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Skytrak 6036 Service Manual Handbücher

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Skytrak 6036 Service Manual Bedienungsanleitung (280 Seiten)


Marke: Skytrak | Kategorie: Spezialmaschinen | Größe: 2.98 MB |

 

Inhaltsverzeichnis

Service Manual

1

Effectivity Page

3

SECTION CONTENTS

5

Danger !

7

1.3 PERSONAL CONSIDERATIONS

8

1.4 EQUIPMENT CONSIDERATIONS

8

1.5 GENERAL CONSIDERATIONS

9

1.7 FINAL WORD

10

SECTION 2

12

GENERAL INSTRUCTIONS

12

2.3 REPLACEMENT

13

2.4 HOSES AND TUBES

13

2.1 INTRODUCTION

13

2.2 CLEANING

13

2.7 TORQUES

14

2.5 BEARINGS

14

2.6 PRESSURE TESTING

14

AND ADJUSTMENT

14

2.8 PAINTING

15

2.10 FLUID LEVELS AND

16

LUBRICATION

16

2.9 AFTER SERVICE STARTUP

16

AND CHECKS

16

IMPORTANT:

17

SECTION 3

19

Section 3. Boom

20

GOOSENECK

20

OUTER BOOM

21

3.1.3 Outer Boom Replacement

23

3.1.4 Chain Replacement

27

3.1.5 Chain Lubrication

28

3.1.6 Chain Tension Check

28

3.1.8 Wear Pad Replacement

29

3.1.9 Hose Tensioning

30

3.3 QUICK ATTACH

33

ASSEMBLY

33

3.4 TROUBLESHOOTING

34

3.5 SPECIFICATIONS

35

SECTION 4

37

OPERATOR'S CAB

37

4.2.2 Travel Select and

38

Range Select Levers

38

4.2.3 Boom Control and Grille

40

4.3 MECHANICAL FOOT

41

CONTROLS

41

FUEL PUMP

43

4.4 REAR VIEW MIRRORS

44

SECTION 5

46

Tube within Tire

49

Three Piece Wheel

50

5.1.2 Demounting Tire

50

5.1.11 Mounting Tire

53

5.1.12 Mounting Standard Tire

53

5.1.13 Mounting Optional Tire

54

5.2.6 Park Lock Unit

66

5.2.7 Carrier Assembly

68

5.4 SPECIFICATIONS

72

5.5 TROUBLESHOOTING

73

SECTION 6

75

DRIVE SHAFTS AND DROP BOX

75

6.2 DROP GEAR BOX

77

6.3 SPECIFICATIONS

78

7.2 HOW TO TOW

82

THE FORKLIFT

82

7.3 HOW TO DRAIN

82

TRANSMISSION

82

Section 7. Transmission

83

7.9 TROUBLESHOOTING

84

7.10 SPECIFICATIONS

85

8.1 ENGINE PREVENTIVE

88

MAINTENANCE

88

8.1.4 250 Hour Intervals

90

8.1.5 500 Hour Intervals

91

8.1.6 1,000 Hour Intervals

92

8.2 ENGINE COOLING SYSTEM

95

8.4.5 Fuel Lift Pump

99

8.4.6 Fuel Filter

100

Section 8. Engine

101

8.4.7 Fuel Injection Pump

102

Caution !

103

Warning !

103

8.6 ENGINE REMOVAL

105

8.8 ENGINE INSTALLATION

107

8.7 ENGINE OVERHAUL

107

8.9 HEAD TORQUE CHECK

110

8.10 STEM TIP TO ROCKER

110

ARM CLEARANCE

110

8.11 ENGINE STORAGE

111

8.12 TROUBLESHOOTING

112

Example:

115

9.1.2 Boom Extend/Retract

118

Section 9. Hydraulic System

121

9.1.4 Frame Tilt Circuit

124

9.1.5 Brake Circuits

127

9.1.6 Power Steering Circuit

130

Refer to paragraph 9.2a

138

S/N 8L0333 AND BEFORE

165

Threadlocker 242

178

IMPORTANT

179

DO NOT operate any boom or

179

9.5 TROUBLESHOOTING

184

9.6 SPECIFICATIONS

191

9.6 SPECIFICATIONS (cont.)

192

SECTION 10

194

ELECTRICAL SYSTEM

194

10.2 WARNING DEVICES

196

10.2.2 Backup Alarm

197

10.4 CIRCUIT BREAKERS

198

10.3 WIRING HARNESSES

198

Section 10. Electrical System

200

Electrical System Circuits

202

10.5 STARTING CIRCUIT

203

10.5.3 Starter

208

10.5.4 Starting Motor Relay

213

Weather Starting

214

10.6 CHARGING CIRCUIT

215

Size of Battery

225

Temperature

225

State-of-Charge

225

10.7 SWITCHES

227

AND SOLENOIDS

227

OFF RUN THERMO START START

228

Terminals

228

10.7.2 Neutral Start Switch

229

10.7.3 Fuel Run Solenoid

229

10.7.4 Park Lock Switch

230

10.7.6 Reverse Switch

233

10.7.7 Steering Select Switch

233

10.8 GAUGES AND INDICATOR

234

10.8.3 Hourmeter

235

10.8.4 Warning Lights

236

10.8.5 Engine

237

Low Oil Pressure Sender

237

10.8.6 Engine Coolant

238

High Temperature Sender

238

10.8.8 Transmission

238

10.8.9 Fuel Gauge

239

Lighting System Circuits

242

10.9 OPTIONAL

243

LIGHTING SYSTEM

243

10.9.2 Momentary Brake Light

245

(Stop Light)

245

10.10 WINDSHIELD

246

WASHER/WIPER

246

Reservoir (Enclosed Cab Only)

247

10.12 CAB HEATER

252

(ENCLOSED CAB ONLY)

252

10.11 FAN SWITCH AND FAN

252

MOTOR (OPTIONAL)

252

(Enclosed Cab Only)

254

10.13 EMERGENCY BRAKING

255

AND STEERING SYSTEM

255

Hydraulic Pump

256

(S/N 7P0013 and Before)

256

(S/N 7P0014 thru 9B0499)

257

10.14 TROUBLESHOOTING

258

CONTENTS

258

Important: Never jumper a

260

IMPORTANT: Use only

265

10.15 SPECIFICATIONS

277

JLG Worldwide Locations

280

Skytrak 6036 Service Manual Bedienungsanleitung (342 Seiten)


Marke: Skytrak | Kategorie: Spezialmaschinen | Größe: 4.26 MB |

 

Inhaltsverzeichnis

Service Manual

1

Effectivity Page

3

SECTION CONTENTS

5

SECTION 1

7

SAFETY PRACTICES

7

1.3 PERSONAL CONSIDERATIONS

8

1.4 EQUIPMENT CONSIDERATIONS

8

1.5 GENERAL CONSIDERATIONS

9

1.7 FINAL WORD

10

SECTION 2

11

GENERAL INSTRUCTIONS

11

2.1 INTRODUCTION

12

2.2 CLEANING

12

2.3 REPLACEMENT

12

2.4 HOSES AND TUBES

12

2.7 TORQUES

13

2.5 BEARINGS

13

2.6 PRESSURE TESTING

13

AND ADJUSTMENT

13

2.8 PAINTING

14

2.9 AFTER SERVICE

15

STARTUP AND CHECKS

15

2.10 FLUID LEVELS

16

AND LUBRICATION

16

SECTION 3

19

Fig. 3.3)

20

Section 3 Boom

21

OUTER BOOM

21

3.1.3 Outer Boom Replacement

23

3.1.4 Chain Replacement

27

3.1.5 Chain Lubrication

28

3.1.6 Chain Tension Check

28

3.1.8 Wear Pad Replacement

29

3.1.9 Hose Tensioning

30

3.2 EMERGENCY BOOM

32

LOWERING

32

3.2.2 Hydraulic Line Failure

33

3.3 QUICK ATTACH

34

ASSEMBLY

34

Excessive

35

3.5 SPECIFICATIONS

36

SECTION 4

37

OPERATOR'S CAB

37

4.2.2 Travel Select

38

Section 4 Operator's Cab

39

4.2.3 Boom Control and Grille

40

4.3 ELECTRONIC

41

JOYSTICK

41

(without TLC)

42

Replacement without TLC

45

4.4 MECHANICAL FOOT

46

CONTROLS

46

FUEL PUMP

48

4.5 REAR VIEW MIRRORS

49

SECTION 5

51

5.1 WHEEL ASSEMBLY

52

AND TIRE

52

Tube within Tire

54

5.1.2 Demounting Tire

55

5.1.4 Demounting Tire from

55

Three Piece Wheel

55

(S/N OF1191 & Before)

55

5.1.11 Mounting Tire

58

5.2 AXLE ASSEMBLY

61

5.2.1 Axle

62

ALWAYS replace with new ones

64

5.2.4 Axle Steering Joints

67

5.2.6 Park Lock Unit

71

5.2.7 Carrier Assembly

73

5.3 AXLE LUBRICATION

76

5.3.3 Wheel End Brake Oil

77

5.4 SPECIFICATIONS

78

5.5 TROUBLESHOOTING

78

SECTION 6

79

DRIVE SHAFTS AND DROP BOX

79

6.2 DROP GEAR BOX FOR

81

S/N 9N0941 AND BEFORE

81

6.2.2 Oil Seals

82

6.3 DROP GEAR BOX FOR

83

S/N 9N0942 AND AFTER

83

6.4 SPECIFICATIONS

85

SECTION 7

87

7.2 HOW TO TOW

88

THE FORKLIFT

88

Section 7 Transmission

89

7.9 TROUBLESHOOTING

90

7.10 SPECIFICATIONS

91

SECTION 8A

93

8A.4.2 Maintenance Intervals

95

8A.5.1 Inspect the Engine

95

8A.6 ENGINE MAINTENANCE

98

Every 250 Hours

98

8A.7 ENGINE MAINTENANCE

99

Every 500 Hours

99

8A.7.2 Clean Sediment Chamber

100

8A.8 ENGINE MAINTENANCE

101

Every 1,000 Hours

101

8A.8.2 Replace Air Filter

102

Primary Element

102

8A.9 ENGINE MAINTENANCE

103

Every 2,500 Hours

103

8A.10 ENGINE OIL

104

SPECIFICATIONS

104

8A.11 ENGINE COOLING

104

8A.11.2 Radiator Pressure Cap

105

Section 8A Perkins Engine

106

8A.12 ENGINE ELECTRICAL

107

8A.13 ENGINE FUEL SYSTEM

107

8A.13.4 Fuel Pre-Filter

109

8A.13.5 Fuel Lift Pump

109

8A.13.6 Fuel Filter

110

8A.13.7 Fuel Injection Pump

111

8A.13.8 Fuel Injectors

111

8A.14 ENGINE EXHAUST

112

8A.15 HOW TO REMOVE

113

ENGINE FROM FORKLIFT

113

8A.16 HOW TO OVERHAUL

115

THE ENGINE

115

8A.17 HOW TO INSTALL THE

115

ENGINE IN FORKLIFT

115

8A.18 HOW TO TORQUE

117

CYLINDER HEAD

117

SCREWS AND NUTS

117

8A.19 ENGINE STORAGE

118

8A.20 TROUBLESHOOTING

119

SECTION 8B

121

Section 8B Cummins Engine

122

8B.3.2 Maintenance Intervals

123

8B.4.1 Inspect the Engine

123

8B.5 ENGINE MAINTENANCE

126

EVERY 250 HOURS

126

OR 3 MONTHS

126

8B.6 ENGINE MAINTENANCE

128

EVERY 500 HOURS

128

OR 6 MONTHS

128

8B.7 ENGINE MAINTENANCE

130

EVERY 1,000 HOURS OR

130

ANNUALLY

130

8B.7.2 Tensioner Bearing

131

8B.7.3 Fan Hub

131

8B.7.4 Check Valve Stem

131

8B.7.5 Drain Cooling System

132

8B.7.8 Replace Air Filter

133

8B.8 ENGINE OIL

134

8B.9 ENGINE COOLING

134

8B.9.2 Radiator Pressure Cap

135

8B.10 ENGINE ELECTRICAL

136

8B.11 ENGINE FUEL SYSTEM

136

8B.11.2 Fuel Tank

138

8B.11.7 Fuel Injectors

139

8B.11.5 Dual Head Fuel Filter

139

8B.12 ENGINE EXHAUST

141

8B.13 HOW TO REMOVE

143

8B.14 HOW TO OVERHAUL

144

8B.15 HOW TO INSTALL THE

144

8B.16 ENGINE STORAGE

147

8B.17 TROUBLESHOOTING

149

SECTION 9

151

HYDRAULIC SYSTEM

151

9.1 SYSTEM OPERATION

152

9.2 MAIN CONTROL VALVE

152

OPERATION

152

CABLE CONTROL

152

Section 9 Hydraulic System

153

9.3 MAIN CONTROL VALVE

160

ELECTRONIC CONTROL

160

9.4 SECONDARY CONTROL

166

VALVE OPERATION

166

Example:

167

9.4.3 Frame Tilt Circuit

171

9.4.4 Brake Circuits

174

(S/N 9B0500 thru OE1179 –

174

Without Trans. De-Clutch)

174

9.4.5 Brake Circuits

176

(S/N OE1180 and After –

176

With Trans. De-Clutch)

176

9.4.6 Power Steering Circuit

179

9.5 CYLINDERS

185

Refer to paragraph 9.5.a

187

9.5.4 Boom Extend Cylinder

192

9.5.7 Slave Cylinder

197

9.5.8 Grille Tilt Cylinder

200

9.5.9 Frame Tilt Cylinder

203

9.5.10 Steering Cylinder

206

(S/N 3101 & Before)

206

9.5.11 Steering Cylinder

209

(S/N 3102 & After)

209

(Optional)

212

9.6 VALVES

218

Electronic Control

222

SUPPLY PORT

224

RETURN PORT

224

EXT. RAISE

224

9.6.3 Brake Valve

232

9B0500 thru OE1179)

237

9.6.7 Steer Select Valve

239

9.6.8 Priority Valve

240

9.7 PUMPS

241

Threadlocker 242

246

IMPORTANT

247

DO NOT operate any boom or

247

9.8 TROUBLESHOOTING

248

HYDRAULIC DIAGRAM

258

(Cable Controlled with

258

Transmission De-Clutch)

258

Hydraulic Pump Flow Test

259

HYDRAULIC TESTING

259

9.9 SPECIFICATIONS

260

9.9 SPECIFICATIONS (cont.)

261

SECTION 10

263

ELECTRICAL SYSTEM

263

Warning !

264

10.2 WARNING DEVICES

265

EMERGENCY

266

10.3 WIRING HARNESSES

267

10.4 CIRCUIT BREAKERS

267

AND/OR FUSES

267

Section 10. Electrical System

268

S/N 1883 and After

269

10.5 STARTING CIRCUIT

276

10.5.2 Starter

278

10.5.3 Starting Motor Relay

279

Weather Starting - Perkins

281

10.6 CHARGING CIRCUIT

282

Size of Battery

286

Temperature

286

State-of-Charge

286

Charger Capacity

286

10.7 SWITCHES

288

AND SOLENOIDS

288

10.7.2 Neutral Start Switch

289

10.7.3 Fuel Run Solenoid

290

10.7.4 Park Lock Switch

292

10.7.6 Steering Select Switch

293

10.7.5 Reverse Switch

293

10.8 GAUGES AND INDICATOR

294

10.8.3 Hourmeter

295

10.8.5 Engine

297

Low Oil Pressure Sender

297

10.8.6 Engine Coolant

298

High Temperature Sender

298

10.8.8 Transmission

298

10.8.9 Fuel Gauge

299

10.9 OPTIONAL

305

LIGHTING SYSTEM

305

10.9.2 Momentary Brake Light

307

(Stop Light)

307

Reservoir (Enclosed Cab Only)

309

(Enclosed Cab Only)

311

10.10.5 Roof Washer Motor and

313

Reservoir - Later Models

313

(Enclosed Cab Only) - Later

313

Cab Only) - Later Models

314

10.11 FAN SWITCH AND FAN

315

MOTOR (OPTIONAL)

315

10.12 CAB HEATER

315

(ENCLOSED CAB ONLY)

315

10.14 TROUBLESHOOTING

318

CONTENTS

318

Important: Never jumper a

320

IMPORTANT: Use only

325

10.15 SPECIFICATIONS

337

JLG Worldwide Locations

342

Skytrak 6036 Service Manual Bedienungsanleitung (276 Seiten)


Marke: Skytrak | Kategorie: Spezialmaschinen | Größe: 18.21 MB |

 

Inhaltsverzeichnis

Service Manual

1

EFFECTIVITY PAGE

3

READ THIS FIRST

4

SECTION CONTENTS

5

Section Subject Page

6

Section 1

9

Safety Practices

9

1.1 INTRODUCTION

10

1.2 DISCLAIMER

10

1.4 DO NOT OPERATE TAGS

10

1.5 SAFETY INFORMATION

10

1.6 SAFETY INSTRUCTIONS

11

1.7 SAFETY DECALS

12

Section 2

13

2.1 REPLACEMENT PARTS AND

14

WARRANTY INFORMATION

14

2.2 THREAD LOCKING COMPOUND

14

2.3 TORQUE CHARTS

15

SOCKET HEAD CAP SCREWS

19

2.4 SPECIFICATIONS

26

2.4.3 Electrical System

27

8042, 10042 & 10054

27

2.4.5 Tires

28

2.5 FLUID SPECIFICATIONS

29

2.7 SERVICE AND

32

MAINTENANCE SCHEDULES

32

2.7.3 500 & 1000 Hour

34

2.7.4 2000 Hour

35

2.8 LUBRICATION SCHEDULES

36

6042 ONLY

39

2.8.3 1000 Hour

41

Section 3

43

3.1 BOOM SYSTEM COMPONENT

45

3.2 SAFETY INFORMATION

46

(498 cm)

54

3.4.8 Boom Installation

56

3.5.1 Boom System Operation

57

3.6.7 Third Boom Installation

66

BOOM EXTEND AND RETRACT

70

3.7.2 Inspection Guidelines

71

3.7.4 Chain Lubrication

73

Replacement (10054)

82

3.8 QUICK ATTACH ASSEMBLY

90

3.9 BOOM WEAR PADS

90

3.10 FORKS

91

3.11 TROUBLESHOOTING

92

Section 4

95

4.1 OPERATOR CAB AND COVERS

96

4.2 OPERATOR CAB

97

4.3 CAB COMPONENTS

97

4.3.2 Service Brake Pedal

98

4.3.3 Throttle Pedal

99

Cab and Covers

100

4.3.4 Joystick Assemblies

100

4.4 CAB REMOVAL

102

4.5 CAB INSTALLATION

104

Section 5

107

COMPONENT TERMINOLOGY (6036)

108

COMPONENT TERMINOLOGY (6042)

109

COMPONENT TERMINOLOGY (8042)

110

COMPONENT TERMINOLOGY

111

(10042 & 10054)

111

5.5 GENERAL INFORMATION

112

5.6 AXLE ASSEMBLIES

112

5.6.4 Axle Maintenance

113

5.6.6 Axle Replacement

115

(8042, 10042 & 10054)

115

Problem Cause Remedy

119

TO TRANSMISSION

122

5.9 WHEELS AND TIRES

123

5.10 BRAKES

124

FRONT OF

125

6036 & 6042

125

8042, 10042 & 10054

126

Section 6

127

Transmission

127

6.1 TRANSMISSION ASSEMBLY

128

AND MAINTENANCE INFORMATION

129

6.4 TRANSMISSION REPLACEMENT

129

Replacement

132

6.5 TRANSMISSION

133

TROUBLESHOOTING

133

Section 7

137

7.1 INTRODUCTION

138

7.2 ENGINE SERIAL NUMBER

138

7.3 SPECIFICATIONS AND

138

MAINTENANCE INFORMATION

138

IF EQUIPPED FOR ULS

140

IF EQUIPPED FOR LS

140

7.5 ENGINE ELECTRICAL SYSTEM

141

7.6 FUEL SYSTEM

141

VIEW FROM REAR OF MACHINE

145

7.8 AIR CLEANER ASSEMBLY

147

7.9 ENGINE REPLACEMENT

148

7.9.2 Engine Installation

149

7.10 ISOLATION COUPLER

150

Section 8

153

Hydraulic System

153

8.1 HYDRAULIC COMPONENT

154

TERMINOLOGY

154

8.2 SAFETY INFORMATION

156

8.4 HYDRAULIC CIRCUITS

157

8.4.2 Hydraulic Schematics

164

8.5 HYDRAULIC RESERVOIR

172

8.6 HYDRAULIC SYSTEM PUMP

173

REXROTH PUMP

174

SAUER PUMP

174

EATON PUMP

174

8.7 VALVES AND MANIFOLDS

175

6036 6042

178

8042, 10042, 10054

179

8.8 HYDRAULIC CYLINDERS

183

AFTER the head gland

185

AXLE CENTER SECTION

186

STEERING CYLINDER

186

Section 9

189

Electrical System

189

9.1 ELECTRICAL COMPONENT

190

9.2 SPECIFICATIONS

191

9.3 SAFETY INFORMATION

191

9.4 FUSES AND RELAYS

191

HARNESS, DASH/THROTTLE

193

HARNESS, WIRING, OUTRIGGERS

199

BOOM EXTEND

200

HARNESS, LOGIC

200

HARNESS, CAB/PWR DISTRIBUTION

201

HARNESS, ENGINE/CHASSIS

202

9.7.1 Alternator

205

9.8 WINDOW WIPER/WASHER

206

WINDSHIELD WIPER MOTOR

206

9.8.2 Skylight Wiper Motor

207

9.9 CAB HEATER AND FAN

208

9.10 SOLENOIDS, SENSORS AND

209

9.10.5 Service Brake Switch

212

9.10.6 Boom Angle Sensor

213

(10054 only)

214

(10054 Only)

215

9.11.1 Instrument Cluster

215

9.12 DASH SWITCHES

216

9.12.2 Dash Switches

217

9.13 TROUBLESHOOTING

218

Section 10

229

10.1 STABIL-TRAK™ SYSTEM

231

10.2 BOOM EXTEND INTERLOCK

232

SYSTEM COMPONENT

232

TERMINOLOGY (10054 ONLY)

232

10.4 STABIL-TRAK™ OPERATION

234

(SN 13198 through 17984)

235

10.4.4 Relay Testing

236

10.5 BOOM EXTEND INTERLOCK

237

SYSTEM DESCRIPTION

237

10.6 BOOM EXTEND INTERLOCK

238

SYSTEM OPERATION (10054 ONLY)

238

Instructions

239

10.7.2 Stabil-TRAK™ System

239

Test Procedures

239

Electrical Circuit

243

FREE PIVOT Mode

243

SLOW PIVOT Mode

244

LOCKED MODE

245

TROUBLESHOOTING (10054)

246

Boom Extend Mode 1

248

Boom Extend Mode 2

249

Boom Extend Mode 3

250

SYSTEM TEST

251

10.11 STABIL-TRAK™ HYDRAULIC

253

CIRCUIT OPERATION AND

253

Pressure

256

Load Sense

256

LOCKED MODE, Frame Level Left

266

10.12 BOOM EXTEND SYSTEM

268

HYDRAULIC CIRCUIT OPERATION

268

AND TROUBLESHOOTING

268

Extend Interlock Mode

270

Outrigger Interlock Mode

272

JLG Worldwide Locations

276

Skytrak 6036 Service Manual Bedienungsanleitung (460 Seiten)


Marke: Skytrak | Kategorie: Spezialmaschinen | Größe: 24.69 MB |

 

Inhaltsverzeichnis

Service Manual

1

EFFECTIVITY PAGE

3

SECTION CONTENTS

5

Section Subject Page

6

Section 1

9

1.1 INTRODUCTION

10

1.2 OWNERS/OPERATORS MANUAL

10

1.3 TRAINING MECHANICS AS

11

OPERATORS

11

1.4 SAFETY INFORMATION

11

DANGER:

12

WARNING:

12

CAUTION:

12

1.6 SAFETY INSTRUCTIONS

13

Safety Practices

14

1.6.3 General Hazards

14

1.6.4 Operational Hazards

14

1.8 HAZARD/EMERGENCY

15

INFORMATION DECALS

15

Domestic: 1-877-554-5438

15

International: 1-717-485-5161

15

Section 2

17

2.2 INTRODUCTION

20

2.3 TORQUES

21

2.4 METRIC CONVERSION FACTORS

22

2.4.2 Approximate Metric to

23

American Conversions

23

2.5 SPECIFICATIONS

24

2.5.2 Vehicle Weights

26

2.5.3 Attachment Weights

27

2.5.6 Electrical System

28

2.5.9 Hydraulic System

31

2.5.10 Tires

31

4000 x 24

32

2.6.2 Axle Wheel Ends

33

2.6.3 Transmission

33

2.6.5 Hydraulic System

34

2.6.6 Engine

34

2.6.7 Drive Shaft Splines

35

2.6.8 General Anti-Corrosion

35

2.6.9 Electrical

35

2.7 CLEANING

36

2.8 REPLACEMENT

37

2.9 HOSES AND TUBES

37

2.10 BEARINGS

37

2.11 PRESSURE TESTING AND

38

ADJUSTMENT

38

2.12.8 After Engine Service

40

2.12.9 After Boom Service

40

2.12.10 After Axle Service

40

Section 3

41

3.1 BOOM SYSTEM COMPONENT

42

3.2 BOOM SYSTEM

43

3.3 BOOM ASSEMBLY MAINTENANCE

43

Front Top Wear Pads

44

Tilt Cylinder Hoses

45

Hose Reel Side Plate

51

Hose Reel Assembly

51

Auxiliary Hydraulics Hoses

52

Cylinder Rod End Pin

52

Boom Rear Wear Pads

53

Upper Rear Wear Pads

53

3.3.3 Outer Boom Removal

54

Attachment Tilt Tubes

56

Cylinder Pivot Pins

58

Cylinder Base End Pin

59

3.3.4 Outer Boom Installation

60

Slave Cylinder Bearings

61

Tube Assemblies

67

Lower Wear Pads

68

Boom Front Wear Pads

72

3.3.6 Inner Boom Installation

73

Inside the Inner Boom

74

Boom Front Side Wear Pads

77

Intermediate Boom Sections

79

Hydraulic Coupler and Nipple

82

Cylinder Base End Pivot Pin

82

3.3.7 Boom Chains

84

Adjustment Locknuts

89

Extend Chain Installation

92

Retract Chain Removal

94

3.3.8 Boom Wear Pads

96

Intermediate Boom

97

Outer Boom

98

3.4 QUICK ATTACH ASSEMBLY

99

3.4.3 Quick Attach Removal

100

3.5 TROUBLESHOOTING

101

Problem Cause Remedy

101

Model 6036 Legacy

104

Section 4

105

Cab and Covers

105

COMPONENT TERMINOLOGY

106

4.2 OPERATOR’S CAB

107

4.3 OPEN CAB COMPONENTS

108

4.3.4 Brake Pedal and Valve

114

Assembly Replacement

119

4.3.8 Electrical Components

121

4.4 ENCLOSED CAB (OPTIONAL)

123

COMPONENTS

123

4.4.5 Door and Latches

127

4.4.6 Windows

128

4.5 CAB REMOVAL

129

4.6 CAB INSTALLATION

133

4.7 ACCESS PANELS AND COVERS

136

Section 5

137

5.2 GENERAL INFORMATION

139

5.3 AXLE ASSEMBLIES

139

5.3.4 Axle Specifications

140

5.3.5 Axle Maintenance

140

5.3.6 Axle Replacement

141

Troubleshooting

150

5.4 DRIVE SHAFTS

151

5.4.2 Drive Shaft Maintenance

152

5.4.3 Drive Shaft Removal

152

5.4.4 Drive Shaft Disassembly

153

5.4.6 Drive Shaft Assembly

155

Direction of Forward Travel

157

WARNING: Damaged, modified

159

Section 6

163

Transmission: ZF 4 WG-98 TC

163

6.1 TRANSMISSION ASSEMBLY

164

6.2 TRANSMISSION DESCRIPTION

165

6.3 TRANSMISSION OPERATION

165

6.6 TRANSMISSION MAINTENANCE

166

6.7 TRANSMISSION REPLACEMENT

168

6.8 TOWING A DISABLED VEHICLE

175

6.9 TROUBLESHOOTING

176

Section 7

179

Engine: Cummins 4BT3.9

179

7.1 INTRODUCTION

180

7.2 SAFETY INFORMATION

182

7.3 ENGINE SERIAL NUMBER

184

7.4 SPECIFICATIONS AND

184

MAINTENANCE INFORMATION

184

7.5 STANDARD PRACTICES

184

7.6 ENGINE COOLING SYSTEM

185

Heater Replacement

188

7.7 ENGINE ELECTRICAL SYSTEM

192

7.8 FUEL SYSTEM

193

7.8.1 Diesel Fuel

194

7.9 ENGINE EXHAUST SYSTEM

201

7.10 AIR CLEANER ASSEMBLY

202

7.11 ENGINE REPLACEMENT

203

7.11.3 Engine Installation

208

7.12 ENGINE STORAGE

215

7.13 TROUBLESHOOTING

216

Section 8

217

Hydraulic System

217

8.1 HYDRAULIC COMPONENT

219

TERMINOLOGY

219

8.2 SAFETY INFORMATION

220

8.3 SPECIFICATIONS

221

8.4 HYDRAULIC FLUID

221

Replacement

222

8.7 HYDRAULIC SYSTEM TESTING

226

8.8 HYDRAULIC CIRCUITS AND

229

TROUBLESHOOTING

229

3. Air in the lines

241

Pressure

262

Load Sense

262

Description

268

PROCEDURE

274

8.10 HYDRAULIC RESERVOIR

276

8.11 HYDRAULIC SYSTEM PUMP

277

8.11.2 Pump Replacement

278

8.12 VALVES AND MANIFOLDS

284

8.12.2 Main Control Valve

286

8.12.4 Service Brake Valve

305

8.12.5 Shuttle Valve

309

8.12.6 Power Steering Valve

310

8.12.7 Steer Select Valve

312

8.13 HYDRAULIC CYLINDERS

316

8.13.5 Slave Cylinders

321

8.13.7 Lift/Lower Cylinder

330

8.13.8 Frame Sway Cylinder

334

8.13.11 Steering Cylinders

351

Section 9

353

Electrical System

353

9.1 ELECTRICAL COMPONENT

355

9.2 SERVICE WARNINGS

357

9.3 SPECIFICATIONS

357

9.5 WIRING HARNESSES

358

9.5.3 Cleaning and Drying

359

9.5.4 Inspection and Repair

359

9.5.5 Installation

359

9.5.6 Wire Code and Color

359

9.6 FUSES AND RELAYS

360

9.7 ELECTRICAL SYSTEM

362

9.10 ENGINE START CIRCUIT

409

9.10.2 Starter

410

9.11 CHARGING CIRCUIT

411

9.11.2 Battery

414

9.12 ELECTRICAL SYSTEM

417

9.12.2 Back-Up Alarm

418

9.12.3 Instrument Cluster

419

9.13.2 Windshield Wiper Motor

422

9.13.3 Roof Wiper Switch

424

9.13.4 Roof Wiper Motor

424

9.14.1 Cab Heater Controls

427

9.15 SWITCHES AND SOLENOIDS

428

9.15.2 Fuel Shut-off Solenoid

430

9.15.4 Park Brake Switch

433

9.15.7 Steering

441

9.15.8 Steer Select Switches

443

9.15.9 Steer Select Valve

444

9.15.13 Engine Block Heater

448

9.15.15 Hourmeter

451

Section 10

453

Accident Prevention Tags

457

8990403 Origin 5/00

458

JLG Worldwide Locations

460




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