SkyTrak 8042 Service Manual

An Oshkosh Corporation Company

Service Manual

Models

6036, 6042, 8042,

10042 & 10054

6036

S/N 0160039338 & After including

0160024571 & 0160037911

6042

S/N 0160039075 & After

8042, 10042 & 10054

S/N 0160029593 & After

31200353

Revised

April 14, 2011

EFFECTIV IT Y PAGE

February 23, 2007 - A - Original Issue Of Manual November 2, 2010 - B - Revised pages 1-4, 2-3 thru 2-18, 3-4, 3-14, 3-49, 3-53, 7-3 thru 7-9, 8-13, 8-16 thru 8-20, 9-2

thru 9-13, 9-17, 9-21, 9-23, 9-24 & 9-25. April 14, 2011 - C - Revised pages 1-3, 2-3 thru 2-9, 2-12 thru 2-18 thru 2-24, 3-31, 3-49, 4-9, 5-4, 6-3, 6-5 & 9-5 thru

9-11.

31200353 6036, 6042, 8042, 10042, 10054

EFFECTIV IT Y PAGE

6036, 6042, 8042, 10042, 10054 31200353

SECTION CONTENTS

Section Subject Page

Section 1

Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.7 Safety Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

Section 2

General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1 Replacement Parts and Warranty Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.2 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

2.3 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.4 Fluid and Lubricant Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.5 Service and Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Section 3

Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.3 Boom System - Three Section (6036, 6042, 8042 & 10042) . . . . . . . . . . . . . . . . . . . . . 3-4

3.4 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.5 Boom System - Four Section (10054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3.6 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3.7 Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

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

3.9 Boom Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

3.10 Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

3.11 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

3.12 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-54

Section 4

Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4.3 Cab Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

6036, 6042, 8042, 10042, 10054

Section Subject Page

Section 5

Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 Axle, Drive Shaft and Wheel Component Terminology (6036 & 6042) . . . . . . . . . . . . . 5-2

5.2 Axle, Drive Shaft and Wheel Component Terminology (8042, 10042 & 10054) . . . . . . 5-3

5.3 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.4 Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.5 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.6 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5.7 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

5.8 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5.9 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Section 6

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.2 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.3 Transmission Specifications and Maintenance Information. . . . . . . . . . . . . . . . . . . . . . 6-3

6.4 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.5 Transmission Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Section 7

Engine - Cummins QSB3.3T/QSB4.5T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5

7.7 Engine Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7.8 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7.10 Isolation Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10

7.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12

Section 8

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5

8.5 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21

8.6 Hydraulic System Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22

8.7 Valves and Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23

8.8 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32

6036, 6042, 8042, 10042, 10054

Section Subject Page

Section 9

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9.2 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

9.3 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

9.4 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

9.5 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

9.6 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

9.7 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-13

9.8 Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14

9.9 Cab Heater and Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16

9.10 Solenoids, Sensors and Senders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17

9.11 Display Monitor and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23

9.12 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-24

9.13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-26

Section 10

Stabil-TRAK™ System and Boom Interlock System . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10.1 Stabil-TRAK System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

10.2 Boom Extend Interlock System Component Terminology (10054 Only) . . . . . . . . . . . . 10-3

10.3 Stabil-TRAK Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

10.4 Stabil-TRAK Electrical Circuit Operation and Troubleshooting (6042, 8042 & 10042) . 10-5

10.5 Stabil-TRAK System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7

10.6 Stabil-TRAK Boom Interlock Electrical Circuit Operation and Troubleshooting (10054) 10-10

10.7 Boom/Outrigger Interlock System Test (10054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12

10.8 Stabil-TRAK Hydraulic Circuit Operation and Troubleshooting . . . . . . . . . . . . . . . . . . . 10-14

6036, 6042, 8042, 10042, 10054

iii

Section Subject Page

6036, 6042, 8042, 10042, 10054

Section 1

Safety Practices

Contents

PARAGRAPH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4 Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.5 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.5.1 Safety Alert System and Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6.3 General Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.7 Safety Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

6036, 6042, 8042, 10042, 10054

1-1

Safety Practices

1.1 INTRODUCTION

This service manual provides general directions for accomplishing servic e and re pai r proc edu res. Fo ll owi ng the procedures in this manual will help assure safety and equipment reliability.

Read, understand and follow the information in this manual, and obey all locally appro ved safe ty p r actices, procedures, rules, codes, regulations and laws.

These instructions cannot cover all details or variations in the equipment, procedures, or processes described, nor provide directions for meeting every possible contingency during opera tion, maintenance, or testing. When additi onal information is desired consult your local authorized service distributor.

Many factors contribute to unsafe conditions: carelessness, fatigue, overload, inattentiveness, unfamiliarity, even drugs and alcohol, among others. For optimal safety, encourage everyone to think, and to act, safely.

Appropriate service methods and proper repair procedures are essential for the safety of the individual doing the work, for the safety of the operator, and for the safe, reliable operation of the machine. All references to the right side, left side, front and rear are given from the operator seat looking in a forwar d direction.

Supplementary information is available from JLG in the form of Service Bulletins, Service Campaigns, Service Training Schools, the manufacturer website, other literature, and through updates to the manual itself.

1.4 DO NOT OPERATE TAGS

Place Do Not Operate Tags on the ignition key switch and the steering wheel before attempting to perform any service or maintenance. Remove key and disconnect battery leads.

1.5 SAFETY INFORMATION

To avoid possible death or injury, carefully read, understand and comply with all safety messages.

In the event of an accident, know where to obtain medical assistance and how to use a first-aid kit and fire extinguisher/fire suppression system. Keep emergency telephone numbers (fire department, ambulance, rescue squad/paramedics, police department, etc.) nearby. If working alone, check with another person routinely to help assure personal safety.

1.5.1 Safety Alert System and Signal Words

DANGER

DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or serious injury.

WARNING

1.2 DISCLAIMER

All information in this manual is based on the latest product information available at the time of publication. The manufacturer reserves the right to make changes and improvements to its products, and to discontinue the manufacture of any product, at its discretion at any time without public notice or obligation.

1.3 OPERATION & SAFETY MANUAL

The mechanic must not operate the machine until the Operation & Safety Manual has been read and understood, training has been accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator.

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

1-2

WARNING indicates a potentially hazardous situation

which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION indicates a potentially hazardous situation

which, if not avoided, may result in minor or moderate injury.

6036, 6042, 8042, 10042, 10054

Safety Practices

1.6 SAFETY INSTRUCTIONS

Following are general safety statements to consider before performing maintenance procedures on the telehandler. Additional statements related to specific tasks and procedures are located throughout this manual and are listed prior to any work instructi ons to prov ide safety information before the potential of a hazard occurs.

For all safety messages, carefully read, understand and follow the instructions before

1.6.1 Personal Hazards

PERSONAL SAFETY GEAR: Wear all the protective clothing and personal safety gear necessary to perform the job safely. This might include heavy gloves, safety glasses or goggles, filter mask or respirator, safety shoes or a hard hat.

LIFTING: NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist.

1.6.2 Equipment Hazards

LIFTING OF EQUIPMENT: Before using any lifting equipment (chains, slings, brackets, hooks, etc.), verify that it is of the proper capacity, in good working order, and is properly attached.

NEVER stand or otherwise become positioned under a suspended load or under raised equipment. The load or equipment could fall or tip.

DO NOT use a hoist, jack or jack stands only to support equipment. Always support equipment with the proper capacity blocks or stands properly rated for the load.

HAND TOOLS: Always use the proper tool for the job; keep tools clean and in good working order, and use special service tool s onl y as re co mme nde d.

proceeding.

1.6.3 General Hazards

SOLVENTS: Only use approved solvents that are known to be safe for use.

HOUSEKEEPING: Keep the work area and operator cab clean, and remove all hazards (debris, oil, tools, etc.).

FIRST AID: Im mediately clean, dress and report a ll injuries (cuts, abrasions, burns, etc.), no matter how minor the injury may seem. Know the location of a First Aid Kit, and know how to use it.

CLEANLINESS: Wear eye protection, and clean all components with a high-pressure or steam cleaner before attempting service.

When removing hydraulic components, plug hose ends and connections to prevent excess leakage and contamination. Place a suitable catch basin beneath the machine to capture fluid run-off.

It is good practice to avoid pressure-washing electrical/ electronic components. In the event pressure-washing the machine is needed, ensure the machine is shut down before pressure-washing. Should pressure-washing be utilized to wash areas containing electrical/electronic components, it is recommended a maximum pressure of 750 psi (52 bar) at a minimum distance of 12 in (30,5 cm) away from these components. If electrical/electronic components are sprayed, spraying must not be direct and for brief time periods to avoid heavy saturation.

Check and obey all Federal, State and/or Local regulations regarding waste storage, disposal and recycling.

6036, 6042, 8042, 10042, 10054

1-3

Safety Practices

1.6.4 Operational Hazards

ENGINE: Stop the engine before performing any service unless specificall y instr uc ted othe rw is e.

VENTILATION: Avoid prolonged engine operation in enclosed areas without adequate ventilation.

SOFT SURFACES AND SLOPES: NEVER work on a machine that is parked on a soft surface or slope. The machine must b e on a hard leve l surfa ce, wit h th e wh eel s blocked before performing any service.

FLUID TEMPERATURE: NEVER work on a machine when the engine, cooling or hydraulic systems are hot. Hot components and fluids can cause severe burns. Allow systems to cool before proceeding.

FLUID PRESSURE: Before loosenin g any hydr aul ic or diesel fuel component, hose or tube, turn the engine OFF. Wear heavy, protective gloves and eye protection. NEVER check for leaks using any part of your body; use a piece of cardboard or wood instead. If injured, seek medical attention immediately. Diesel fluid leaking under pressure can explode. Hydraulic fluid and diesel fuel leaking under pressure can penetrate the skin, cause infection, gangrene and other serious personal injury.

Relieve all pressure before disconnecting any component, part, line or hose. Slowly loosen parts and allow release of residual pressure before removing any part or component. Before starting the engine or applying pressure, use components, parts, hoses and pipes that are in good condition, connected properly and are tightened to the proper torque. Capture fluid in an appropriate container and dispose of in accordance with prevailing environmental regulations.

RADIATOR CAP: The cooling system is under pressure, and escaping coolant can cause severe burns and eye injury. To prevent personal injury, NEVER remove the radiator cap while the cooling system is hot. Wear safety glasses. Turn the radiator cap to the first stop and allow pressure to escape before removing the cap completely. Failure to follow the safety practices could result in death or serious injury.

FLUID FLAMABILTITY: DO NOT service the fuel or hydraulic systems near an open flame, sparks or smoking materials.

NEVER drain or store fluids in an open container. Engine fuel and hydraulic fluid are flammable and can cause a fire and/or explosion.

DO NOT mix gasoline or alcohol with diesel fuel. The mixture can cause an explosion.

PRESSURE TESTING: When conducting any test, only use test equipment that is correctly calibrated and in good condition. Use the correct equipment in the pr ope r manner, and make changes or repairs as indicated by the test procedure to achieve the desired result.

LEAVING MACHINE: Lower the forks or attachment to the ground before leaving the machine.

TIRES: Always keep tires inflated to the proper pressure to help prevent tipover. DO NOT over-inflate tires.

NEVER use mismatched tire types, sizes or ply ratings. Always use matched sets according to machine specifications.

MAJOR COMPONENTS: Never alter, remove, or substitute any items such as counterweights, tires, batteries or other items that may reduce or affect the overall weight or stability of the machine.

BATTERY: DO NOT charge a frozen battery.Charging a frozen battery may cause it to explode. Allow the battery to thaw before jump-starting or connecting a battery charger.

1.7 SAFETY DECALS

Check that all safety decals are present and readable on the machine. Refer to the Operation & Safety Manual supplied with machine for information.

1-4

6036, 6042, 8042, 10042, 10054

Section 2

General Information and Specifications

Contents

PARAGRAPH TITLE PAGE

2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.2 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.2.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.2.2 Mertic Fastener Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2.2.3 Hydraulic Hose To rque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.3.1 Travel Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.3.2 Hydraulic Cylinder Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.3.3 Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.3.4 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.3.5 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2.4 Fluid and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.5 Service and Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2.5.1 10 & 1st 50 Hour. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2.5.2 50, 250 & 1st 500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

2.5.3 500 & 1000 Hour. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2.5.4 2000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

6036, 6042, 8042, 10042, 10054

2-1

General Information and Specifications

OH0281

2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION

Before ordering parts or initiating service inquiries, make note of the machine serial number. The machine serial number plate (1) is located as indicated in the figure.

Note: The replacement of any part on this machine with any other than JLG authorized repla ce men t part s can adversely affect the performance, durability, or safety of the machine, and will void the warranty. JLG disclaims liability for any claims or damages, whether regarding property damage, personal injury or death arising out of the use of unauthorized replacement parts.

A warranty registration form must be filled out by the JLG distributor, signed by the purchaser and returned to JLG when the machine is sold and/or put into use.

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

2-2

6036, 6042, 8042, 10042, 10054

General Information and Specifications

MY3141

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

4 40 0.1120 0.00604 380 8 0.9 6 0.7

48 0.1120 0.00661 420 9 1.0 7 0.8

6 32 0.1380 0.00909 580 16 1.8 12 1.4

40 0.1380 0.01015 610 18 2.0 13 1.5

8 32 0.1640 0.01400 900 30 3.4 22 2.5

36 0.1640 0.01474 940 31 3.5 23 2.6

10 24 0.1900 0.01750 1120 43 4.8 32 3.5

32 0.1900 0.02000 1285 49 5.5 36 4

1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12

28 0.2500 0.0364 2320 120 13.5 86 10 135 15

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22

24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23

3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38

24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43

7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61

20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68

1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92

20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108

9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133

18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148

5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183

18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207

3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325

16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363

7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523

14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576

1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785

12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858

1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968

12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087

1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368

12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516

1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792

12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042

1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379

12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676

NO. 5000059 REV. J

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 5 BOLTS & GRADE 2 NUTS

Torque

(Dry)

Torque

(Loctite® 262

or Vibra-

TITE

131)

Torque

Lubricated

Torque

(Loctite® 242

or 271

OR Vibra-TITETM111 or

140)

3. * ASSEMBLY USES HARDENED WASHER

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TOCADMIUM PLATED FASTENERS

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODSTOLERANCE = ±10%

2.2 TORQUE CHARTS

2.2.1 SAE Fastener Torque Chart

6036, 6042, 8042, 10042, 10054

2-3

General Information and Specifications

MY3151

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

In Sq In

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318

28 0.2500 0.0364

In Sq In

5/16 18 0.3125 0.0524

24 0.3125 0.0580

3/8 16 0.3750 0.0775

24 0.3750 0.0878

7/16 14 0.4375 0.1063

20 0.4375 0.1187

1/2 13 0.5000 0.1419

20 0.5000 0.1599

9/16 12 0.5625 0.1820

18 0.5625 0.2030

5/8 11 0.6250 0.2260

18 0.6250 0.2560

3/4 10 0.7500 0.3340

16 0.7500 0.3730

7/8 9 0.8750 0.4620

14 0.8750 0.5090

1 8 1.0000 0.6060

12 1.0000 0.6630

1 1/8 7 1.1250 0.7630

12 1.1250 0.8560

1 1/4 7 1.2500 0.9690

12 1.2500 1.0730

1 3/8 6 1.3750 1.1550

12 1.3750 1.3150

1 1/2 6 1.5000 1.4050

12 1.5000 1.5800

NO. 5000059 REV. J

3. *ASSEMBLY USES HARDENED WASHER

NOTES: 1. THESE TORQUE VALUES DONOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUESARE STATICTORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

1320 43 5 1580 60 7 1800 68 8 2860 143 16 129 15 3280 164 19 148 1 7

LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m

4720 25 35 20 25 20 25 5220 25 35 25 35 20 25 7000 45 60 40 55 35 50 7900 50 70 45 60 35 50

9550 70 95 65 90 50 70 10700 80 110 70 95 60 80 12750 105 145 95 130 80 110 14400 120 165 110 150 90 120 16400 155 210 140 190 115 155 18250 170 230 155 210 130 175 20350 210 285 190 260 160 220 23000 240 325 215 290 180 245 30100 375 510 340 460 280 380 33600 420 570 380 515 315 430 41600 605 825 545 740 455 620 45800 670 910 600 815 500 680 51500 860 1170 770 1045 645 875 59700 995 1355 895 1215 745 1015 68700 1290 1755 1160 1580 965 1310 77000 1445 1965 1300 1770 1085 1475

87200 1815 2470 1635 2225 1365 1855 96600 2015 2740 1810 2460 1510 2055

104000 2385 3245 2145 2915 1785 2430

118100 2705 3680 2435 3310 2030 2760 126500 3165 4305 2845 3870 2370 3225 142200 3555 4835 3200 4350 2665 3625

Torque

(Loctite® 242

or 271

OR Vibra-TITETM111 or

140) K=.18

Torque

(Loctite® 262

or Vibra-

TITE

131)

K=0.15

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*

Torque

(Dry orLoctite® 263)

K= 0.20

2.2.1 SAE Fastener Torque Chart (Continued)

2-4

6036, 6042, 8042, 10042, 10054

General Information and Specifications

MY3161

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

See Note4

In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 122 14 114 13

28 0.2500 0.0364 3280 139 16 131 15

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25

24 0.3125 0.0580 5220 25 35 20 25 20 25

3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50

24 0.3750 0.0878 7900 40 55 40 55 35 50

7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70

20 0.4375 0.1187 10700 65 90 60 80 60 80

1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110

20 0.5000 0.1599 14400 100 135 95 130 90 120

9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155

18 0.5625 0.2030 18250 145 195 135 185 130 175

5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220

18 0.6250 0.2560 23000 205 280 190 260 180 245

3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380

16 0.7500 0.3730 33600 355 485 335 455 315 430

7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620

14 0.8750 0.5090 45800 570 775 535 730 500 680

1 8 1.0000 0.6060 51500 730 995 685 930 645 875

12 1.0000 0.6630 59700 845 1150 795 1080 745 1015

1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310

12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475

1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855

12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055

1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430

12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760

1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225

12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

NO. 5000059 REV. J

4. CLAMPLOAD LISTEDFOR SHCS IS SAMEAS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITYOF SHCS.IF HIGHER LOAD IS REQUIRED, ADDITIONALTESTING ISREQUIRED.

SOCKET HEAD CAP SCREWS

Magni Coating (Ref 4150701)*

Torque

(Dry) K =.17

Torque

(Loctite® 242

or 271

OR Vibra-TITETM111 or

140 ORPrecoat 85®

K=0.16

Torque

(Loctite® 262

or Vibra-

TITE

131)

K=0.15

2. ALL TORQUE VALUESARE STATICTORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

NOTES: 1.THESE TORQUE VALUESDO NOTAPPLY TO CADMIUM PLATED FASTENERS

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATEDSTEEL OR RAWALUMINUM

2.2.1 SAE Fastener Torque Chart (Continued)

6036, 6042, 8042, 10042, 10054

2-5

General Information and Specifications

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

See Note4

In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 143 16 129 15

28 0.2500 0.0364 3280 164 19 148 17

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25

24 0.3125 0.0580 5220 25 35 25 35 20 25

3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50

24 0.3750 0.0878 7900 50 70 45 60 35 50

7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70

20 0.4375 0.1187 10700 80 110 70 95 60 80

1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110

20 0.5000 0.1599 14400 120 165 110 150 90 120

9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155

18 0.5625 0.2030 18250 170 230 155 210 130 175

5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220

18 0.6250 0.2560 23000 240 325 215 290 180 245

3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380

16 0.7500 0.3730 33600 420 570 380 515 315 430

7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620

14 0.8750 0.5090 45800 670 910 600 815 500 680

1 8 1.0000 0.6060 51500 860 1170 775 1055 645 875

12 1.0000 0.6630 59700 995 1355 895 1215 745 1015

1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310

12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475

1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855

12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055

1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430

12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760

1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225

12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625

NO. 5000059 REV. J

4. CLAMPLOAD LISTED FOR SHCS IS SAMEAS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITYOF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONALTESTING ISREQUIRED.

SOCKET HEAD CAP SCREWS

Torque

(Dry)

K=.20

Torque

(Loctite® 242

or 271

OR Vibra-TITETM111 or

140 ORPrecoat 85®

K=0.18

Zinc Yellow Chromate Fasteners (Ref 4150707)*

2. ALL TORQUE VALUESARE STATICTORQUE MEASURED PER STANDARDAUDIT METHODSTOLERANCE =±10%

NOTES: 1.THESE TORQUE VALUESDO NOTAPPLYTO CADMIUM PLATEDFASTENERS

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATEDSTEEL OR RAWALUMINUM

Torque

(Loctite® 262

or Vibra-

TITE

131)

K=0.15

MY3400

2.2.1 SAE Fastener Torque Chart (Continued)

2-6

6036, 6042, 8042, 10042, 10054

2.2.2 Mertic Fastener Torque Chart

MY3171

SizePITCH

Tensile

Stress

Area

Clamp

Load

Torque

(Dry orLoctite®

263

)

Torque

(Lub)

Torque

(Loctite® 262

OR Vibra-

TITE

131)

Torque

(Loctite®

242

or 271

OR Vibra-

TITE

111 or

140)

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

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4

3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3 4 0.7 8.78 3.82 3.1 2.3 2.8 3.4 5 0.8 14.20 6.18 6.2 4.6 5.6 6.8 6 1 20.10 8.74 11 7.9 9.4 12 7 1 28.90 12.6 18 13 16 19 8 1.25 36.60 15.9 26 19 23 28

10 1.5 58.00 25.2 50 38 45 55 12 1.75 84.30 36.7 88 66 79 97 14 2 115 50.0 140 105 126 154

16 2 157 68.3

219 164 197 241 18 2.5 192 83.5 301 226 271 331 20 2.5 245 106.5 426 320 383 469 22 2.5 303 132.0 581 436 523 639 24 3 353 153.5 737 553 663 811 27 3 459 199.5 1080 810 970 1130 30 3.5 561 244.0 1460 1100 1320 1530 33 3.5 694 302.0 1990 1490 1790 2090 36 4 817 355.5 2560 1920 2300 2690 42 4.5 1120 487.0 4090 3070 3680 4290

4. CLAMPLOAD LISTEDFOR SHCS IS SAMEAS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IFHIGHER LOAD IS REQUIRED,

ADDITIONAL TESTING IS REQUIRED.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED

STEEL OR RAWALUMINUM

CLASS 8.8 METRIC BOLTS

CLASS 8 METRIC NUTS

NOTES: 1.THESE TORQUE VALUESDO NOTAPPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUESARE STATICTORQUE MEASURED PER STANDARD AUDIT

METHODS TOLERANCE = ±10%

NO. 5000059 REV. J

General Information and Specifications

6036, 6042, 8042, 10042, 10054

2-7

General Information and Specifications

MY3181

SizePITCH

Tensile

Stress

Area

Clamp

Load

Torque

(Dry orLoctite®

263

)

K =0.20

Torque

(Lub ORLoctite®

242

or 271TMOR

Vibra-TITE

111 or

140)

K= 0.18

Torque

(Loctite® 262

Vibra-TITE

131)

K=0.15

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

3 0.5 5.03 3.13

3.5 0.6 6.78 4.22 4 0.7 8.78 5.47 5 0.8 14.20 8.85 6 1 20.10 12.5 7 1 28.90 18.0 25.2 22.7 18.9 8 1.25 36.60 22.8 36.5 32.8 27.4

10 1.5 58.00 36.1 70 65 55 12 1.75 84.30 52.5 125 115 95 14 2 115 71.6 200 180 150

16 2 157 97.8

315 280 235 18 2.5 192 119.5 430 385 325 20 2.5 245 152.5 610 550 460 22 2.5 303 189.0 830 750 625 24 3 353 222.0 1065 960 800 27 3 459 286.0 1545 1390 1160 30 3.5 561 349.5 2095 1885 1575 33 3.5 694 432.5 2855 2570 2140 36 4 817 509.0 3665 3300 2750 42 4.5 1120 698.0 5865 5275 4395

CLASS 10.9 METRIC BOLTS

CLASS 10 METRIC NUTS

CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*

4. CLAMPLOAD LISTEDFOR SHCS IS SAMEAS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IFHIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED

STEEL OR RAWALUMINUM

NOTES: 1.THESE TORQUE VALUESDO NOTAPPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUESARE STATICTORQUE MEASURED PER STANDARDAUDIT METHODS TOLERANCE = ±10%

NO. 5000059 REV. J

2.2.2 Mertic Fastener Torque Chart (Continued)

2-8

6036, 6042, 8042, 10042, 10054

2.2.2 Mertic Fastener Torque Chart

MY3191

SizePITCH

Tensile

Stress

Area

Clamp Load

See Note4

Torque

(Dry orLoctite®

263

)

K =.17

Torque

(Lub ORLoctite®

242

or 271

OR Vibra-TITE

111 or 140)

K =.16

Torque

(Loctite® 262

OR Vibra-TITE

131)

K=.15

Sq mm kN [N.m] [N.m] [N.m]

3 0.5 5.03

3.5 0.6 6.78 4 0.7 8.78 5 0.8 14.20 6 1 20.10 12.5 13 12 11 7 1 28.90 18.0 21 20 19 8 1.25 36.60 22.8 31 29 27

10 1.5 58.00 36.1 61 58 54 12 1.75 84.30 52.5 105 100 95 14 2 115 71.6 170 160 150

16 2 157

97.8 265 250 235 18 2.5 192 119.5 365 345 325 20 2.5 245 152.5 520 490 460 22 2.5 303 189.0 705 665 625 24 3 353 220.0 900 845 790 27 3 459 286.0 1315 1235 1160 30 3.5 561 349.5 1780 1680 1575 33 3.5 694 432.5 2425 2285 2140 36 4 817 509.0 3115 2930 2750 42 4.5 1120 698.0 4985 4690 4395

CLASS 12.9 SOCKET HEAD CAP SCREWS

M6 ANDABOVE*

4. CLAMPLOAD LISTEDFOR SHCS IS SAMEAS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IFHIGHER LOAD IS REQUIRED,

ADDITIONAL TESTING IS REQUIRED.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED

STEEL OR RAWALUMINUM

NOTES: 1.THESE TORQUE VALUESDO NOTAPPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUESARE STATICTORQUE MEASURED PER STANDARDAUDIT METHODS TOLERANCE = ±10%

NO. 5000059 REV. J

Magni Coating (Ref 4150701)*

(Continued)

General Information and Specifications

6036, 6042, 8042, 10042, 10054

2-9

General Information and Specifications

2.2.3 Hydraulic Hose Torque Chart

O-Ring Face Seal & JIC Torque Chart

Size ORFS JIC Flats Method

13 lb-ft

(18 Nm)

23 lb-ft

(31 Nm)

40 lb-ft

(54 Nm)

60 lb-ft

(81 Nm)

74 lb-ft

(100 Nm)

115 lb-ft

(156 Nm)

170 lb-ft

(230 Nm)

200 lb-ft

(271 Nm)

13 lb-ft

(18 Nm)

23 lb-ft

(31 Nm)

40 lb-ft

(54 Nm)

60 lb-ft

(81 Nm)

85 lb-ft

(115 Nm)

115 lb-ft

(156 Nm)

170 lb-ft

(230 Nm)

200 lb-ft

(271 Nm)

1.5 to 1.75

1 to 1.5

1.5 to 1.75

1.0 to 1.5

0.75 to 1.0

Flats Method:

1. If equipped, lubricate o-ring with hydraulic oil. Hand tighten the swivel nut until no lateral movement of the swivel nut can be detected. Average hand torque is 3 lb-ft (4 Nm).

2. Mark a dot on one of the swivel nut flats and another dot in line on the hex of the adapter it’s connecting to.

3. Use the double wrench method while tightening to avoid hose twist.

4. After the connection has been properly tightened, mark a straight line across the connecting parts, not covering the dots indicating that the con necti on has been properly tightened.

32 N/A

270 lb-ft

(366 Nm)

0.75 to 1.0

Note: By definition the “Flats Method“ will contain some variance. Use the “Flats Method” only when accessibility with a torque wrench is not possible.

Torque Wrench:

1. Identify the appropriate application and refer to the above chart for the correct torque value.

2. If equipped, lubricate o-ring with hydraulic oil. Hand tighten the swivel nut until no lateral movement of the swivel nut can be detected. Average hand torque is 3 lb-ft (4 Nm).

3. Use the double wrench method while tightening to avoid hose twist.

4. Torque wrench must be held at the center of the grip. Apply constant force until it clicks.

5. After the connection has been properly tightened, mark a straight line across the connecting parts indicating that the connection has been properly tightened.

2-10

6036, 6042, 8042, 10042, 10054

General Information and Specifications

2.3 SPECIFICATIONS

2.3.1 Travel Speeds

6036 & 6042 8042, 10042 & 10054

First Gear 3.5 mph (5,6 km/hr) 3.5 mph (5,6 km/hr) Second Gear 5.5 mph (9,7 km/hr) 6 mph (9,7 km/hr) Third Gear 13.5 mph (22 km/hr) 14 mph (23 km/hr) Fourth Gear 20 mph (32 km/hr) 20 mph (32 km/hr)

2.3.2 Hydraulic Cylinder Performance

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

APPROXIMATE TIMES (seconds)

FUNCTION

Boom Extend Less than 15.0 Less than 19.0 Less than 19.0 Less than 19.0 Less than 19.0

6036 6042 8042 10042 10054

Boom Retract Less than 15.0 Less than 19.0 Less than 17.0 Less than 17.0 Less than 17.0 Boom Lift Retracted Less than 15.0 Less than 17.0 Less than 17.5 Less than 17.5 Less than 17.5 Boom Lower Retracted Less than 10.0 Less than 13.0 Less than 15.5 Less than 15.5 Less than 15.5 Attachment Tilt - Up 4.0-6.0 6.5 Less than 8.0 Less than 8.0 Less than 8.0 Attachment Tilt - Down 3.5-5.5 6.0 Less than 11.0 Less than 11.0 Less than 11.0 Frame Sway Left to

Right with Boom Down Frame Sway L eft to Right

with Boom Abov e 40 and Emergency Brake Engaged

Frame Sway Right to Left with Boom Down

Frame Sway Right to Left with Boom Abov e 40 and Emergency Brake

Engaged Outrigger - Left or Right,

UP or DOWN

3.0-6.0 12.0-15.0 5.5-12.0 5.5-12.0 3-6

— 23.0-3.03 23.0-33.0 23.0-33.0 23.0-33.0

4.0-8.0 12.0-15.0 4.0-8.0 4.0-8.0 4.0-8.0

— 26.0-52.0 26.0-52.0 26.0-52.0 26.0-52.0

— — — 4.0-9.0 4.0-9.0

Outrigger - Left and Right, UP or DOWN

6036, 6042, 8042, 10042, 10054

— — — 4.0-10.0 4.0-10.0

2-11

General Information and Specifications

2.3.3 Electrical System

Battery

Type, Rating 12 BCI, Negative (-) Ground, Maintenance Free Quantity 3.3 Liter - 1, 4.5 Liter - 2 Reserve Capacity 3.3 Liter - 700 Cold Cranking Amps @ 0° F (-18° C)

4.5 Liter - 900 Cold Cranking Amps @ 0° F (-18° C) Group/Series Group 31 Alternator (6036 & 6042) 12V, 120 Amps Alternator (8042, 10042 & 10054) 12V, 100 Amps

2.3.4 Engine Performance Specifications

Description 6036 & 6042

Engine Make/Model Cummins QSB3.3 Displacement 201 in

(3,3 liters) Low Idle 1100 rpm High Idle 2600 rpm Horsepower 99 hp (74 Kw) @ 2600 rpm Peak Torque 306 lb-ft (415 Nm) @ 1600 rpm Fuel Delivery Fuel Injection Air Cleaner Dry Type, Replaceable Primary and Safety Elements

Description 8042, 10042 & 10054

(Before S/N 0160040220 excluding 0160039850, 0160040126, 0160040129

& 0160040171)

Engine Make/Model Cummins QSB4.5 Displacement 274 in

(4,5 liters) Low Idle 1000 rpm High Idle 2500 rpm Horsepower 110 hp (82 Kw) @ 2500 rpm Peak Torque 360 lb-ft (488 Nm) @ 1500 rpm Fuel Delivery Fuel Injection Air Cleaner Dry Type, Replaceable Primary and Safety Elements

2-12

6036, 6042, 8042, 10042, 10054

General Information and Specifications

Description 8042, 10042 & 10054

(S/N 0160040220 & After including 0160039850, 0160040126, 0160040129

& 0160040171)

Engine Make/Model Cummins QSB3.3 Displacement 274 in

(4,5 liters) Low Idle 900 rpm High Idle 2400 rpm Horsepower 110 hp (82 Kw) @ 2400 rpm Peak Torque 306 lb-ft (415 Nm) @ 1600 rpm Fuel Delivery Fuel Injection Air Cleaner Dry Type, Replaceable Primary and Safety Elements

2.3.5 Tires

Note: Standard wheel lug nut torque is 430 - 470 lb-ft (583 - 637 Nm). Note: Pressure for foam filled tires are for initial fill ONLY.

a. 6036

Size Tire Type Minimum Ply/

Star Rating

13.0 x 24 G-2/L- 2 Bi as Ply Tracti on 12 Ply

13.0 x 24 G-3/L-3 Bias Ply Rock 12 Ply

13.0 R 24 G-2/L-2 Radial 1 Star

15.5 x 25 G-2/L- 2 Bi as Ply Tracti on 12 Ply

15.5 x 25 G-3/L-3 Bias Ply Rock 12 Ply

15.5 R 25 G-2/L-2 Radial 1 Star

Fill Type Pressure

Pneumatic 55 psi (3,8 bar)

Foam - Approx 542 lb (246 kg) 65 psi (4,5 bar)

Pneumatic 55 psi (3,8 bar)

Foam - Approx 542 lb (246 kg) 65 psi (4,5 bar)

Pneumatic 55 psi (3,8 bar)

Foam - Approx 542 lb (246 kg) 75 psi (5,2 bar)

Pneumatic 55 psi (3,8 bar)

Foam - Approx 600 lb (272 kg) 58 psi (3,9 bar)

Pneumatic 55 psi (3,8 bar)

Foam - Approx 600 lb (272 kg) 58 psi (3,9 bar)

Pneumatic 58 psi (3,9 bar)

Foam - Approx 600 lb (272 kg) 73 psi (5,0 bar)

370/75x28 DuraForce 14 Ply

6036, 6042, 8042, 10042, 10054

Pneumatic 76 psi (5,2 bar)

Foam-Approx 464 lb (210 kg) 73 psi (5,0 bar)

2-13

b. 6042

General Information and Specifications

Size Tire Type Minimum Ply/

Star Rating

13.0 x 24 G-2/L-2 Bias Ply Traction 12 Ply

13.0 x 24 G-3/L-3 Bias Ply Rock 12 Ply

13.0 R 24 G-2/L-2 Radial 1 Star

15.5 x 25 G-2/L-2 Bias Ply Traction 12 Ply

15.5 x 25 G-3/L-3 Bias Ply Rock 12 Ply

15.5 R 25 G-2/L-2 Radial 1 Star

370/75x28 DuraForce 14 Ply

Fill Type Pressure

Pneumatic 70 psi (4,8 bar)

Foam - Approx 542 lb (246 kg) 65 psi (4,5 bar)

Pneumatic 70 psi (4,8 bar)

Foam - Approx 542 lb (246 kg) 65 psi (4,5 bar)

Pneumatic 70 psi (4,8 bar)

Foam - Approx 542 lb (246 kg) 65 psi (4,5 bar)

Pneumatic 65 psi (4,5 bar)

Foam - Approx 600 lb (272 kg) 58 psi (3,9 bar)

Pneumatic 65 psi (4,5 bar)

Foam - Approx 600 lb (272 kg) 58 psi (3,9 bar)

Pneumatic 65 psi (4,5 bar)

Foam - Approx 600 lb (272 kg) 58 psi (3,9 bar)

Pneumatic 76 psi (5,2 bar)

Foam-Approx 464 lb (210 kg) 73 psi (5,0 bar)

2-14

6036, 6042, 8042, 10042, 10054

c. 8042

General Information and Specifications

Size Tire Type Minimum Ply/

Star Rating

15.5 x 25 G-2/L-2 Bias Ply Traction 12 Ply

15.5 x 25 G-3/L-3 Bias Ply Rock 12 Ply

15.5 R 25 G2/L-2 Radial 1 Star

370/75x28 DuraForce 14 Ply

d. 10042 & 10054

Size Tire Type Minimum Ply/

Star Rating

17.50 x 25 G-2/L-2 Bias Ply Traction 12 Ply

17.50 x 25 G-3/L-3 Bias Ply Rock 12 Ply

Fill Type Pressure

Pneumatic 70 psi (4,8 bar)

Foam - Approx 600 lb (272 kg) 58 psi (3,9 bar)

Pneumatic 70 psi (4,8 bar)

Foam - Approx 600 lb (272 kg) 58 psi (3,9 bar)

Pneumatic 70 psi (4,8 bar)

Foam - Approx 600 lb (272 kg) 73 psi (5,0 bar)

Pneumatic 76 psi (5,2 bar)

Foam-Approx 464 lb (210 kg) 73 psi (5,0 bar)

Fill Type Pressure

Pneumatic 60 psi (4,1 bar)

Foam - Approx 785 lb (356 kg) 51 psi (3,5 bar)

Pneumatic 60 psi (4,1 bar)

Foam - Approx 785 lb (356 kg) 51 psi (3,5 bar)

17.50 x 25 G-2/L-2 Radial 1 Star

370/75x28 DuraForce 14 Ply

Pneumatic 73 psi (5,0 bar)

Foam - Approx 785 lb (356 kg) 73 psi (5,0 bar)

Pneumatic 76 psi (5,2 bar)

Foam-Approx 464 lb (210 kg) 73 psi (5,0 bar)

6036, 6042, 8042, 10042, 10054

2-15

General Information and Specifications

2.4 FLUID AND LUBRICANT CAPACITIES

Engine Crankcase Oil

Capacity with Filter Change

Cummins QSB3.3 7.6 quart (7,2 liter) Cummins QSB4.5 11.0 quart (10,4 liter)

Type of Oil 15W-40 CH

Fuel Tank

Capacity 37 gallon (140 liter) Type of Fuel #2 Diesel

Cooling System

System Capacity

Cummins QSB3.3 6.3 gallon (23,8 liter)

Cummins QSB4.5 5.0 gallon (18,9 liter) Overflow Bottle Capacity 3 quart (2,8 liter) Type of Fluid 50/50 ethylene glycol & water

Hydraulic System

System Capacity

6036 & 6042 57 gallon (216 liter)

8042 58 gallon (218 liter)

10042 & 10054 64 gallon (242 liter) Reservoir Capacity to Full Mark 32 gallon (122 liter) T ype of Fluid Mobilfluid 424

Tractor Hydraulic Fluid

Transmission

Capacity with Filter Change 4.8 gallon (13,6 liter) Filter 1.5 quart (1,4 liter) T ype of Fluid Mobilfluid 424

Tractor Hydraulic Fluid

2-16

6036, 6042, 8042, 10042, 10054

General Information and Specifications

Axles

8042 Before S/N 0160038967 including 0160038971 10042 Before S/N 0160038368 including 0160038375, 0160038378, 0160038379, 0160038381 & 0160038383 10054 Before S/N 0160038740 excluding 0160021270, 0160036713, 0160036715 & 0160036723

Differential Housing Capacity

Front Axle 9.5 quart (9 liter) Rear Axle 10.6 quart (10 liter)

Wheel End Capacity

Front Axle 1.7 quart (1,6 liter) Rear Axle 1.3 quart (1,2 liter)

Type of Fluid Mobilfluid 424

6036 & 6042 8042 S/N 0160038967 & After excluding 0160038971 10042 S/N 0160038368 & After excluding 0160038375, 0160038378, 0160038379, 0160038381 & 0160038383 10054 S/N 0160038740 & After including 0160021270, 0160036713, 0160036715 & 0160036723

Differential Housing Capacity 12.5 quart (11,8 liter)

Tractor Hydraulic Fluid

Wheel End Capacity

Front Axle 2.1 quart (2,0 liter) Rear Axle 2.2 quart (2,1 liter)

Type of Fluid Mobilfluid 424

Tractor Hydraulic Fluid

6036, 6042, 8042, 10042, 10054

2-17

General Information and Specifications

OH4132

Change

Transmission

Filter

Change

Hydraulic

Filter

Change Axle Oil

(Before

S/N 0160037788)

Change Wheel

End Oil (Before

S/N 0160037788)

Change Engine

Oil & Filter

Check Wheel

Lug Nut

Torque

LB/FT (Nm)

Check Boom

Chain Tension

Check

Transmission

Oil Level

Check Hydraulic

Oil Level

Check Engine

Oil Level

EVERY

Additional

Checks -

Section 8

Check Tire

Condition &

Pressure

Check Fuel

Level

Air Filter

Restriction

Indicator

Check Engine Coolant Level

Drain Fuel/

Water Seprator

OMM

2.5 SERVICE AND MAINTENANCE SCHEDULES

2.5.1 10 & 1st 50 Hour

2-18

6036, 6042, 8042, 10042, 10054

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