" (38 and 64 mm) and the extend chain is no closer than 3/4" (19 mm) from the inner boom, proceed no further, the boom chains are adjusted correctly.

2.If the distance between the front edges of the intermediate and inner booms is 2" or more but less than 2-1/2" (51 mm or more but less than 63 mm):

Section 3. Boom

(a)Tighten the locknut, Fig. 3.15, on the bottom of the outer boom. This retracts the inner boom and takes up the sag in the extend chains.

(b)Cycle the boom in and out; then, with the boom horizontal (level), fully extend the boom and retract it 2" which is 1" per section (51 mm which is 25,5 mm per section).

(c)Measure the chain sag, Fig. 3.12. Acceptable boom extend chain sag is between 3/4 and 1-3/4" (19 and 45 mm). If the chain sag is less than 3/4" (19 mm) repeat steps

(a) through (c).

3.If the distance measured in Step 1 is less than 2" but greater than 1-1/2" (less than 51 mm but greater than 38 mm):

(a)Remove the rear cover from the outer boom and adjust the top extend boom chains.

(b)Tighten the locknuts, Fig. 3.14, for each chain. Be sure each locknut is tightened equally so that chain maintains the same tension. Equal chain tension can be checked by observing the position of the yoke on the outer boom, Fig. 3.13. The front of the yoke should be parallel with the front edge of the boom.

(c)Cycle the boom in and out; then, with the boom horizontal (level), fully extend the boom and retract it 2" which is 1" per section (51 mm which is 25,5 mm per section).

(d)Measure the chain sag. Acceptable boom chain sag is between 3/4 and 1-3/4" (19 and 45 mm). If chain sag is less than 3/4" (19 mm), repeat steps (a) through (d).

(e)Replace the rear cover of the outer boom.

3.1.8 Wear Pad Replacement

After the first 50 hours of operation or when severe wear is suspected

There are 26 wear pads (Fig's 3.3, 3.5, 3.6 and 3.8) between the outer, intermediate, and inner booms. Five are attached to the inner boom, thirteen to the intermediate boom, and eight to the outer. Four additional wear pads may be used in severe twist applications.

The wear pads and wear pads with spacers are shimmed to maintain a gap between the wear pads and the booms of 0.07 to 0.13" (1,8 to 3,3 mm).

Model 6036 S/N 9B0499 and Before

3-11

Section 3. Boom

IMPORTANT: Inspect the pads as follows:

•Replace wear pads that are less than 0.5" (13

mm)thick.

•The ends of wear pad attaching capscrews must not protrude beyond the wear pad insert; the ends must range from flush to 0.19" (5 mm) recessed in the wear pad insert; refer to Fig. 3.3.

•When you install a wear pad on one side (including top or bottom) of boom, replace the corresponding wear pad on the other side of the boom. Usually shimming will remain the same when installing new wear pads on corresponding sides of the boom.

•Apply Loctite® 242 to all wear pad screws and torque them to 28 to 34 lb-ft (38 to 46 N m).

a. Inner Boom Wear Pads (Fig. 3.3)

1.All inner boom wear pads can be removed by working through the rear boom cover opening.

2.The bottom pad may be removed by first removing the top pads. Use a wooden wedge between the inner and intermediate boom to provide clearance for removing the bottom pad.

3.Inspect the wear pads removed as described in the preceding IMPORTANT notice.

b.Intermediate Boom Wear Pads (Fig. 3.5 and 3.6)

1.The rear wear pads can be removed by working through the rear boom cover opening.

2.The rear bottom pad may be removed by first removing the top pads, by using a wooden wedge between the inner and intermediate boom, thereby providing clearance for removing the bottom pad.

3.Front pads can be removed at the front of the boom.

4.The front bottom pad may be removed by first removing the top pads. Lower the gooseneck end of the inner boom to the ground until the intermediate boom raises up to provide clearance for removing the bottom pad.

5.Inspect the wear pads removed as described in the preceding IMPORTANT notice.

c. Outer Boom Wear Pads (Fig. 3.9)

1.All outer wear pads can be removed working at the front of the boom.

2.The front bottom pad may be removed by first removing the top pads. Lower the gooseneck end of the inner boom to the ground until the

3-12

intermediate boom raises up, thereby providing clearance for removing the bottom pad.

3.Inspect the wear pads removed as described in the preceding IMPORTANT notice.

3.1.9 Hose Tensioning

100 Hour Intervals

Adjust grille tilt cylinder hose or auxiliary hydraulic hose tension whenever the boom is disassembled, a hose is changed, or whenever proper hose adjustment is in question. Check hose tension as part of general maintenance every 100 hours.

IMPORTANT: Before you begin tensioning the hoses make sure that the hoses are not twisted within the boom. Keep the hose manufacturers marking in line as a guide.

1.Park forklift on level surface, engage park lock and fully retract and level the boom.

2.Remove the rear boom cover, Fig. 3.1.

3.If the vehicle has auxilliary hydraulics there will be four hoses in hose clamps, Fig. 3.16b, with the auxilliary hose clamps stacked on top of the grille tilt cylinder hose clamps, Fig. 3.16a. Remove the capscrews and hose clamps, holding upper hoses in place, Fig. 3.16b, and move aside to gain access to the lower capscrews and hose clamps.

Pull hoses, through hose clamps, 1" further to tension hoses

Hose must have a minimum of 180° of contact with pulley

Inner boom hose clamps and capscrews

180°

MA6040

Fig. 3.16a Cylinder Hose Tensioning

Pull hoses, through hose clamps, 1" further to tension hoses

Lower set of hose clamps and stacking capscrews

Upper set of hose clamps and capscrews

180°

Hose must have a minimum of
180° of contact with pulley	MA6050

When vehicle has auxilliary hydraulics option, remove upper clamps in stack and tension lower hoses first and then tension top hoses

Fig. 3.16b Cylinder Hose Tensioning

Model 6036 S/N 9B0499 and Before