JLG SkyTrak 6036, 6042, 8042, 10042 & 10054 (T4i) Models Telehandler ANSI Repair Service Manual

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This service manual PDF download for the 6036, 6042, 8042, 10042 & 10054 (T4i) Models JLG SkyTrak Telehandler has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

JLG SkyTrak Telehandlers
6036, 6042, 8042, 10042 & 10054

JLG SkyTrak 6036 & 6042
S/N 0160045066 & After including
0160042742, 0160042747 & 0160042755

JLG SkyTrak 8042, 10042 & 10054
S/N 0160045250 & After including
0160042754, 0160042762, 0160042877,
0160042911, 0160043185, 0160043220
& 0160043244 excluding 0160045255


TABLE OF CONTENTS :

Section 1 Safety Practices
    Section 2 General Information and Specifications
    Section 3 Boom
    Section 4 Cab and Covers
    Section 5 Axles, Drive Shafts, Wheels and Tires
    Section 6 Transmission
    Section 7 Engine
    Section 8 Hydraulic System
    Section 9 Electrical System
    Section 10 Stabil-TRAK™ System and Boom Interlock System


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 31200796
Total Pages : 276


This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

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    Effectivity Page
    Table of Contents
    Section 1 Safety Practices
        1.1 Introduction
        1.2 Disclaimer
        1.3 Operation & Safety Manual
        1.4 Do Not Operate Tags
        1.5 Safety Information
            1.5.1 Safety Alert System and Signal Words
        1.6 Safety Instructions
            1.6.1 Personal Hazards
            1.6.2 Equipment Hazards
            1.6.3 General Hazards
            1.6.4 Operational Hazards
        1.7 Safety Decals
        
    Section 2 General Information and Specifications
        2.1 Replacement Parts and Warranty Information
        2.2 Thread Locking Compound
        2.3 Torque Charts
            2.3.1 SAE Fastener Torque Chart
            2.3.2 Metric Fastener Torque Chart
            2.3.3 Hydraulic Hose Torque Chart
        2.4 Specifications
            2.4.1 Travel Speeds
            2.4.2 Hydraulic Cylinder Performance
            2.4.3 Electrical System
            2.4.4 Engine Performance Specifications
            2.4.5 Tires
        2.5 Fluid Specifications
        2.6 Fluid and Lubricant Capacities
        2.7 Service and Maintenance Schedules
            2.7.1 10 & 1st 50 Hour
            2.7.2 50, 250 & 1st 500 Hour
            2.7.3 500 & 1000 Hour
            2.7.4 2000 Hour
        2.8 Lubrication Schedules
            2.8.1 50 Hour
            2.8.2 250 Hour
            2.8.3 1000 Hour
            
    Section 3 Boom
        3.1 Boom System Component Terminology
        3.2 Safety Information
        3.3 Boom System - Three Section (6036, 6042, 8042 & 10042)
            3.3.1 Boom System Operation
        3.4 Boom Assembly Maintenance
            3.4.1 Boom Removal
            3.4.2 Third Boom Section Removal
            3.4.3 Second Boom Section Removal
            3.4.4 First Boom Section Removal
            3.4.5 First Boom Section Installation
            3.4.6 Second Boom Section Installation
            3.4.7 Third Boom Section Installation
            3.4.8 Boom Installation
        3.5 Boom System - Four Section (10054)
            3.5.1 Boom System Operation
        3.6 Boom Assembly Maintenance
            3.6.1 Fourth Boom Section Removal
            3.6.2 Third Boom Section Removal
            3.6.3 Second Boom Section Removal
            3.6.4 First Boom Section Removal
            3.6.5 First Boom Section Installation
            3.6.6 Second Boom Section Installation
            3.6.7 Third Boom Installation
            3.6.8 Fourth Boom Section Installation
        3.7 Boom Extend and Retract Chains
            3.7.1 Boom Chain Inspection
            3.7.2 Inspection Guidelines
            3.7.3 Expose Chains for Inspection
            3.7.4 Chain Lubrication
            3.7.5 Boom Chain Tension Check
            3.7.6 Boom Chain Tension Adjustment (6036, 6042, 8042 & 10042)
            3.7.7 Boom Chain Tension Adjustment (10054)
            3.7.8 Extend Chains Removal and Replacement (6036, 6042, 8042 & 10042)
            3.7.9 Retract Chain Removal and Replacement (6036, 6042, 8042 & 10042)
            3.7.10 Extend Chains Removal and Replacement (10054)
            3.7.11 Retract Chain Removal and Replacement (10054)
        3.8 Quick Attach Assembly
            3.8.1 Quick Attach Removal
            3.8.2 Quick Attach Installation
        3.9 Boom Wear Pads
            3.9.1 Wear Pad Inspection
            3.9.2 Wear Pad Installation and Lubrication
        3.10 Forks
        3.11 Troubleshooting
        
    Section 4 Cab and Covers
        4.1 Operator Cab and Covers Component Terminology
        4.2 Operator Cab
            4.2.1 Cab Safety
            4.2.2 Serial Number Decal
        4.3 Cab Components
            4.3.1 Steering Column and Steering Valve
            4.3.2 Service Brake Pedal
            4.3.3 Throttle Pedal
            4.3.4 Joystick Assemblies
            4.3.5 Windshield Wiper Assembly
            4.3.6 Heater/Defroster System (If Equipped)
        4.4 Cab Removal
        4.5 Cab Installation
        
    Section 5 Axles, Drive Shafts, Wheels and Tires
        5.1 Axle, Drive Shaft and Wheel Component Terminology (6036)
        5.2 Axle, Drive Shaft and Wheel Component Terminology (6042)
        5.3 Axle, Drive Shaft and Wheel Component Terminology (8042)
        5.4 Axle, Drive Shaft and Wheel Component Terminology (10042 & 10054)
        5.5 General Information
        5.6 Axle Assemblies
            5.6.1 Axle Serial Number Plate
            5.6.2 Axle Specifications
            5.6.3 Axle Internal Service
            5.6.4 Axle Maintenance
            5.6.5 Axle Replacement (6036 & 6042)
            5.6.6 Axle Replacement (8042, 10042 & 10054)
        5.7 Axle Assembly and Drive Shaft Troubleshooting
        5.8 Drive Shafts
            5.8.1 Drive Shaft Inspection and Service
            5.8.2 Drive Shaft Maintenance
            5.8.3 Drive Shaft Removal
            5.8.4 Drive Shaft Cleaning and Drying
            5.8.5 Drive Shaft Installation
        5.9 Wheels and Tires
            5.9.1 Removing Wheel and Tire Assembly from Machine
            5.9.2 Installing Wheel and Tire Assembly onto Machine
        5.10 Brakes
            5.10.1 Brake Disc Inspection
        5.11 Towing a Disabled Machine
        
    Section 6 Transmission
        6.1 Transmission Assembly Component Terminology
        6.2 Transmission Serial Number
        6.3 Transmission Specifications and Maintenance Information
        6.4 Transmission Replacement
            6.4.1 Transmission Removal
            6.4.2 Transmission Inspection and Internal Repair
            6.4.3 Transmission Installation
            6.4.4 After Transmission Service or Replacement
        6.5 Transmission Troubleshooting
        
    Section 7 Engine
        7.1 Introduction
            7.1.1 Disclaimer and Scope
            7.1.2 Component Terminology
        7.2 Engine Serial Number
        7.3 Specifications and Maintenance Information
        7.4 Engine Cooling System
            7.4.1 Coolant System Pressure Cap
            7.4.2 Radiator/Oil Cooler and Replacement
        7.5 Engine Electrical System
        7.6 Fuel System
            7.6.1 Diesel Fuel
            7.6.2 Fuel/Hydraulic Oil Tank
            7.6.3 After Fuel System Service
        7.7 Engine Exhaust System
            7.7.1 Exhaust System Removal
            7.7.2 Exhaust System Installation - LS
            7.7.3 Exhaust System Installation - ULS
        7.8 Air Cleaner Assembly
            7.8.1 Air Cleaner Assembly Removal - ULS
            7.8.2 Air Cleaner Assembly Installation - ULS
            7.8.3 Air Cleaner Assembly Removal - LS
            7.8.4 Air Cleaner Assembly Installation - LS
        7.9 Engine Replacement
            7.9.1 Engine Removal
            7.9.2 Engine Installation
        7.10 Isolation Coupler
            7.10.1 Isolation Coupler Removal
            7.10.2 Isolation Coupler Installation
            
    Section 8 Hydraulic System
        8.1 Hydraulic Component Terminology
        8.2 Safety Information
        8.3 Hydraulic Pressure Diagnosis
            8.3.1 Pressure Checks and Adjustments
        8.4 Hydraulic Circuits
            8.4.1 Hydraulic Pressures
            8.4.2 Hydraulic Schematics
        8.5 Hydraulic Reservoir
            8.5.1 Hydraulic Oil Reservoir Draining
            8.5.2 Hydraulic Oil Reservoir Filling
            8.5.3 Hydraulic Filter Replacement
            8.5.4 Hydraulic Oil Reservoir Replacement
        8.6 Hydraulic System Pump
            8.6.1 Pump Replacement
        8.7 Valves and Manifolds
            8.7.1 Main Control Valve
            8.7.2 Secondary Function Manifold
            8.7.3 Service Brake Valve
            8.7.4 Service Brake Valve Installation
            8.7.5 Brake Bleeding
            8.7.6 Power Steering Valve
            8.7.7 Steer Select Valve
            8.7.8 Unloader Valve (6036 & 6042 only)
            8.7.9 Outrigger Valve (10042 & 10054 only)
            8.7.10 Extend Lockout Valve (10054 only)
        8.8 Hydraulic Cylinders
            8.8.1 General Cylinder Instructions
            8.8.2 Cylinder Pressure Checking
            8.8.3 Steering Cylinders
            8.8.4 Cylinder Torque Specifications
            
    Section 9 Electrical System
        9.1 Electrical Component Terminology
            9.1.1 General Overview
        9.2 Specifications
        9.3 Safety Information
        9.4 Fuses and Relays
            9.4.1 Engine Compartment
            9.4.2 Cab Harness Fuses and Relays
        9.5 Electrical System Schematics
            9.5.1 Electrical Schematic (if equipped for ULS)
            9.5.1 Electrical Schematic (if equipped for ULS) (Continued)
            9.5.1 Electrical Schematic (if equipped for ULS) (Continued)
            9.5.1 Electrical Schematic (if equipped for ULS) (Continued)
            9.5.1 Electrical Schematic (if equipped for ULS) (Continued)
            9.5.2 Electrical Schematic (if equipped for LS)
            9.5.2 Electrical Schematic (if equipped for LS) (Continued)
            9.5.2 Electrical Schematic (if equipped for LS) (Continued)
            9.5.2 Electrical Schematic (if equipped for LS) (Continued)
            9.5.2 Electrical Schematic (if equipped for LS) (Continued)
        9.6 Engine start circuit
            9.6.1 Starter
        9.7 Charging Circuit
            9.7.1 Alternator
        9.8 Window Wiper/Washer Windshield Wiper Motor
            9.8.1 Windshield Wiper Motor
            9.8.2 Skylight Wiper Motor
            9.8.3 Windshield Washer Reservoir
        9.9 Cab Heater and Fan
            9.9.1 Cab Heater Controls
        9.10 Solenoids, Sensors and Senders
            9.10.1 Coolant Level Switch (if equipped for ULS)
            9.10.2 Hydraulic Oil Temperature Switch
            9.10.3 Transmission Solenoid Valves
            9.10.4 Transmission Temperature Sender
            9.10.5 Service Brake Switch
            9.10.6 Boom Angle Sensor
            9.10.7 Boom Extend Interlock Sensor (10054 only)
            9.10.8 Outrigger Pressure Switches (10054 Only)
        9.11 Display Monitor and Gauges
            9.11.1 Instrument Cluster
        9.12 Dash Switches
            9.12.1 Ignition Key Switch
            9.12.2 Dash Switches
        9.13 Troubleshooting
            9.13.1 Fault Detection
            9.13.2 Offboard Diagnostics
            9.13.3 Engine Fault Codes Chart
            
    Section 10 Stabil-TRAK™ System and Boom Interlock System
        10.1 Stabil-TRAK™ System Component Terminology
        10.2 Boom Extend Interlock System Component Terminology (10054 Only)
        10.3 Stabil-TRAK™ Description
        10.4 Stabil-TRAK™ Operation
            10.4.1 Understanding Stabil-TRAK™ System
            10.4.2 Stabil-TRAK™ Solenoid Valves
            10.4.3 Logic Wiring Harness (10054 Only)
            10.4.4 Relay Testing
            10.4.5 Outrigger Pressure Switches (10054 Only)
        10.5 Boom Extend Interlock System Description
        10.6 Boom Extend Interlock System Operation (10054 Only)
            10.6.1 Extend Interlock Mode
            10.6.2 Outrigger Interlock Mode
        10.7 Stabil-TRAK™ System Test
            10.7.1 Stabil-TRAK™ System Test Instructions
            10.7.2 Stabil-TRAK™ System Test Procedures
        10.8 Stabil-TRAK™ Boom Interlock Electrical Circuit Operation and Troubleshooting (6042/8042/10042)
        10.9 Stabil-TRAK™ Boom Interlock Electrical Circuit Operation and Troubleshooting (10054)
        10.10 Boom/Outrigger Interlock System Test
            10.10.1 System Test Procedures
        10.11 Stabil-TRAK™ Hydraulic Circuit Operation and Troubleshooting
            10.11.1 Stabil-TRAK™ Cylinder Oil Flow
            10.11.2 Hydraulic Circuit Operation - FREE PIVOT Mode, Rod Oil Out
            10.11.3 Hydraulic Troubleshooting - FREE PIVOT Mode, Rod Oil Out
            10.11.4 Hydraulic Circuit Operation - FREE PIVOT Mode, Base Oil Out
            10.11.5 Hydraulic Troubleshooting - FREE PIVOT Mode, Base Oil Out
            10.11.6 Hydraulic Circuit Operation - SLOW PIVOT Mode, Rod Oil Out
            10.11.7 Hydraulic Troubleshooting - SLOW PIVOT Mode, Rod Oil Out
            10.11.8 Hydraulic Circuit Operation - SLOW PIVOT Mode, Base Oil Out
            10.11.9 Hydraulic Troubleshooting - SLOW PIVOT Mode, Base Oil Out
            10.11.10 Hydraulic Circuit Operation - LOCKED MODE
            10.11.11 Hydraulic Circuit Operation - LOCKED MODE, Frame Level Right
            10.11.12 Hydraulic Troubleshooting - LOCKED MODE, Will Not Frame Level Right
            10.11.13 Hydraulic Circuit Operation - LOCKED MODE, Frame Level Left
            10.11.14 Hydraulic Troubleshooting - LOCKED MODE, Will Not Frame Level Left
        10.12 Boom Extend System Hydraulic Circuit Operation and Troubleshooting
            10.12.1 Troubleshooting Symptom Chart
            10.12.2 Hydraulic Circuit Operation - Extend Interlock Mode
            10.12.3 Hydraulic Troubleshooting - Extend Interlock Mode
            10.12.4 Hydraulic Circuit Operation - Outrigger Interlock Mode
            10.12.5 Hydraulic Troubleshooting - Outrigger Interlock Mode
            
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