SkyTrak 6036 Service Manual
Service Manual
Model
6036
S/N 9B0500 thru 14833
8990163
Revised February 11, 2005
Effectivity Page
August, 1997 - 001 - Original Issue
February 11, 2005 - B - Replaced all branding with JLG.
Model 6036 S/N 9B0500 thru 14833
A
Effectivity Page
B
Model 6036 S/N 9B0500 thru 14833
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 8A Engine, Perkins Series 4.236 and T4.236 ...................................... 8A-1
Section 8B Engine, Cummins Series 4B3.9 and 4BT3.9 .................................. 8B-1
Section 9 Hydraulic System .............................................................................. 9-1
Section 10 Electrical System ............................................................................. 10-1
Model 6036/6036T S/N 9B0500
thru 14833
This Page Left Blank Intentionally
SECTION 1
SAFETY PRACTICES
Section 1 Safety Practices
CONTENTS
Par Title Page
1.1 INTRODUCTION .................................1-1
1.2 SIGNAL WORDS ................................1-1
1.3 PERSONAL CONSIDERATIONS ........ 1-2
1.4 EQUIPMENT CONSIDERATIONS ...... 1-2
1.5 GENERAL CONSIDERATIONS ..........1-3
1.6 OPERATIONAL
CONSIDERATIONS ............................1-3
1.7 FINAL WORD ...................................... 1-4
1.1 INTRODUCTION
Practically all SERVICE work involves the need to
drive the forklift. The Operator’s 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.
Signal Word:
Is a distinctive word on safety decals and throughout this manual that alerts the viewer to the
existence and relative degree of the hazard.
Danger
The signal word "Danger" means an extremely
hazardous situation exists on or near the machine
which would result in high probability of death or
serious injury if proper precautions are not taken.
Warning
The signal word “Warning” means a hazard exists
on or near the machine which can result in seriuos
injury or death if the proper precautions are not
taken.
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
with the following signal words to attract your
attention to safety messages found on safety
decals and throughout this manual. The message
that follows the symbol contains important information about Safety. To avoid injury and possible
death, carefully read the message! Be sure to
fully understand the causes of possible injury or
death.
Caution
The signal word “Caution” is a reminder of safety
practices or directs attention to unsafe practices
on or near the machine which could result in
personal injury if the proper precautions 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.
6036/6036T S/N 9B0500 thru 14833
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, weld- if foreign matter enters the eye.
ing, painting, when repairing hydraulic
systems, or checking, testing or
charging the battery.
Breathing Wear respiratory protection if grinding or Fumes, dust and paint spray are harmful
Protection painting. when inhaled.
Hearing Always wear ear protection if noise is Continuous loud noise can damage
Protection excessive. your hearing.
Foot Wear protective footwear with reinforced To protect feet from falling objects and
Protection toe caps and oil-resistant soles. to prevent slipping.
Lifting Make sure you are capable of lifting an To avoid injury through incorrect hand-
object. Get help or use a sling on large ling of heavy components.
components.
1.4 EQUIPMENT CONSIDERATIONS
Item What to do Why
Operator’s Before using the forklift, be sure the The cab protects the operator from
Cab 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
Equipment brackets, hooks, etc.), before use. Be to falling objects.
sure equipment is the proper capacity.
Never stand under a suspended load To prevent serious injury or death.
or raised implement.
Do not work on equipment which is To prevent serious injury or death.
supported only by a hoist or jacks.
Always support equipment with blocks
or approved stands
Compressed Always use a general purpose nozzle To prevent serious injury to operator
Air to 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.
Look around before using an air hose. To prevent injury to other personnel
in the work area.
1-2
6036/6036T S/N 9B0500 thru 14833
Section 1 Safety Practices
1.4 EQUIPMENT 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,
recommended. labor and costs.
1.5 GENERAL CONSIDERATIONS
Item What to do Why
Solvents Use only approved cleaning fluids and Certain types of fluid cause damage
solvents that are known to be safe. to 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 to be trivial, could
burn. Have it cleaned and dressed become painful and injurious.
properly.
Make sure you know the location Quick application of first aid procedures.
of the First Aid Box.
Cleanliness Plug all hose ends and connections To prevent dirt and foreign material from
when removing components. Clean entering the system. Dirt and abrasive
exterior of all parts before repairing. dust can reduce the efficiency and
A high pressure or steam cleaner is working life of a component and lead to
recommended. Always wear eye costly replacement. Permanent eye
protection when steam 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.
6036/6036T S/N 9B0500 thru 14833
1-3
Section 1 Safety Practices
1.6 OPERATIONAL CONSIDERATIONS (cont.)
Item What to do Why
Ventilation Avoid prolonged running of the engine Exhaust fumes are highly toxic and
in a closed area with inadequate can kill.
ventilation.
Radiator Cap Always turn the radiator cap slowly to Escaping coolant can burn you ser-
the first stop to relieve pressure. iously.
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 A pressure explosion will cause ser-
off the engine and operate the controls ious 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 Lower carriage to the ground. To prevent accidental injury.
Forklift
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.
1.7 FINAL WORD
1-4
The safety precautions and practices in this manual
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. It is not possible to anticipate
every possible circumstance that can involve a
potential hazard.
6036/6036T S/N 9B0500 thru 14833
SECTION 2
GENERAL INSTRUCTIONS
TABLE OF CONTENTS
Section 2 General Instructions
Par. Title Page
2.1 INTRODUCTION ................................. 2-2
2.2 CLEANING .......................................... 2-2
2.3 REPLACEMENT ................................. 2-2
2.4 HOSES AND TUBES .......................... 2-2
2.4.1 Inspection .................................................... 2-2
2.4.2 Installation ................................................... 2-2
2.5 BEARINGS .......................................... 2-3
2.5.1 Removal ...................................................... 2-3
2.5.2 Cleaning ...................................................... 2-3
2.5.3 Installation ................................................... 2-3
2.6 PRESSURE TESTING
AND ADJUSTMENT ............................ 2-3
2.7 TORQUES ........................................... 2-3
2.7.1 Fasteners..................................................... 2-3
2.7.2 Bolts and Nuts ............................................. 2-3
2.7.3 Flared Fittings (37°, steel) ........................... 2-3
2.7.4 Straight Thread O-ring Fitting
(non-adjustable) ................................... 2-4
2.7.5 Straight Thread O-ring Fitting
(adjustable) ........................................... 2-4
2.8 PAINTING ........................................... 2-4
2.8.1 Orange Paint ............................................... 2-4
2.8.2 Black Paint................................................... 2-4
2.8.3 White Paint .................................................. 2-4
Par. Title Page
2.9 AFTER SERVICE
STARTUP AND CHECKS ................... 2-5
2.9.1 Starting After Servicing ................................ 2-5
2.9.2 After Electronic Component
Servicing ............................................... 2-5
2.9.3 After Hydraulic Component
Servicing ............................................... 2-5
2.9.4 After Brake System Servicing ...................... 2-5
2.9.5 After Fuel System Servicing ........................ 2-5
2.9.6 After Replacing Transmission...................... 2-5
2.9.7 After Tire Servicing ...................................... 2-5
2.9.8 After Engine Servicing ................................. 2-5
2.9.9 After Boom Servicing ................................... 2-5
2.9.10 After Axle Servicing ..................................... 2-6
2.10 FLUID LEVELS AND
LUBRICATION ..................................... 2-6
2.10.1 Wheel Ends & Oil Recommendations ......... 2-6
2.10.2 Hydraulic Reservoir ..................................... 2-7
2.10.3 Engine Oil .................................................... 2-7
2.10.4 Cooling System ........................................... 2-7
2.10.5 Splines ......................................................... 2-7
2.10.6 Drop Box ...................................................... 2-7
2.10.7 Grease Fittings ............................................ 2-7
6036/6036T S/N 9B0500 thru 14833
2-1
Section 2 General Instructions
2.1 INTRODUCTION
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 personal safety and
then vehicle integrity.
2.2 CLEANING
Clean the exterior of all parts before repairing. Dirt
and abrasive dust reduce the efficient working 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:
2.3 REPLACEMENT
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.
2.4 HOSES AND TUBES
2.4.1 Inspection
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. 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.
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.
2-2
6036/6036T S/N 9B0500 thru 14833
2.5 BEARINGS
2.5.1 Removal
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.
Section 2 General Instructions
the oil temperature. The oil temperature can be
checked by placing a hand against the side or the
bottom of the reservoir. If the tank is too hot for
you to keep your hand against the reservoir, the oil
temperature is acceptable.
2.7 TORQUES
2.7.1 Fasteners
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:
Size Torque Size Torque
Inch lb-ft Nm mm Nm 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 75 102 12.0 80 59
9/16 110 150 14.0 130 95
5/8 150 203 16.0 200 146
3/4 250 340 20.0 360 263
7/8 380 515 22.0 510 372
1.0 585 793 24.0 650 475
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.
2.6 PRESSURE 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 measure the specified pressure.
Comply with the correct procedure to prevent
damage to the system or the equipment and to
eliminate the possibility of injury.
Be sure that hydraulic oil is at operating temperature, 80 to 120° F (27 to 49° C), before adjusting
relief valves, pressure reducing valve or sequence
valve. If necessary, operate the machine to raise
2.7.3 Flared Fittings (37o, steel)
1. Align tube and fitting
2. Tighten nut to the following torque:
SAE
Size lb-ft Nm
4 8-12 11-16
6 19-23 26-31
8 38-46 52-62
10 50-58 68-79
12 84-92 114-125
14 100-108 136-146
16 117-129 159-175
20 176-200 239-271
24 251-283 340-384
Torque
6036/6036T S/N 9B0500 thru 14833
2-3
Section 2 General Instructions
2.7.4 Straight 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 Nm
4 22-26 30-35
6 46-54 62-73
8 95-105 129-142
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
2.7.5 Straight 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 Nm
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
2.8 PAINTING
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 8528074 ...................... 1 gallon service paint
P/N 8528071 ...................... 16 oz Spray can
2.8.2 Black Paint
Use P/N 8528036 ............... 16 oz spray can
Boom Angle Indicator Pointer
Wheels (Early Models)
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
Wheels (Later Models)
2-4
6036/6036T S/N 9B0500 thru 14833
Section 2 General Instructions
2.9 AFTER SERVICE
STARTUP AND CHECKS
2.9.1 Starting After Servicing
NOTE: Refer to Owners/Operators Manual for
engine cold start procedure.
1. Check fluid levels.
2. Connect negative cable to batteries if it had
been disconnected before equipment was
serviced.
3. Start engine at idle. Check for leaks from
hydraulic components, engine, axles, transmission, brakes and reservoirs.
4. Purge systems of air by operating functions.
5. Check for proper operation.
6. Retract all cylinders. Shut down and check
reservoir levels. Recheck levels when oil is
cold.
3. If a hydraulic component failed and contaminated the system, flush the system, clean the
reservoir and replace the filter.
4. Following normal hydraulic component servicing, check hydraulic fluid level and replenish
as required.
5. Start forklift and bleed systems of air.
6. Recalibrate sensors; refer to the Owners/
Operators Manual for the Total Load Control
System.
7. Check operation.
2.9.4 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.
2.9.5 After Fuel System Servicing
1. Drain fuel tank if it was contaminated.
7. Replace hydraulic filter if required.
2.9.2 After Electrical/Electronic
Component Servicing
1. Check torque on fastening hardware of
components being replaced.
2. Check wiring connections to components.
3. Be sure wiring connections are dry and free of
moisture.
4. Check for broken or loose wires at connector.
5. Check for brittle and frayed wire shielding.
6. Connect negative (–) cable to the batteries.
7. Start forklift and bleed hydraulic system of air.
8. Recalibrate sensors; refer to the Owners/
Operators Manual for the Total Load Control
System.
9. Check operation.
2.9.3 After Hydraulic Component
Servicing
1. Check torque on fastening hardware of
components being replaced.
2. Check that hoses are in place and tightly
connected.
2. Bleed fuel system.
3. Fill tank with clean fuel as required.
2.9.6 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”.
2.9.7 After Tire Servicing
1. Check hydrofill mixture, air pressure and
weight of tire (empty and full).
2. Check wheel nut torque.
2.9.8 After Engine Servicing
Consult the qualified service agent for proper
procedure before startup.
2.9.9 After Boom Servicing
1. Check wear pads.
2. Check chain tension adjustment.
3. Lubricate all grease points.
6036/6036T S/N 9B0500 thru 14833
2-5
Section 2 General Instructions
2.9.10 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”.
2.10 FLUID LEVELS
AND LUBRICATION
2.10.1 Wheel Ends
Use the following procedure to check fluid level on
the wheel ends:
1. Be sure that arrow on the wheel end housing
is pointing down. Level the vehicle, ground
the carriage, place the travel select lever in (N)
Neutral, engage the emergency brake switch
and shut off engine.
2. Clean the area around the magnetic drain plug
and remove the plug and check fluid level.
Add oil (refer to “IMPORTANT” statement and
tables on this page) as required to bring level
up even with the plug hole (for temperatures
below -15° F (-26° C) 75W gear oil can be
used).
3. Clean and install drain plug.
TABLE 1
Recommended oils for DANA SPICER® axles
P/N 070BP126-13 (front axle) and
070BP139-2 (rear axle) w/graphite based friction discs.
BRAND DESCRIPTION
Amoco Amoco 1000
Case IH MS-1207 (Hy-Tran® Plus)
(J.I. Case & International MS-1210/JIC145 (TCH Fluid)
Harvester)
John Deere JDM J20C (Hy-Gard®)
Ford-New Holland ESN-M2C134-D
(Hydraulic Oil 134)
Massey-Ferguson M-1141 (Permatran®III)
M-1135 Massey-Ferguson
Mobil 424
FRICTION MODIFIER PART NUMBER
BRAND
TRAK 8522043 (32 oz)
Ford C8AZ19B546A (4 oz)
TABLE 2
Recommended oil for DANA SPICER® axles
P/N 070BP126-2 (front axle) and
070BP139-1 (rear axle) with paper based friction discs.
OIL BRAND PART NUMBER
TRAK Wet Disc Brake Oil 8522042
IMPORTANT: All wheel ends are factory filled
with oil that contains friction modifier. DO NOT
add additional friction modifier to factory filled
wheel ends. The addition of friction modifier to a
factory fill will dilute the properties of the oil and
can reduce braking ability.
2-6
To assure a quiet brake condition when servicing
wheel end oil, use only recommended oils as
defined in Table 1 or Table 2 above.
If a noisy brake condition exists after a fresh fill
from oils listed in Table 1 only, add 6 ozs.
(0,18 ltr) of friction modifier per wheel end.
NEVER add more than 6 ozs. (0,18 ltr) of friction
modifier to any wheel end as too much modifier
can reduce braking ability.
NEVER add friction modifier to the recommended
oil listed in Table 2. This oil already contains
friction modifier and additional friction modifier
can reduce braking ability.
6036/6036T S/N 9B0500 thru 14833
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 on the right side of the main frame.
The oil level should be visible in the gauge window. If it is not, open the locked hydraulic fill
access door. Remove the fill cap and add
MIL-L-2104C Oil as required to bring the oil level
up to the minimum oil level line on the adjacent
decal.
2.10.3 Engine Oil
Oil level should be between the full and add mark
on the dipstick. Refer to Sections 8 and 8A for the
type of oil to add.
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).
Section 2 General Instructions
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 fluid 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. Refer to Section 6 for the type of fluid to
add.
2.10.7 Grease Fittings
1. Lubricate the following grease fittings with a
multi–purpose lithium–based grease:
• Hydraulic cylinder pins ................... 10 points
• Drive shaft slip joints ........................ 3 points
• Boom chain sheaves ................ 1 or 2 points
• Boom pivot pins ............................... 2 points
• Carriage pivot pin............................. 2 points
• Axle pivot pins ................................. 4 points
• Boom Attachments ........................ All points
• Axle steer knuckles .......................... 8 points
• Axle tie rod ball joints ....................... 4 points
• Axle steer cylinder ball joints ........... 8 points
2. Wipe off excess grease.
6036/6036T S/N 9B0500 thru 14833
2-7
Section 2 General Instructions
Notes
2-8
6036/6036T S/N 9B0500 thru 14833
SECTION 3
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 Chain Replacement .................................... 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 ............................. 3-14
3.2.1 Loss of Engine Power
or Hydraulic Pump Failure ........................ 3-14
3.2.2 Hydraulic Line Failure ............................... 3-15
3.3 QUICK ATTACH ASSEMBLY ............. 3-16
3.4 TROUBLESHOOTING ........................ 3-17
3.5 SPECIFICATIONS .............................. 3-18
Section 3 Boom
BOOM
3.1 BOOM 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
EXTEND CHAIN SHEAVE
GOOSENECK
INTERMEDIATE BOOM
INNER BOOM
BOOM EXTEND/RETRACT CYLINDER
Fig. 3.1 Boom Assembly
OUTER BOOM
RETRACT CHAIN
REAR BOOM COVER
MA0011
6036/6036T S/N 9B0500 thru 14833
3-1
Section 3 Boom
INNER
BOOM
BASE END
PIN
QUICK ATTACH
PIVOT PIN
WITH GREASE
FITTING
LOCK
PIN
GOOSENECK
GRILLE TILT
CYLINDER
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 9.5.8.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 and auxiliary
hyraulics (if so equipped) 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 locknut and
washer or shoulder screw and locknut that
attaches the retract chain to the inner boom.
Disconnect the extend chains from the outer
boom section. Remove the chain sheave from
the front of the intermediate 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 JLG if
structural damage is detected.
2. Inspect hoses and replace if damaged.
3. Inspect and replace wear pads as described in
paragraph 3.1.8.
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 Nm).
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 Nm).
7. Secure the retract chain to the inner boom
with washers and locknuts (S/N 2515 &
Before) or shoulder screw and locknut
(S/N 2516 & After). Make sure the chain is not
twisted. Be sure the extend chains are inplace
under the chain sheave at the front of the
intermediate boom and then reassemble the
chain sheave to the mounts. Reconnect the
extend chains to the outer boom, Fig. 3.1.
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 9.5.8.f.
3-2
6036/6036T S/N 9B0500 thru 14833
GAP MUST BE 0.07 TO
0.13" (1,8 TO 3,3 mm)
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)
Section 3 Boom
PAD, SPACER, INSERT (2),
LOCK WASHER (6),
FLAT WASHER (6),
3/8-16 X 1-3/4"
CAPSCREW (6),
14 GA SHIM
INTERMEDIATE
BOOM
INNER BOOM
PAD, INSERT (1),
LOCK WASHER (2),
FLAT WASHER (2),
3/8-16 X 7/8"
CAPSCREW (2)
Fig. 3.3 Rear Wear Pads Attached to Inner Boom
12. Adjust hose tension as described in paragraphs 3.1.9.
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
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
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
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 antibuckle bar.
6036/6036T S/N 9B0500 thru 14833
ROD END PIN
INTERMEDIATE
BOOM
Fig. 3.4 Extend/Retract Cylinder
BASE END PIN
EXTEND/RETRACT
CYLINDER
MA0041
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.
Fig. 3.5 Front Wear Pads Attached to Intermediate
PAD, INSERT (2),
SPACER, #10 GA SHIM,
FLAT WASHER (4),
LOCK WASHER (4),
3/8-16 X 1-3/4"
CAPSCREW (4)
2. Inspect hoses and replace if damaged.
3. Inspect and replace wear pads as described in
paragraph 3.1.8.
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 Nm).
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).
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),
FLAT WASHER (6),
3/8-16 X 7/8"
CAPSCREW (2),
3/8-16 X 1-3/4"
CAPSCREW (4)
INNER BOOM
INTERMEDIATE
BOOM
MA0051
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
0.13 inches (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
Nm).
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.
3-4
Boom
6036/6036T S/N 9B0500 thru 14833
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
0.13" (1,8 TO 3,3 mm)
GAP MUST BE 0.07 TO
0.13" (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)
PAD, INSERT (1),
LOCK WASHER (3),
FLAT WASHER (3),
3/8-16 X 7/8"
CAPSCREW (3)
GAP MUST BE 0.07 TO
0.13" (1,8 TO 3,3 mm)
PAD, SPACER, #10 GA
SHIM, INSERT (1),
LOCK WASHER (2),
FLAT WASHER (2),
3/8-16 X 2"
CAPSCREW (2)
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 retract chain from
the outer boom. Check the condition of the
chain and replace if worn or damaged.
3 Refer to paragraph 9.5.4.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.
INTERMEDIATE
BOOM
OUTER BOOM
HOIST CYLINDER
OUTER BOOM
EXTEND/RETRACT
CYLINDER BASE
END PIN
Fig. 3.7 Outer Boom Pivot Pins
ROD END PIN
MA0061
BOOM PIVOT
PIN
FRAME
SLAVE CYLINDER
ROD END PIN
MA0071
6036/6036T S/N 9B0500 thru 14833
3-5
Section 3 Boom
HOSES
OUTER BOOM
INTERMEDIATE BOOM
INNER BOOM
HOSE GUIDE
CONNECTION
GRILLE TILT
CYLINDER
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 locknuts and
capscrews that secures the hoist cylinder rod
end pins. Remove the pins. Check the
condition of the bearings in the cylinder rod
ends; replace bearings 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.
CLAMP
TUBING
SUPPORT PLATE
TO MAIN
CONTROL
VALVE
MA0081
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 JLG if
structural damage is detected.
2. Inspect hoses and replace if damaged.
3. Inspect and replace wear pads as described in
paragraph 3.1.8.
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).
Fig. 3.9 Front Wear Pads Attached to Outer Boom
3-6
6036/6036T S/N 9B0500 thru 14833
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
0.13" (1,8 TO 3,3 mm)
INTERMEDIATE
BOOM
PAD, SPACER, #10 GA
SHIM, INSERT (1),
LOCK WASHER (3),
FLAT WASHER (3),
3/8-16 X 1-3/4"
CAPSCREW (3)
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 (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)
OUTER BOOM
PAD, SPACER, #10 GA
SHIM, INSERT (1),
LOCK WASHER (3),
FLAT WASHER (3),
3/8-16 X 1-3/4"
CAPSCREW (3)
MA0091
(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.
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.
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
LOCK NUT
FRAME
DO NOT
SHIM HERE
Fig. 3.10 Boom Pivot Pin Shimming
USING #10 AND/OR 14 GA
WASHER SPACERS
FRAME
BEARING
OUTER
BOOM
BOOM PIVOT
PIN
GREASE FITTING
MA0101
6036/6036T S/N 9B0500 thru 14833
3-7
Section 3 Boom
INNER
BOOM
1-1/2"
TO
2-1/2"
(38 mm
TO
63 mm)
INTERMEDIATE
BOOM
EXTEND CHAIN
CLEVIS
CHAIN LINK
PIN AND
RETAINING
RING
OUTER BOOM
SHOULDER
SCREW AND
LOCKNUT
SHOULDER
SCREW AND
LOCKNUT
BLOCK
YOKE
EXTEND CHAIN,
LOCKNUT AND
FLAT WASHER
INNER BOOM
INTERMEDIATE BOOM
OUTER BOOM
RETRACT CHAIN
LOCKNUT AND
FLAT WASHER
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.
INNER BOOM
RETRACT CHAIN
LOCKNUT AND
FLAT WASHER
(S/N 2515 & BEFORE)
CHAIN
SUPPORT
PLATE
RETRACT
CHAIN
RETRACT CHAIN
SHOULDER SCREW
AND LOCKNUT
(S/N 2516 & AFTER)
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
Nm).
MA0111
3-8
18. Lubricate the outer boom pivot pins, Fig. 3.7,
with multi-purpose lithium based grease.
6036/6036T S/N 9B0500 thru 14833
Section 3 Boom
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.
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.
Retract Chain
a. Removal
1. Fully retract the boom.
2. Remove the rear boom cover.
3. On the underside of the outer boom, remove
the outer boom retract chain locknut and flat
washer, Fig. 3.11, securing the retract chain to
a chain support plate at the underside of the
outer boom.
4. Remove the inner boom retract chain locknut
and flat washer (S/N 2515 & Before) attaching
the retract chain clevis to a block at the lower
rear of the inner boom. For S/N 2516 & After
remove the shoulder screw and locknut from
the mount plates.
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. Refer to paragraph 3.1.5 and lubricate the
chain.
4. Secure the rear of the chain to a block at the
lower rear of the inner boom with a flat washer
and locknut (S/N 2515 & Before). Route the
chain around the chain sheave. The elastic
collar on the locknut must engage the chain
clevis by at least one full thread. For S/N 2516
& After secure the chain clevis to the mount
plates with a shoulder screw and a locknut.
5. 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.
6. Secure chain clevis to the chain support plate
using a flat washer and locknut. Torque the
locknut to 35 to 40 lb-ft (47,5 to 54,2 Nm).
7. Refer to paragraphs 3.1.6 and 3.1.7 and check
and adjust the chain.
6036/6036T S/N 9B0500 thru 14833
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 Aerosol .0002 Waxy Film Rust
Inhibitor, TRAK part number 8526405.
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 1-1/2" (38 mm)
FRONT FACE
OF YOKE
MUST BE
PARALLEL
TO FRONT
FACE OF
OUTER
BOOM
BOOM
EXTEND
CHAINS
EXTEND
CHAIN
SHEAVE
LUBE
FITTING
OA0531
CENTER SECTION
OF INTERMEDIATE
BOOM
Fig. 3.12 Maximum Extend Chain Sag
OA0491
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 1-1/2" (38 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
PADS
EXTEND CHAIN
LOCKNUTS
WEAR
PADS
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
RETRACT CHAIN SHEAVE
LUBE FITTING
Fig. 3.14 Rear Boom Cover Opening
Model 6036/6036T S/N 9B0500 thru 14833
OA0521
Section 3 Boom
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 intermediate boom at their closest point,
Fig. 3.12. Acceptable boom extend chain sag
is between 1-1/2 & 2-1/2" (38 & 64 mm). If the
measurement is less than 1-1/2" (38 mm),
adjust the boom chains as described in the
following steps.
RETRACT CHAIN
LOCKNUT
(c) Measure the chain sag, Fig. 3.12. Accept-
able boom extend chain sag is between
1-1/2 & 2-1/2" (38 & 64 mm). If the chain
sag is less than 1-1/2" (38 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).
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, Fig. 3.11. If the
distance between the front edges of the
intermediate and inner booms is between
1-1/2 & 2-1/2" (38 & 64 mm) and the extend
chain is no closer than 1-1/2" (38 mm) from
the intermediate 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 64 mm):
(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.
(d) Measure the chain sag. Acceptable boom
chain sag is between 1-1/2 and 2-1/2" (38
and 64 mm). If chain sag is less than 1-1/
2" (38 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).
ANGLED
CUT
ANGLED
CUT
(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).
Model 6036/6036T S/N 9B0500 thru 14833
MA2070
Fig. 3.16 Boom Wear Pads
3-11
Section 3 Boom
IMPORTANT: Inspect the pads as follows:
• Replace wear pads that are less than 0.375"
(9,5 mm) thick.
• Each boom wear pad is manufactured with a
convenient wear pad indicator. This is the
angled cut at each end of all wear pads,
Fig. 3.16. The total thickness of a new wear
pad is .625" (15,9 mm), the angled cut will
provide a total wear thickness of .25"
(6,4 mm). This will leave approximately
.375" (9,5 mm) of total unused material. The
wear pads must never be worn past the
angled cut indicator because the metal pad
insert that holds the pads in place will begin
to wear into the boom pad sliding surfaces.
If pads are worn past this point it will cause
gouging on boom plate surfaces which will
result in premature wear of any new wear
pads installed if the surfaces are not ground
smooth again.
• 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 31 lb-ft (42 Nm).
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
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.
IMPORTANT
notice.
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
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
intermediate boom raises up, thereby providing clearance for removing the bottom pad.
3. Inspect the wear pads removed as described
in the preceding
IMPORTANT
IMPORTANT
notice.
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. 3.17b,
with the auxilliary hose clamps stacked on top
of the grille tilt cylinder hose clamps,
Fig. 3.17a. Remove the capscrews and hose
clamps, holding upper hoses in place,
Fig. 3.17b, and move aside to gain access to
the lower capscrews and hose clamps.
4. Loosen capscrews securing the hose clamps
to the inner boom, Fig. 3.17a or Fig. 3.17b.
5. Manually remove all hose slack between the
pulley and the inner boom hose clamps and
the pulley and the outer boom tubes. Pull the
hoses through the hose clamps, towards the
front of the boom, until there is 180° of hose in
contact with the pulley.
3-12
Model 6036/6036T S/N 9B0500 thru 14833
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