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Accident Prevention Tags
OS2180
899040
3
Or
igin
5/00
1
2
...
453
454
455
456
457
458
459
460
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
Load Sense
262
Pressure
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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