Manual de Serviço - Skytrak

Service Manual
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6036, 6042, 8042,
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10042, 10054, 12054
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PVC 1911
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31211388
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January 21, 2020 - Rev A

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An Oshkosh Corporation Company

Discount-Equipment.com is your online resource for quality parts & equipment.
Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101
Need parts?
Click on this link: http://www.discount-equipment.com/category/5443-parts/ and
choose one of the options to help get the right parts and equipment you are looking
for. Please have the machine model and serial number available in order to help us
get you the correct parts. If you don’t find the part on the website or on once of the
online manuals, please fill out the request form and one of our experienced staff
members will get back to you with a quote for the right part that your machine needs.
We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman,
Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,
Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack,
Lull, Skytrak, Tsurumi, Husquvarna Target, , Stow, Wacker, Sakai, Mi-T- M, Sullair, Basic,
Dynapac, MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti,
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Jax, F.S. Curtis, Gehl Pavers, Heli, Honda, ICS/PowerGrit, IHI, Partner, Imer, Clipper, MMD,
Koshin, Rice, CH&E, General Equipment, ,AMida, Coleman, NAC, Gradall, Square Shooter,
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Rol-Air, Small Line, Wanco, Yanmar
EFFECTIVITY PAGE
DATE REVISION DESCRIPTION

January 21, 2020 A Original Issue Of Manual
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6036, 6042, 8042, 10042, 10054, 12054 31211388 i

READ THIS FIRST
Modifications
Modifications to this machine may affect compliance with Industry Standards and/or Governmental Regulations. Any
modification must be approved by JLG.
Machine Configuration
Two configurations of each machine are included in this manual. Determine if machine is equipped with Ultra Low Sulfur Fuel
Decal (1) as indicated below.
• If equipped with the Ultra Low Sulfur decal, all specific references to this machine configuration will be referred to as
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Ultra Low Sulfur (ULS) from this point forward.
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• If not equipped with the Ultra Low Sulfur decal, all specific references to this machine configuration will be referred to as
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Low Sulfur (LS) from this point forward.
Maximum engine power can be found on the decals (2) located on the inside of the side engine compartment doors.
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(8042, 10042, 10054, 12054)
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2 1
ULTRA LOW
XXXhp (XXkW) @ XXXX RPM SULFUR DIESEL
FUEL ONLY
S < 15 mg/kg
or
XXXXXXXXXX_A
1001125387 A
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OH5604
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XXXhp (XXkW) @ XXXX RPM 2

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(6036, 6042)
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ii 31211388 6036, 6042, 8042, 10042, 10054, 12054

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
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1.6 Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
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1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
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Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
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2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
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2.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
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2.3 Fluid & Lubricant Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.4 Service and Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
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2.5 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2.6
2.7 to
Threadlocking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-25
2-26
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2.8 Hydraulic Connection Assembly and Torque Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
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Section 3
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Boom ....................................................................... 3-1

3.1 Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
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3.3 Boom System - Three Section (6036, 6042, 8042 & 10042) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
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3.4 Boom Assembly Maintenance (6036, 6042, 8042 & 10042) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
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3.5 Boom System - Four Section (10054 & 12054). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

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3.6 Boom Assembly Maintenance (10054 & 12054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

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3.7 Boom Extend and Retract Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

3.8 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
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3.9 Quick Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

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3.10 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

3.11 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
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Section 4
Go
Cab ....................................................................... 4-1

4.1 Operator Cab Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Operator Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.5 Cab Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
6036, 6042, 8042, 10042, 10054, 12054 31211388 I

Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Axle, Drive Shaft and Wheel Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.3 Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.4 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.5 Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.6 Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.7 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5.8 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
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Section 6
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Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
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6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
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6.2 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3 Transmission Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
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6.4 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
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6.5 Transmission Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
or
Section 7
to
Engine ....................................................................... 7-1
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
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7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.3 Specifications and Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
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7.4 Engine Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

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7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

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

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7.7 Engine Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

7.8 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
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7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

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7.10 Isolation Coupler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

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Section 8
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Hydraulic Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

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

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8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

8.3 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
to
8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Go
8.5 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

8.6 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
8.7 Hydraulic System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
8.8 Valves and Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
8.9 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50
II 31211388 6036, 6042, 8042, 10042, 10054, 12054

Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 Electrical Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.5 Electrical System Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.6 Dielectric Grease Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
9.7 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
9.8 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
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9.9 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
9.10 Window Wiper/Washer Windshield Wiper Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
pa
9.11 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
9.12 Solenoids, Sensors and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
ur
9.13 Display Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35
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9.14 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
9.15 Machine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
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9.16 Analyzer Software Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41
or
9.17 Telematics Gateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-45
9.18 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-51
9.19
9.20 to
Machine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-52
9-56
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Section 10
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Stabil-TRAK™ System and Boom Interlock System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

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10.1 Stabil-TRAK™ System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

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10.2 Boom Extend Interlock System Component Terminology (10054 & 12054 Only). . . . . . . . . . . . . 10-4
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10.3 Stabil-TRAK™ Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5

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10.4 Stabil-TRAK™ Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

10.5 Boom Extend Interlock System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
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10.6 Boom Extend Interlock System Operation (10054 & 12054 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
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10.7 Stabil-TRAK™ System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12

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10.8 Stabil-TRAK™ Electrical Circuit Operation and Troubleshooting (6042/8042/10042) . . . . . . . . . 10-15

10.9 Stabil-TRAK™ and Boom Interlock Electrical Circuit Operation and
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Troubleshooting (10054 & 12054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19

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10.10 Boom/Outrigger Interlock System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24

10.11 Stabil-TRAK™ Hydraulic Circuit Operation and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
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10.12 Boom Extend System Hydraulic Circuit Operation and Troubleshooting . . . . . . . . . . . . . . . . . . . . 10-40
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6036, 6042, 8042, 10042, 10054, 12054 31211388 III

Need parts?
Section 1
Safety Practices
Contents
PARAGRAPH TITLE PAGE
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1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
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1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
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1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
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1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
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1.5.1 Safety Alert System and Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
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1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
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1.6.1 Personal Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.2 Equipment Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.3
1.6.4
to
General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3
1-4
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1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
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6036, 6042, 8042, 10042, 10054, 12054 31211388 1-1

Safety Practices
1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS

This service manual provides general directions for Place Do Not Operate Tags on the ignition key switch and the
accomplishing service and repair procedures. Following the steering wheel before attempting to perform any service or
procedures in this manual will help assure safety and maintenance. Remove key and disconnect battery leads.
equipment reliability.
Read, understand and follow the information in this manual, 1.5 SAFETY INFORMATION
and obey all locally approved safety practices, procedures,
rules, codes, regulations and laws. To avoid possible death or injury, carefully read, understand
and comply with all safety messages.
These instructions cannot cover all details or variations in the
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equipment, procedures, or processes described, nor provide In the event of an accident, know where to obtain medical
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directions for meeting every possible contingency during assistance and how to use a first-aid kit and fire extinguisher/
fire suppression system. Keep emergency telephone
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operation, maintenance, or testing. When additional
information is desired consult your local authorized service numbers (fire department, ambulance, rescue squad/
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distributor. paramedics, police department, etc.) nearby. If working
alone, check with another person routinely to help assure
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Many factors contribute to unsafe conditions: carelessness, personal safety.
fatigue, overload, inattentiveness, unfamiliarity, even drugs
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and alcohol, among others. For optimal safety, encourage
1.5.1 Safety Alert System and Signal Words
or
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
to DANGER
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operation of the machine. All references to the right side, left
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side, front and rear are given from the operator seat looking in DANGER indicates an imminently hazardous situation
a forward direction. which, if not avoided, will result in death or serious injury.
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Supplementary information is available from JLG in the form

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of Service Bulletins, Service Campaigns, Service Training

WARNING
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Schools, the manufacturer website, other literature, and

through updates to the manual itself.
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1.2 DISCLAIMER WARNING indicates a potentially hazardous situation which,

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

All information in this manual is based on the latest product
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information available at the time of publication. The

CAUTION
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manufacturer reserves the right to make changes and

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improvements to its products, and to discontinue the

manufacture of any product, at its discretion at any time
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without public notice or obligation. CAUTION indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate injury.
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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 31211388 6036, 6042, 8042, 10042, 10054, 12054

Safety Practices
1.6 SAFETY INSTRUCTIONS 1.6.3 General Hazards

SOLVENTS: Only use approved solvents that are known to be
Following are general safety statements to consider before
safe for use.
performing maintenance procedures on the telehandler.
Additional statements related to specific tasks and HOUSEKEEPING: Keep the work area and operator cab clean,
procedures are located throughout this manual and are and remove all hazards (debris, oil, tools, etc.).
listed prior to any work instructions to provide safety FIRST AID: Immediately clean, dress and report all injuries
information before the potential of a hazard occurs. (cuts, abrasions, burns, etc.), no matter how minor the injury
For all safety messages, carefully read, understand and follow may seem. Know the location of a First Aid Kit, and know how
the instructions before proceeding. to use it.
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CLEANLINESS: Wear eye protection, and clean all
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1.6.1 Personal Hazards components with a high-pressure or steam cleaner before
attempting service.
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PERSONAL SAFETY GEAR: Wear all the protective clothing
and personal safety gear necessary to perform the job safely. When removing hydraulic components, plug hose ends and
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This might include heavy gloves, safety glasses or goggles, connections to prevent excess leakage and contamination.
Place a suitable catch basin beneath the machine to capture
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filter mask or respirator, safety shoes or a hard hat.
LIFTING: NEVER lift a heavy object without the help of at fluid run-off.
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least one assistant or a suitable sling and hoist. It is good practice to avoid pressure-washing electrical/
or
electronic components. In the event pressure-washing the
1.6.2 Equipment Hazards machine is needed, ensure the machine is shut down before
LIFTING OF EQUIPMENT: Before using any lifting equipment to
pressure-washing. Should pressure-washing be utilized to
wash areas containing electrical/electronic components, it is
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(chains, slings, brackets, hooks, etc.), verify that it is of the
recommended a maximum pressure of 750 psi (52 bar) at a
proper capacity, in good working order, and is properly
minimum distance of 12 in (30,5 cm) away from these
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attached.
components. If electrical/electronic components are
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NEVER stand or otherwise become positioned under a sprayed, spraying must not be direct and for brief time
suspended load or under raised equipment. The load or periods to avoid heavy saturation.
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equipment could fall or tip.

Check and obey all Federal, State and/or Local regulations
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DO NOT use a hoist, jack or jack stands only to support regarding waste storage, disposal and recycling.
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equipment. Always support equipment with the proper

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capacity blocks or stands properly rated for the load.

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HAND TOOLS: Always use the proper tool for the job; keep
tools clean and in good working order, and use special
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service tools only as recommended.

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6036, 6042, 8042, 10042, 10054, 12054 31211388 1-3

Safety Practices
1.6.4 Operational Hazards FLUID FLAMABILTITY: DO NOT service the fuel or hydraulic
systems near an open flame, sparks or smoking materials.
ENGINE: Stop the engine before performing any service
unless specifically instructed otherwise. NEVER drain or store fluids in an open container. Engine fuel
and hydraulic fluid are flammable and can cause a fire and/or
VENTILATION: Avoid prolonged engine operation in
explosion.
enclosed areas without adequate ventilation.
DO NOT mix gasoline or alcohol with diesel fuel. The mixture
SOFT SURFACES AND SLOPES: NEVER work on a machine
can cause an explosion.
that is parked on a soft surface or slope. The machine must be
on a hard level surface, with the wheels blocked before PRESSURE TESTING: When conducting any test, only use test
performing any service. equipment that is correctly calibrated and in good condition.
Use the correct equipment in the proper manner, and make
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FLUID TEMPERATURE: NEVER work on a machine when the
changes or repairs as indicated by the test procedure to
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engine, cooling or hydraulic systems are hot. Hot
achieve the desired result.
components and fluids can cause severe burns. Allow
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systems to cool before proceeding. LEAVING MACHINE: Lower the forks or attachment to the
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ground before leaving the machine.
FLUID PRESSURE: Before loosening any hydraulic or diesel
fuel component, hose or tube, turn the engine OFF. Wear TIRES: Always keep tires inflated to the proper pressure to
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heavy, protective gloves and eye protection. NEVER check help prevent tipover. DO NOT over-inflate tires.
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for leaks using any part of your body; use a piece of NEVER use mismatched tire types, sizes or ply ratings.
cardboard or wood instead. If injured, seek medical attention Always use matched sets according to machine
or
immediately. Diesel fluid leaking under pressure can specifications.
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explode. Hydraulic fluid and diesel fuel leaking under
MAJOR COMPONENTS: Never alter, remove, or substitute any
pressure can penetrate the skin, cause infection, gangrene
items such as counterweights, tires, batteries or other items
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and other serious personal injury.
that may reduce or affect the overall weight or stability of the
Engine fuel lines are pressurized. DO NOT attempt repairs machine.
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unless specific training has been completed. Refer to the

BATTERY: DO NOT charge a frozen battery.Charging a frozen
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engine manufacturers’ manual for specific details

battery may cause it to explode. Allow the battery to thaw
concerning the fuel system.
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before jump-starting or connecting a battery charger.

Relieve all pressure before disconnecting any component,
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part, line or hose. Slowly loosen parts and allow release of 1.7 SAFETY DECALS
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residual pressure before removing any part or component.

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Before starting the engine or applying pressure, use Check that all safety decals are present and readable on the
components, parts, hoses and pipes that are in good
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machine. Refer to the Operation & Safety Manual supplied

condition, connected properly and are tightened to the with machine for information.
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proper torque. Capture fluid in an appropriate container and

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dispose of in accordance with prevailing environmental

regulations.
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COOLANT SYSTEM CAP: The cooling system is under

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pressure, and escaping coolant can cause severe burns and

eye injury. To prevent personal injury, NEVER remove the
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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.
Properly disconnect battery(s) prior to service the fuel or
hydraulic systems.
1-4 31211388 6036, 6042, 8042, 10042, 10054, 12054

Section 2
General Information and Specifications
Contents
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2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
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2.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.1 Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
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2.2.2 Hydraulic Cylinder Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
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2.2.3 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.2.4 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
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2.2.5 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
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2.3 Fluid & Lubricant Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.3.1 Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.4
2.3.2
to
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-12
2-14
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2.4.1 Every 10 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
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2.4.2 First 50 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.4.3 Every 50 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
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2.4.4 First 250 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

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2.4.5 Every 250 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

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2.4.6 First 500 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

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2.4.7 Every 500 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.4.8 Every 750 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
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2.4.9 Every 1000 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

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2.4.10 Every 1500 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

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2.4.11 Every 2000 Hours or 2 Year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.4.12 Every 4000 Hours or 3 Years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
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2.4.13 Every 5000 Hours or 4 Years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

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2.5 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

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2.5.1 50 Hour. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2.5.2 250 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
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2.5.3 1000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

2.6 Threadlocking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2.7 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2.7.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2.7.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-1

2.8 Hydraulic Connection Assembly and Torque Specification . . . . . . . . . . . . . . . . . . . . . . . 2-36

2.8.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
2.8.2 Assembly Instructions for American Standard Pipe Thread Tapered Connections 2-40
2.8.3 Assembly Instructions for British Standard Pipe Thread Tapered Connections. 2-41
2.8.4 Assembly Instructions for 37° (JIC) Flare Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
2.8.5 Assembly Instructions for 45° SAE Flare Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
2.8.6 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings. . . . . . . . . . . . . . . . . . . 2-46
2.8.7 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS) . . 2-48
2.8.8 Assembly Instructions for Bulkhead (BH) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
2.8.9 Assembly Instructions for O-Ring Boss (ORB) Fittings . . . . . . . . . . . . . . . . . . . . . . . . 2-54
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2.8.10 Assembly Instructions for Adjustable Port End Metric Fittings . . . . . . . . . . . . . . . . 2-62
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2.8.11 Assembly Instructions for Metric ISO 6149 Port Assembly Stud Ends . . . . . . . . . 2-70
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2.8.12 Assembly Instructions for Adjustable Port End (BSPP) Fittings . . . . . . . . . . . . . . . . 2-72
2.8.13 Assembly Instructions for Flange Connections (FL61 and FL62) . . . . . . . . . . . . . . 2-80
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2.8.14 Double Wrench Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
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2.8.15 FFWR and TFFT Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84
2.8.16 Adjustable Stud End Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84
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2.8.17 O-ring Installation (Replacement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84
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2-2 31211388 6036, 6042, 8042, 10042, 10054, 12054

2.1 REPLACEMENT PARTS AND WARRANTY

INFORMATION
1911
1
* Refer to load capacity chart for truck with attachment, and individual load ratings stamped
on forks, if equipped. Use lowest capacity of all ratings.
As released from factory this truck meets design specifications in
1001253912A
Manufactured by
JLG Industries Inc.
McConnellsburg, P A
17233-9533 USA
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MAE41200A
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Before ordering parts or initiating service inquiries, make
note of the machine serial number. The machine serial
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number plate (1) is located as indicated in the figure.

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Note: The replacement of any part on this machine with any

other than JLG authorized replacement parts can adversely
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affect the performance, durability, or safety of the machine,

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and will void the warranty. JLG disclaims liability for any claims
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or damages, whether regarding property damage, personal

injury or death arising out of the use of unauthorized
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replacement parts.
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A warranty registration form must be filled out by the JLG

ou
distributor, signed by the purchaser and returned to JLG

sc
when the machine is sold and/or put into use.

Di
Registration activates the warranty period and helps to

assure that warranty claims are promptly processed. To
to
guarantee full warranty service, verify that the distributor has

returned the business reply card of the warranty registration
Go
form to JLG.
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-3

2.2 SPECIFICATIONS
2.2.1 Travel Speeds
a. 6036, 6042
Transmission 6036 6042

First Gear 3.6 mph (5,8 km/hr) 3.6 mph (5,8 km/hr)
Second Gear 6.1 mph (9,8 km/hr) 6.1 mph (9,8 km/hr)
ts
ar
Third Gear 14.5 mph (23,3 km/hr) 14.5 mph (23,3 km/hr)
rp
Fourth Gear 19.5 mph (31.4 km/hr) 19 mph (30,6 km/hr)
ou
b. 8042
ry
de
Transmission If equipped for ULS If equipped for LS/74 hp (55kW)
or
First Gear 3.3 mph (5,3 km/hr) 3 mph (4,8 km/hr)
Third Gear 13.3 mph (21,4 km/hr) to 11.7 mph (18,8 km/hr)
om
Fourth Gear 18.7 mph (30,1 km/hr) 16.6 mph (26,7 km/hr)
t.c
en
c. 10042
m
If equipped for 74 hp
ip
Transmission If equipped for ULS If equipped for LS

(55kW)
qu
First Gear 3.5 mph (5,6 km/hr) 3.5 mph (5,6 km/hr) 3.0 mph (4,8 km/hr)
-E
Second Gear 5.8 mph (9,3 km/hr) 5.8 mph (9,3 km/hr) 4.9 mph (7,9 km/hr)
nt
Third Gear 13.8 mph (23 km/hr) 13.8 mph (23 km/hr) 12.0 mph (19,3 km/hr)
ou
Fourth Gear 19.6 mph (31,5 km/hr) 19.6 mph (31,5 km/hr) 16.2 mph (26,1 km/hr)
sc
Di
d. 10054
to
Transmission If equipped for ULS/LS If equipped for 74 hp (55kW)

Go
First Gear 3.5 mph (5,6 km/hr) 3.0 mph (4,8 km/hr)
Third Gear 13.8 mph (23 km/hr) 12.0 mph (19,3 km/hr)
2-4 31211388 6036, 6042, 8042, 10042, 10054, 12054

e. 12054
Transmission If equipped for 110 hp If equipped for 74 hp

First Gear 3.1 mph (5 km/hr) 3.1 mph (5 km/hr)
Third Gear 12.3 mph (19,8 km/hr) 12.2 mph (19,6 km/hr)
ts
2.2.2 Hydraulic Cylinder Performance
ar
Note: Machine with no attachment or load, engine at full throttle, hydraulic oil above 130° F (54° C) minimum, engine at operating
rp
temperature.
ou
a. 6036, 6042, 8042, 10042 & 10054
ry
APPROXIMATE TIMES (seconds)
de
FUNCTION
6036 6042 8042 10042 10054
or
Less than 18.5
Boom Extend
Less than
13.0
Less than 16.0 to
Less than 16.5
for ULS
Less than 19.5
om
Less than 18.0
for LS/74 HP
t.c
Less than
Boom Retract Less than 15.0 Less than 13.5 Less than 16.0 Less than 16.0
en
12.0
m
Less than
Boom Lift Retracted Less than 13.0 Less than 16.0 Less than 17.0 Less than 17.0
ip
11.0
qu
Less than 17.0 Less than 15.5

for ULS for ULS
-E
Boom Lower Retracted Less than 8.0 Less than 11.0 Less than 14.0
nt
Less than 18.0 Less than 17.0

for LS/74 HP for LS/74 HP
ou
Attachment Tilt - Up 8.0 8.0 10.0 10.0 10.0

sc
Attachment Tilt - Down 8.0 8.0 8.0 8.0 8.0

Di
Frame Level Left to Right

to
12.0 - 14.0 12.0 - 14.0 12.0 - 14.0 12.0 - 14.0 12.0 - 14.0
with Boom Down
Go
Frame Level Left to Right

with Boom Above 40° and — 23.0-33.0 23.0 - 33.0 23.0 - 33.0 23.0 - 33.0
Emergency Brake Engaged
Frame Level Right to Left
12.0 - 14.0 12.0 - 14.0 12.0 - 14.0 12.0 - 14.0 12.0 - 14.0
with Boom Down
Frame Level Right to Left
with Boom Above 40° and — 26.0-52.0 26.0 - 52.0 26.0 - 52.0 26.0 - 52.0
Emergency Brake Engaged
Outrigger - Left or Right, UP
— — — — —
or DOWN
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-5

b. 12054
APPROXIMATE TIMES (seconds)

FUNCTION 12054 110 HP 12054 74 HP
Min. Time Max. Time Min. Time Max. Time
Boom Up 16.0 18.0 17.0 19.0
Boom Down* 15.0 17.5 17.0 19.0
Boom Extend 15.0 17.0 16.0 18.0
ts
Boom Retract 14.0 16.5 16.5 18.5
ar
rp
Attachment Tilt Fwd 10.0 13.0 10.0 13.0
Attachment Tilt Back 8.0 10.0 8.0 10.0
ou
Sway full right to full left 14.0 17.0 14.0 17.0
ry
Sway full right to full left
de
with boom above 40
23.0 33.0 23.0 33.0
or
degrees and park brake
engaged
Sway full left to full right 12.0 14.0 to 12.0 13.5
om
Sway full left to full right
with boom above 40
t.c
26.0 52.0 26.0 52.0

degrees and park brake
en
engaged
m
Outriggers Extend Both 7.0 10.0 7.0 10.0

ip
Outriggers Retract Both 5.0 8.0 5.0 8.0

qu
*With standard fork tilt carriage installed.

-E
nt
ou
sc
Di
to
Go
2-6 31211388 6036, 6042, 8042, 10042, 10054, 12054

2.2.3 Electrical System
Battery
Type, Rating 12 BCI, Negative (-) Ground, Maintenance Free
Quantity 1
Cold Cranking Amps 3.8 Liter - 950 CCA @ 0° F (-18° C)
Reserve Capacity 205 Minutes @ 80° F (27° C)
Group/Series Group 31 - 950
ts
ar
Alternator 12V, 135 Amps
rp
2.2.4 Engine Performance Specifications
ou
a. 6036 & 6042
ry
de
Description If Equipped for ULS If Equipped for LS If Equipped w/ 74hp (55kW)
or
Engine Make/Model Cummins Turbo QSF3.8 Cummins Turbo QSF3.8 Cummins Turbo QSF3.8
232 in3 (3,8 liters) 232 in3 (3,8 liters) 232 in3 (3,8 liters)
to
Displacement
Low Idle (no load) 1000 rpm 1000 rpm 1000 rpm
om
High Idle (no load) 2500 rpm 2500 rpm 2500 rpm
t.c
Horsepower 85 hp (63 kW) @ 2500 rpm 85 hp (63 kW) @ 2500 rpm 74 hp (55 kW) @ 2500 rpm
en
Peak Torque 340 lb-ft (461 Nm) @ 1400 rpm 340 lb-ft (461 Nm) @ 1400 rpm 295 lb-ft (400 Nm) @ 1300 rpm
m
Fuel Delivery High Pressure Common Rail (HPCR) Fuel Injection

ip
Air Cleaner Dry Type, Replaceable Primary and Safety Elements

qu
-E
b. 8042, 10042, 10054 & 12054

nt
ou
Description If Equipped for ULS If Equipped for LS If Equipped w/ 74hp (55kW)

sc
Engine Make/Model Cummins Turbo QSF3.8 Cummins Turbo QSF3.8 Cummins Turbo QSF3.8
Di
Displacement 232 in3 (3,8 liters) 232 in3 (3,8 liters) 232 in3 (3,8 liters)
to
Low Idle 1000 rpm 1000 rpm 1000 rpm

Go
High Idle 2500 rpm 2500 rpm 2500 rpm

Horsepower 110 hp (82 kW) @ 2500 rpm 110 hp (82 kW) @ 2500 rpm 74 hp (55 kW) @ 2500 rpm
Peak Torque 348 lb-ft (472 Nm) @ 1500 rpm 348 lb-ft (472 Nm) @ 1500 rpm 295 lb-ft (400 Nm) @ 1300 rpm
Fuel Delivery High Pressure Common Rail (HPCR) Fuel Injection
Air Cleaner Dry Type, Replaceable Primary and Safety Elements
Note: No adjustment of the throttle is required. The engine Low Idle and High Idle are controlled by the engine ECM and cannot be
adjusted without Cummins programing tools.
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-7

2.2.5 Tires
Note: Standard wheel lug nut torque is 350 - 400 lb-ft (474 - 542 Nm).
Note: Pressure for foam filled tires are for initial fill ONLY.
a. 6036
Size Tire Type Minimum Ply/ Fill Type Pressure

Star Rating
Pneumatic 70 psi (4,8 bar)
13.0 x 24 G-2/L2 Bias Ply Traction 12 Ply
ts
Foam - Approx 542 lb (246 kg)
ar
315/95x28 Solid Tires NA NA NA
rp
370/75x28 DuraForce 14 Ply
ou
ry
b. 6042
de
or
Star Rating
to
G-2/L-2 Bias Ply Traction
13.0 x 24 12 Ply Foam - Approx 542 lb (246 kg)
om
TG/G-3 Bias Ply Grader Foam - Approx 542 lb (246 kg)
t.c

en

m
c. 8042
ip
qu

-E
Star Rating
nt
15.5 x 25 G-2/L-2 Bias Ply Traction 12 Ply

ou

sc

Di

to
d. 10042 & 10054

Go

Star Rating
16 Ply Pneumatic 60 psi (4,1 bar)
17.50 x 25 G-2/L-2 Bias Ply Traction
12 Ply Foam - Approx 785 lb (356 kg)
2-8 31211388 6036, 6042, 8042, 10042, 10054, 12054

e. 12054

Star Rating
16 Ply Pneumatic 65 psi (4,5 bar)
17.50 x 25 G-2/L-2 Bias Ply Traction
12 Ply Foam - Approx 785 lb (356 kg)
400/75x28 TLH 753 18 Ply
ts
ar
rp
ou
ry
de
or
to
om
t.c
en
m
ip
qu
-E
nt
ou
sc
Di
to
Go
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-9

2.3 FLUID & LUBRICANT CAPACITIES
2.3.1 Fluids
a. If Equipped for ULS

Ambient Temperature
Range
Compartment or System Type and Classification Viscosities
°F °C
Min Max Min Max
SAE 5W-40 -12 114 -24 45
ts
ar
SAE 15W-40 15 114 -10 45
Engine Crankcase API CJ-4 Plus CES-20081 Fully Synthetic* SAE 10W-30 10 104 -12 40
rp
SAE 5W-30 -12 104 -24 40
ou
SAE 0W-30 -40 32 -40 0
ry
MobilFluid 424 10W-30 -4 120 -20 49
Transmission and Transfer Case
ZF TE-ML-03 75W-80 -20 15 -29 -10
de
75W-90 LS -20 114 -29 45
or
API GL5 with 80W-90 LS
Axle Differential and Wheel End
LS Additives or -4 114 -20 45
to 85W-90 LS
om
MobilFluid 424 10W-30 15 120 -10 49
Hydraulic System
Exxon Univis HVI -20 120 -29 49
t.c
Boom Wear Pad Grease Mystik Tetrimoly NLGI Grade 2 -4 104 -20 40
en
NLGI Grade 2 EP
m
or
ip
Grease Fittings Extreme Pressure Grease NLGI Grade 3 EP 5 114 -15 45

qu
with Moly
-E
Additive
nt
Boom Chain Lubricant Gear Oil 80W-90 -20 114 -29 45

Ethylene Glycol 50/50 Mix Standard
ou
Engine Coolant
and Water 60/40 Mix Cold Weather
sc
EN590
Di
ASTM D975 Grade 1-D Ultra Low Sulfur

Fuel
ASTM D975 Grade 2-D (S <15 mg/kg)
to
(Maximum B5 Biodiesel)
Go
Diesel Exhaust Fluid (DEF)

ISO22241-1 32.5% Urea
(85 or 110 HP)
Brake Fluid Mobil ATF-D/M -20 114 -29 45
Air Conditioning Refrigerant R-134A Tetrafluoroethane
Note: *See Note on page 2-16 for details.
2-10 31211388 6036, 6042, 8042, 10042, 10054, 12054

b. If Equipped for LS
Ambient
Temperature Range
Compartment or System Type and Classification Viscosities
°F °C
Min Max Min Max
SAE 5W-40 -12 114 -24 45
SAE 15W-40 15 114 -10 45
API CI-4 Multigrade
Engine Crankcase SAE 10W-30 10 104 -12 40
CES-20078
ts
SAE 5W-30 -12 104 -24 40
ar
SAE 0W-30 -40 32 -40 0
rp
Mobilfluid 424 10W-30 -4 120 -20 49
Transmission and Transfer Case
ZF TE-ML-03 75W-80 -20 15 -29 -10
ou
75W-90 LS -20 114 -29 45
ry
API GL5 with 80W-90 LS
Axle Differential and Wheel End
LS Additives or -4 114 -20 45
de
85W-90 LS
or
MobilFluid 424 10W-30 15 120 -10 49
Hydraulic System
to
Exxon Univis HVI -20 120 -29 49
Boom Wear Pad Grease Mystik Tetrimoly NLGI Grade 2 -4 104 -20 40
om
NLGI Grade 2 EP
t.c
or
Grease Fittings Extreme Pressure Grease NLGI Grade 3 EP 5 114 -15 45
en
with Moly
m
Additive
ip
Boom Chain Lubricant Gear Oil 80W-90 -20 114 -29 45

qu
Ethylene Glycol 50/50 Mix Standard

-E
Engine Coolant
and Water 60/40 Mix Cold Weather
nt
EN590
ou
ASTM D975 Grade 1-D Low Sulfur

Fuel
ASTM D975 Grade 2-D (S < 500 mg/kg)
sc
(Maximum B5 Biodiesel)
Di
Brake Fluid Mobil ATF-D/M -20 114 -29 45

Air Conditioning Refrigerant R-134A Tetrafluoroethane
to
Go
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-11

2.3.2 Capacities
Engine Crankcase Oil

Capacity w/Filter Change 12.7 quart (12,0 liter)
Fuel Tank
Capacity 35 gallon (133 liter)
DEF Tank (if equipped for ULS 85 or 110 hp (63kW or 82kW)
Capacity 5 gallon (19 liter)
ts
ar
Cooling System
rp
System Capacity 5 gallon (19 liter)
ou
Hydraulic System
ry
System Capacity
6036, 6042 & 8042 46 gallon (174 liter)
de
10042 & 10054 52 gallon (196,8 liter)
or
12054 50 gallon (188 liter)
Reservoir Capacity to Full Mark to 20.2 gallon (76,5 liter)
om
Transmission
t.c
Capacity with Filter Change 12.4 quart (11,8 liter)

en
Axles
m
Differential Housing Capacity

ip
6036 & 6042 6.6 quart (6,3 liter)

qu
8042
-E
Front Axle 7.9 quart (7,5 liter)

nt
ou
Rear Axle 8.2 quart (7,8 liter)

10042 & 10054
sc
Di
Front Axle 12.7 quart (12 liter)

to
12054
Go
Front Axle 12.7 quart (12 liter)

Note: If axle fluid does not contain LS Additives, Friction Modifier may be added when replacing fluid. Pre-mix before placing in
axle differential. Not pre-mixing fluids can lead to excessive brake noise.
2-12 31211388 6036, 6042, 8042, 10042, 10054, 12054

Wheel End Capacity

6036 & 6042 1.9 quart (1,8 liter)
8042 2.1 quart (2 liter)
10042, 10054 & 12054
Front Axle 1.9 quart (1,8 liter)
Rear Axle 2.1 quart (2 liter)
Window Washer Bottle (if equipped)
ts
Capacity 2.2 quart (2,1 liter)
ar
Air Conditioning System (if equipped)
rp
Capacity 1.9 lbs (0,86 kg)
ou
ry
de
or
to
om
t.c
en
m
ip
qu
-E
nt
ou
sc
Di
to
Go
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-13

2.4 SERVICE AND MAINTENANCE

SCHEDULES
Note: If hour and year intervals are listed, perform maintenance at interval that occurs first.
2.4.1 Every 10 Hours
ts
OC0960 OC0970 OC0910 OC0920 OC0930 OC0890
ar
Drain Fuel/Water Check Engine Check Engine Oil Check Hydraulic Check Check Tire
Separator Coolant Level Level Oil Level Transmission Oil Condition and
rp
Level Pressure
ou
ry
de
OC0950 OC0880 OC0940 OC0900
or
Check Air Cleaner Check Fuel Level Check DEF Level (if Check Brake Fluid
to
equipped for ULS/ Level
85 or 110HP)
om
2.4.2 First 50 Hours

t.c
en
m
ip
OC1000 OC0990
qu
Check Boom Chain Check Wheel Lug

Tension Nut Torque
-E
nt

ou
sc
G
MP
Di
OC1020 OC1010
to
Check Washer Lubrication

Go
Fluid Schedule
OC1040 OC1050 OC1070
Change Axle Oil Change Wheel End Change

Oil Transmission Fluid
and Filter
2-14 31211388 6036, 6042, 8042, 10042, 10054, 12054

G
MP
OC1010 OC1110 OC1130 OC1090 OC1080
Lubrication Check Axle Oil Check Wheel End Check Boom Wear Check Boom
Schedule Level Oil Level Pads Chains
ts
ar
rp
ou
OC1140
Change Engine Oil
ry
and Filter (if
equipped for ULS)
de
or
to
om
t.c
OC1160 OC1140 OC1150 OC0990
Check Fan Belt Change Engine Oil Check Battery Check Wheel Lug
en
and Filter (if Not Torque

equipped for LS)
m
ip

qu
-E
nt
ou
OCXXX6 MAE41060G
sc
Change Change Hydraulic

Hydraulic Fluid Tank Breather (if
Di
equipped for ULS)

to
Go
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-15

G
MP
OC1010 OC1040 OC1050 OC1140 OC1070 OC1000
Lubrication Change Axle Oil Change Wheel End Change Engine Oil Change Check Boom
Schedule Oil and Filter (if Transmission Fluid Chain Tension
equipped for ULS) and Filter
ts
ar
rp
OCXXX7 OC1210 OC1220 OC1200
Grease Boom Check Park Brake Change Check Air Intake
ou
Chains Fuel Filters System
ry
Note: If using fully synthetic oil, metal engine oil filter and fuel consumption is less than 11.4 liter per hour (3 gallon per hour), oil
change intervals are 1,000 hours or 1 year. If any of the following are present, conventional oil, plastic engine oil filter or fuel
de
consumption is greater than 11.4 liter per hour (3 gallon per hour), oil change intervals are 500 hours or 6 months.
or
to
om
t.c
OC1230
en
Change Hydraulic
m
Fluid and Filters

ip
2.4.11 Every 2000 Hours or 2 Year

qu
-E
nt
ou
OC1310 OC1250
sc
OC1240
Di
Change Engine Change Change Engine

Coolant and Clean DEF Tank Filter Coolant (if
to
DEF Engine (if equipped for equipped for LS)

Coolant Strainer ULS/85 or 110 HP)
Go
(if equipped for

ULS/85 or 110HP)
2-16 31211388 6036, 6042, 8042, 10042, 10054, 12054

2.4.12 Every 4000 Hours or 3 Years
OC1260
Change
DEF Pump Filter
(if equipped for
ULS/85 or 110HP)
ts
2.4.13 Every 5000 Hours or 4 Years
ar
rp
ou
ry
OC1270
de
Engine Valve Lash
Adjustment
or
to
om
t.c
en
m
ip
qu
-E
nt
ou
sc
Di
to
Go
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-17

2.5 LUBRICATION SCHEDULES
2.5.1 50 Hour
a. 6036 & 6042
EVERY
ts
50
ar
rp
ou
ry
de
or
to
om
t.c
en
m
ip
qu
-E
nt
ou
sc
Di
to
Go
OH5721
2-18 31211388 6036, 6042, 8042, 10042, 10054, 12054

b. 8042 & 10042
EVERY
50
ts
ar
rp
ou
ry
de
or
to
om
t.c
en
m
ip
qu
-E
nt
ou
sc
Di
OH5731
to
Go
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-19

c. 10054 & 12054
EVERY
50
ts
ar
rp
ou
ry
de
or
to
om
t.c
en
m
ip
qu
-E
nt
ou
sc
Di
to
OH5711
Go
2-20 31211388 6036, 6042, 8042, 10042, 10054, 12054

2.5.2 250 Hour
a. 6036 & 6042
EVERY
ts
ar
250
rp
ou
ry
6042 ONLY
de
or
to
om
t.c
en
m
ip
qu
-E
nt
ou
sc
Di
to
Go
MAE41940
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-21

b. 8042, 10042, 10054 & 12054
EVERY
rts
250
pa
ur
ryo
de
or
to
om
t.c
en
m
ip
qu
-E
nt
ou
sc
Di
to
Go
OH4172
2-22 31211388 6036, 6042, 8042, 10042, 10054, 12054

2.5.3 1000 Hour
rts
EVERY
1000
pa
ur
r yo
de
or
to
om
t.c
en
m
ip
qu
-E
nt
ou
sc
Di
to
Go
OH4181
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-23

2.6 THREADLOCKING COMPOUND
JLG PN Loctite® ND Industries Description

0100011 242™ Vibra-TITE™ 121 Medium Strength (Blue)
1001095650 243™ Vibra-TITE™ 122 Medium Strength (Blue)
0100019 271™ Vibra-TITE™ 140 High Strength (Red)
0100071 262™ Vibra-TITE™ 131 Medium - High Strength (Red)
Note: Loctite® 243™ can be substituted in place of Loctite® 242™. Vibra-TITE™ 122 can be substituted in place of Vibra-TITE™ 121.
rts
pa
ur
r yo
de
or
to
om
t.c
en
m
ip
qu
-E
nt
ou
sc
Di
to
Go
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-25

2.7 TORQUE CHARTS
2.7.1 SAE Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)
SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque
Torque
Tensile Stress Clamp Torque Torque (Loctite® 242™ or 271™ or
Size TPI Bolt Dia (Loctite® 262™ or
Area Load (Dry) Lubricated Vibra-TITE™
Vibra-TITE™ 131)
111 or 140)
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
rts
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
pa
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
ur
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
yo
10 24 0.1900 0.01750 1120 43 4.8 32 3.5
32 0.1900 0.02000 1285 49 5.5 36 4
r
de
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
or
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
3/8
24
16
0.3125
0.3750
0.0580
0.0775
3700
4940
19
30
26
41
14
23 to 19
31
21
35
29
48
17
28
23
38
om
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
t.c
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
en
20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108

m
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
ip
5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183
qu
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
-E
16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363
nt
7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523
ou
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
sc
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
Di
12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087
to
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
Go
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
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
2-26 31211388 6036, 6042, 8042, 10042, 10054, 12054

2.7.1 SAE Fastener Torque Chart (Continued)
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Torque Torque
Torque (Loctite® 242™ or 271™ or
Tensile Stress Clamp (Loctite® 262™ or
Size TPI Bolt Dia (Dry or Loctite® 263)
Area Load Vibra-TITE™ 111 or 140) Vibra-TITE™ 131)
K=0.20
K=0.18 K=0.15
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
rts
40 0.1380 0.01015
pa
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 43 5
10 24 0.1900 0.01750 1580 60 7
ur
32 0.1900 0.02000 1800 68 8
yo
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
r
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
de
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
or
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
to
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
om
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
t.c
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
en
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
m
18 0.6250 0.2560 23000 240 325 215 290 180 245

ip
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
qu
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
-E
14 0.8750 0.5090 45800 670 910 600 815 500 680

nt
1 8 1.0000 0.6060 51500 860 1170 770 1045 645 875

12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
ou
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
sc
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
Di
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
to
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
Go
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-27

Values for Magni Coating Fasteners (Ref 4150701)

SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque Torque
Size TPI Bolt Dia (Dry)
K=0.17
K=0.16 K=0.15
4 40 0.1120 0.00604 380 7 0.8
48 0.1120 0.00661 420 8 0.9
rts
6 32 0.1380 0.00909 580 14 1.5
40 0.1380 0.01015 610 14 1.6
pa
8 32 0.1640 0.01400 900 25 2.8
36 0.1640 0.01474 940 26 2.9
ur
10 24 0.1900 0.01750 1120 36 4.1
yo
32 0.1900 0.02000 1285 42 4.7
1/4 20 0.2500 0.0318 2020 86 9.7 80 9
r
28 0.2500 0.0364 2320 99 11.1 95 11
de
5/16 18 0.3125 0.0524 3340 15 20 14 19 15 20
or
24 0.3125 0.0580 3700 15 20 15 21 15 20
to
3/8 16 0.3750 0.0775 4940 25 35 25 34 25 34
24 0.3750 0.0878 5600 30 40 28 38 25 34
om
7/16 14 0.4375 0.1063 6800 40 55 40 54 35 48
20 0.4375 0.1187 7550 45 60 44 60 40 54
1/2 13 0.5000 0.1419 9050 65 90 60 82 55 75
t.c
20 0.5000 0.1599 10700 75 100 71 97 65 88

en
9/16 12 0.5625 0.1820 11600 90 120 87 118 80 109

18 0.5625 0.2030 12950 105 145 97 132 90 122
m
5/8 11 0.6250 0.2260 14400 130 175 120 163 115 156
ip
18 0.6250 0.2560 16300 145 195 136 185 125 170

3/4 10 0.7500 0.3340 21300 225 305 213 290 200 272
qu
16 0.7500 0.3730 23800 255 345 238 324 225 306

-E
7/8 9 0.8750 0.4620 29400 365 495 343 466 320 435
14 0.8750 0.5090 32400 400 545 378 514 355 483
nt
1 8 1.0000 0.6060 38600 545 740 515 700 480 653

ou
12 1.0000 0.6630 42200 600 815 563 765 530 721

1 1/8 7 1.1250 0.7630 42300 675 920 635 863 595 809
sc
12 1.1250 0.8560 47500 755 1025 713 969 670 911

Di
1 1/4 7 1.2500 0.9690 53800 955 1300 897 1219 840 1142
12 1.2500 1.0730 59600 1055 1435 993 1351 930 1265
to
1 3/8 6 1.3750 1.1550 64100 1250 1700 1175 1598 1100 1496
12 1.3750 1.3150 73000 1420 1930 1338 1820 1255 1707
Go
1 1/2 6 1.5000 1.4050 78000 1660 2260 1560 2122 1465 1992
12 1.5000 1.5800 87700 1865 2535 1754 2385 1645 2237
2-28 31211388 6036, 6042, 8042, 10042, 10054, 12054


SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Torque Torque
Size TPI Bolt Dia (Dry or Loctite® 263)
K=0.17
K=0.16 K=0.15
4 40 0.1120 0.00604
48 0.1120 0.00661
rts
6 32 0.1380 0.00909
40 0.1380 0.01015
pa
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 37 4
ur
10 24 0.1900 0.01750 1580 51 6
yo
32 0.1900 0.02000 1800 58 7
1/4 20 0.2500 0.0318 2860 122 14 114 13
r
28 0.2500 0.0364 3280 139 16 131 15
de
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
or
24 0.3125 0.0580 5220 25 35 20 25 20 25
to
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
om
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
t.c
20 0.5000 0.1599 14400 100 135 95 130 90 120

en
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
m
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
ip
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
qu
16 0.7500 0.3730 33600 355 485 335 455 315 430

-E
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
nt
1 8 1.0000 0.6060 51500 730 995 685 930 645 875

ou
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
sc
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475

Di
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
to
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
Go
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
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-29


SOCKET HEAD CAPSCREWS
Torque Torque
Tensile Stress Clamp Load Torque (Loctite® 242™ or 271™ or (Loctite® 262™ or
Size TPI Bolt Dia
Area See Note 4 (Dry) K=0.17 Vibra-TITE™ 111 or 140) or Vibra-TITE™ 131)
Precoat® 85 K=0.16 K=0.15
4 40 0.1120 0.00604
48 0.1120 0.00661
rts
6 32 0.1380 0.00909
40 0.1380 0.01015
pa
8 32 0.1640 0.01400
36 0.1640 0.01474
ur
10 24 0.1900 0.01750
yo
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
r
28 0.2500 0.0364 3280 139 16 131 15
de
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
or
24 0.3125 0.0580 5220 25 35 20 25 20 25
to
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
om
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
t.c
20 0.5000 0.1599 14400 100 135 95 130 90 120

en
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
m
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
ip
18 0.6250 0.2560 23000 205 280 190 260 180 245

3/4 10 0.7500 0.3340 30100 320 435 300 415 280 380
qu
16 0.7500 0.3730 33600 355 485 335 455 315 430

-E
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
nt
1 8 1.0000 0.6060 51500 730 995 685 930 645 875

ou
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
sc
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475

Di
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
to
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
Go
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
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS.
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED
2-30 31211388 6036, 6042, 8042, 10042, 10054, 12054

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

SOCKET HEAD CAPSCREWS
Torque Torque
Tensile Stress Clamp Load Torque (Loctite® 242™ or 271™ or (Loctite® 262™ or
Size TPI Bolt Dia
Area See Note 4 (Dry) K=0.17 Vibra-TITE® 111 or 140) or Vibra-TITE™ 131)
Precoat® 85 K=0.16 K=0.15
4 40 0.1120 0.00604
48 0.1120 0.00661
ts
6 32 0.1380 0.00909
ar
40 0.1380 0.01015
rp
8 32 0.1640 0.01400
36 0.1640 0.01474
ou
10 24 0.1900 0.01750
ry
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
de
28 0.2500 0.0364 3280 139 16 131 15
or
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
to
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
om
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
t.c
20 0.4375 0.1187 10700 65 90 60 80 60 80

en
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
m
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
ip
18 0.5625 0.2030 18250 145 195 135 185 130 175

qu
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
-E
3/4 10 0.7500 0.3340 30100 320 435 300 415 280 380
nt
16 0.7500 0.3730 33600 355 485 335 455 315 430

ou
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
sc
1 8 1.0000 0.6060 51500 730 995 685 930 645 875

Di
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
to
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475

Go
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
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-31

2.7.2 Metric Fastener Torque Chart

CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS
Torque
Torque
Tensile Stress Clamp Load Torque (Loctite® 262™ or 271™ or (Loctite® 242™ or 271™ or
Size Pitch Torque (Lube)
Area See Note 4 (Dry or Loctite® 263™) Vibra-TITE™ 111
Vibra-TITE™ 131)
or 141)
Sq mm KN [N.m] [N.m] [N.m]

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4
rts
3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3
pa
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
ur
6 1 20.10 8.74 11 7.9 9.4 12
yo
7 1 28.90 12.6 18 13 16 19
r
8 1.25 36.60 15.9 26 19 23 28
de
10 1.5 58.00 25.2 50 38 45 55
or
12 1.75 84.30 36.7 88 66 79 97
to
14 2 115 50.0 140 105 126 154
16 2 157 68.3 219 164 197 241

om
18 2.5 192 83.5 301 226 271 331
t.c
20 2.5 245 106.5 426 320 383 469
22 2.5 303 132.0 581 436 523 639

en
24 3 353 153.5 737 553 663 811

m
27 3 459 199.5 1080 810 970 1130

ip
30 3.5 561 244.0 1460 1100 1320 1530

qu
33 3.5 694 302.0 1990 1490 1790 2090

-E
36 4 817 355.5 2560 1920 2300 2690

nt
42 4.5 1120 487.0 4090 3070 3680 4290

ou
sc
Di

to
Go
2-32 31211388 6036, 6042, 8042, 10042, 10054, 12054

2.7.2 Metric Fastener Torque Chart (Continued)

CLASS 10.9 METRIC (HEX HEAD) BOLTS,
CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAPSCREWS M3 - M5*
Torque
Torque
Torque (Lube or Loctite®
Tensile Stress Clamp Load 242™ or 271™ or (Loctite® 262™ or
Size Pitch (Dry or Loctite® 263™)
Area See Note 4 Vibra-TITE™ 131)
K=0.20 Vibra-TITE™ 111 or 140)
K=0.15
K=0.18
3 0.5 5.03 3.13
ts
3.5 0.6 6.78 4.22
ar
4 0.7 8.78 5.47
rp
5 0.8 14.20 8.85
ou
6 1 20.10 12.5
7 1 28.90 18.0 25 23 19
ry
8 1.25 36.60 22.8 37 33 27
de
10 1.5 58.00 36.1 70 65 55
or
12 1.75 84.30 52.5 125 115 95
14 2 115 71.6 200 180 150
16 2 157 97.8
to
315 280 235
om
18 2.5 192 119.5 430 385 325
20 2.5 245 152.5 610 550 460

t.c
22 2.5 303 189.0 830 750 625

en
24 3 353 222.0 1065 960 800

m
27 3 459 286.0 1545 1390 1160

ip
30 3.5 561 349.5 2095 1885 1575

qu
33 3.5 694 432.5 2855 2570 2140
36 4 817 509.0 3665 3300 2750

-E
42 4.5 1120 698.0 5865 5275 4395

nt
ou
sc
Di

to
Go
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-33

Values for Magni Coated Fasteners (Ref 4150701)*

CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS
Torque Torque
Torque (Lube or Loctite® 242™ or (Loctite® 262™ or
Clamp Load
Size Pitch Tensile Stress Area (Dry or Loctite® 263™) 271™ or Vibra-TITE™ 131)
See Note 4
K=0.17 Vibra-TITE™ 111 or 140) K=0.15
K=0.16
3 0.5 5.03 2.19 1.1 1.1 1.0
ts
3.5 0.6 6.78 2.95 1.8 1.7 1.5
ar
4 0.7 8.78 3.82 2.6 2.4 2.3
rp
5 0.8 14.20 6.18 5.3 4.9 4.6
6 1 20.10 8.74 9 8.4 7.9
ou
7 1 28.90 12.6 15 14 13
ry
8 1.25 36.60 15.9 22 20 19
de
10 1.5 58.00 25.2 43 40 38
or
12 1.75 84.30 36.7 75 70 66
14 2 115 50.0 119 110 105
16 2 157 68.3 186

to 175 165
om
18 2.5 192 83.5 256 240 225
20 2.5 245 106.5 362 340 320

t.c
22 2.5 303 132.0 494 465 435

en
24 3 353 153.5 627 590 555
27 3 459 199.5 916 860 810

m
ip
30 3.5 561 244.0 1245 1170 1100

qu
33 3.5 694 302.0 1694 1595 1495
36 4 817 355.5 2176 2050 1920

-E
42 4.5 1120 487.0 3477 3275 3070

nt
ou
sc

Di
to
Go
2-34 31211388 6036, 6042, 8042, 10042, 10054, 12054

Values for Magni Coated Fasteners (Ref 4150701)*

CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS,
CLASS 12.9 SOCKET HEAD CAPSCREWS M6 AND ABOVE*
Torque
Torque
Torque (Lube or Loctite®
Clamp Load See 242™ or 271™ or (Loctite® 262™ or
Size Pitch Tensile Stress Area (Dry or Loctite® 263™)
Note 4 Vibra-TITE™ 131)
K=0.17 Vibra-TITE™ 111 or 140)
K=0.15
K=0.18
3 0.5 5.03 3.13
ts
3.5 0.6 6.78 4.22
ar
4 0.7 8.78 5.47
rp
5 0.8 14.20 8.85
ou
6 1 20.10 12.5 13 12 11
ry
7 1 28.90 18.0 21 20 19
8 1.25 36.60 22.8 31 29 27
de
10 1.5 58.00 36.1 61 58 55
or
12 1.75 84.30 52.5 105 100 95
to
14 2 115 71.6 170 160 150
16 2 157 97.8 265 250 235

om
18 2.5 192 119.5 365 345 325
t.c
20 2.5 245 152.5 520 490 460
22 2.5 303 189.0 705 665 625

en
24 3 353 222.0 905 850 800

m
27 3 459 286.0 1315 1235 1160

ip
30 3.5 561 349.5 1780 1680 1575

qu
33 3.5 694 432.5 2425 2285 2140

-E
36 4 817 509.0 3115 2930 2750

nt
42 4.5 1120 698.0 4985 4690 4395

ou
sc
Di

to
Go
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-35

2.8 HYDRAULIC CONNECTION ASSEMBLY SAE - 45° flare per SAE J512
AND TORQUE SPECIFICATION
2.8.1 Definitions
a. Tapered Thread Types
NPTF - National tapered fuel (dry seal) per SAE J476/J512

MAE9030
ts
ORFS - O-ring face seal per SAE J1453
ar
rp
ou
ry
de
or
MAE9000 MAE9040
BSPT - British standard pipe tapered per ISO7-1 to

MBTL - Metric flareless bite type fitting, pressure rating L
om
(medium) per ISO 8434, DIN 2353
MBTS - Metric flareless bite type fitting, pressure rating S (high)
t.c
per ISO 8434, DIN 2353

en
m
ip
qu
ÖD
24˚
ÖA
ÖA
-E
C
nt
without O-ring
with O-ring MAE42120
ou
MAE9010
sc
BH - Bulkhead connection – JIC, ORFS, MBTL, or MBTS types

Di
b. Straight Thread Types, Tube and Hose Connections

to
JIC - 37° flare per SAE J514

Go
MAE9020 MAE9060
2-36 31211388 6036, 6042, 8042, 10042, 10054, 12054

c. Straight Thread Types, Port Connections d. Flange Connection Types

FL61 - Code 61 flange per SAE J518, ISO 6162
ORB - O-ring boss per SAE J1926, ISO 11926
FL62 - Code 62 flange per SAE J518, ISO 6162
MPP - Metric pipe parallel o-ring boss per SAE J2244,
ISO 6149, DIN 3852
ts
ar
rp
MAE9090
ou
MAE9070
e. Tightening Methods
ry
MFF - Metric flat face port per ISO 9974-1 Torque - Application of a twisting force to the applicable
de
connection by use of a precise measurement instrument
BSPP - British standard parallel pipe per ISO 1179-1,
or
(i.e. torque wrench).
DIN 3852-2
Finger Tight (Hand Tight) - The point where the connector
to
will no longer thread onto the mating part when tightened
om
by hand or fingers. Finger Tight is relative to user strength
and will have some variance. The average torque applied by
t.c
this method is 3 ft-lb (4 Nm).

en
TFFT - Turns From Finger Tight; Application of a preload to a

connection by first tightening the connection by
m
hand (fingers) and applying an additional rotation counted

ip
by a defined number of turns by use of a tool.

qu
FFWR (Flat method) - Flats From Wrench Resistance;

-E
Application of a preload to a connection by tightening to

the point of initial wrench resistance and turning the nut a
nt
described number of flats. A flat is one side of the hexagonal

ou
tube nut and equates to 1/6 of a turn.

sc
f. Assembly and Torque Specifications

Di
MAE9080
Prior to selecting the appropriate torque from the tables
to
within this section, it is necessary to properly identify the

connector being installed.
Go
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-37

g. General Tube Type Fitting Assembly Instructions 5. To achieve the specified torque, the torque wrench is to
be held perpendicular to the axis of rotation.
1. Take precautions to ensure that fittings and mating
components are not damaged during storage, handling
or assembly. Nicks and scratches in sealing surfaces can
create a path for leaks which could lead to component
contamination and/or failure.
2. When making a connection to tubing, compression or
flare, inspect the tube in the area of the fitting
attachment to ensure that the tube has not been
damaged.
ts
3. The assembly process is one of the leading causes for
ar
contamination in air and hydraulic systems.
rp
Contamination can prevent proper tightening of fittings
and adapters from occurring.
ou
MAE9100
a. Avoid using dirty or oily rags when handling fittings.
ry
6. Refer to the appropriate section in this manual for more
b. If fittings are disassembled, they should be cleaned specific instructions and procedures for each type of
de
and inspected for damage. Replace fittings as fitting connection.
necessary before reinstalling.
or
c. Sealing compounds should be applied where
to
specified; however, care should be taken not to
introduce sealant into the system.
om
d. Avoid applying sealant to the area of the threads
where the sealant will be forced into the system.
t.c
This is generally the first two threads of a fitting.

en
e. Sealant should only be applied to the male threads.

f. Straight thread fittings do not require sealants.
m
O-rings or washers are provided for sealing.

ip
g. When replacing or installing an o-ring, care is to be

qu
taken while transferring the o-ring over the threads

as it may become nicked or torn. When replacing an
-E
o-ring on a fitting, the use of a thread protector is

nt
recommended.
ou
h. When installing fittings with o-rings, lubrication

shall be used to prevent scuffing or tearing of the
sc
o-ring. Refer to Section 2.8.17, “O-ring Installation

Di
(Replacement).”, for procedure.

4. Take care to identify the material of parts to apply the
to
correct torque values.

Go
a. Verify the material designation in the table headings

b. If specifications are given only for steel fittings and
components, the values for alternate materials shall
be as follows:
Aluminum and Brass - reduce steel values by 35%
Stainless Steel - Use the upper limit for steel.
2-38 31211388 6036, 6042, 8042, 10042, 10054, 12054

2.8.2 Assembly Instructions for American

Standard Pipe Thread Tapered
Connections
1. Inspect components to ensure male and female port
NOTICE
threads are free of rust, splits, dirt, foreign matter, or Never back off (loosen) pipe threaded connectors to
burrs. achieve alignment. Meet the minimum required turns
2. Apply a suitable thread sealant, such as low strength and use the last turn for alignment.
threadlocking compound, to the male pipe threads if
not already applied. Ensure the first 1 to 2 threads are 5. Rotate male fitting the number of turns as per below
uncovered to prevent system contamination. mentioned table. Refer to Section 2.8.15, “FFWR and
ts
3. Assemble connection hand tight. TFFT Methods.”, for procedure.
ar
4. Mark fittings, male and female Note: TFFT values provided in below mentioned table are
rp
applicable for the following material configurations:
a. Steel fittings with steel mating components
ou
NOTICE b. Steel fittings with aluminum or brass mating
ry
components
de
Over tightening may cause deformation of the pipe c. Aluminum or brass fittings with steel mating
fitting and damage to the joining fitting, flange or components
or
component may occur. d. Aluminum or brass fittings with aluminum or brass
to
mating components.
om
a. NPTF Pipe Thread
t.c
en
m
ip
qu
MAE9110
-E
nt
TYPE/FITTING IDENTIFICATION
ou
Turns From Finger Tight

Thread Size ØA*
(TFFT)**
sc
Material Dash Size

(UNF) (in) (mm)
Di
2 1/8 - 27 0.40 10.24 2 to 3

to
4 1/4 - 18 0.54 13.61 2 to 3

Go
STEEL, ALUMINUM, OR 6 3/8 - 18 0.67 17.05 2 to 3

BRASS FITTINGS
8 1/2 - 14 0.84 21.22 2 to 3
WITH STEEL,
ALUMINUM, OR 12 3/4 - 14 1.05 26.56 2 to 3
BRASS
16 1 - 11 1/2 1.31 33.22 1.5 to 2.5
MATING
COMPONENTS 20 1 1/4 - 11 1/2 1.65 41.98 1.5 to 2.5
24 1 1/2 - 11 1/2 1.89 48.05 1.5 to 2.5
32 2 - 11 1/2 2.37 60.09 1.5 to 2.5
NOTE: * ØA thread dimension for reference only.

** Refer to Section 2.8.15, “FFWR and TFFT Methods.”, for TFFT procedure requirements.
2-40 31211388 6036, 6042, 8042, 10042, 10054, 12054

2.8.3 Assembly Instructions for British

Standard Pipe Thread Tapered
Connections
1. Inspect components to ensure male and female port
NOTICE
threads are free of rust, splits, dirt, foreign matter, or Never back off (loosen) pipe threaded connectors to
burrs. achieve alignment. Meet the minimum required turns
2. Apply a suitable thread sealant, such as low strength and use the last turn for alignment.
threadlocking compound, to the male pipe threads if
5. Rotate male fitting the number of turns as per below
not already applied. Ensure the first 1 to 2 threads are
mention table.
uncovered to prevent system contamination.
ts
3. Assemble connection hand tight. Note: TFFT values provided in below table are applicable for
ar
the following material configurations:
4. Mark fittings, male and female.
rp
a. Steel fittings with steel mating components
NOTICE
ou
b. Steel fittings with aluminum or brass mating
components
ry
c. Aluminum or brass fittings with steel mating
Over tightening may cause deformation of the pipe
de
components
fitting and damage to the joining fitting, flange or
d. Aluminum or brass fittings with aluminum or brass
or
component may occur.
mating components.
a. BSPT Pipe Thread to

om
t.c
en
m
ip
qu
MAE9120
-E
nt
Turns From Finger Tight
ou
Thread Size ØA* (TFFT)**

Material Dash Size
sc
(BSPT) (in) (mm)

Di
2 1/8 - 28 0.38 9.73 2 to 3

4 1/4 - 19 0.52 13.16 2 to 3
STEEL, ALUMINUM, OR
to
BRASS FITTINGS 6 3/8 - 19 0.66 16.66 2 to 3

8 1/2 - 14 0.83 20.96 2 to 3
Go
WITH STEEL,
ALUMINUM, OR 12 3/4 - 14 1.04 26.44 2 to 3
BRASS 16 1 - 11 1.31 33.25 1.5 to 2.5
MATING
20 1 1/4 - 11 1.65 41.91 1.5 to 2.5
COMPONENTS
24 1 1/2 - 11 1.88 47.80 1.5 to 2.5
32 2 - 11 2.35 59.61 1.5 to 2.5
NOTE: * ØA thread dimension for reference only.

** Refer to Section 2.8.15, “FFWR and TFFT Methods.”, for TFFT procedure requirements.
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-41

2.8.4 Assembly Instructions for 37° (JIC) Flare 3. Align tube to fitting and start threads by hand.
Fittings
1. Inspect the flare for obvious visual squareness NOTICE
2. and concentricity issues with the tube OD. Ensure that
surface is smooth, free of rust, weld and brazing splatter, The torque method should NOT be used on lubricated or
splits, dirt, foreign matter, or burrs. If necessary, replace oily fittings. No lubrication or sealant is required. The
fitting or adapter. lubrication would cause increased clamping force and
cause fitting damage.
NOTICE 4. Torque assembly to value listed in below mentioned
ts
table while using the Double Wrench Method.
ar
DO NOT force a misaligned or short hose/tube into Note: Torque values provided in below table are segregated
alignment. It puts undesirable strain onto the joint
rp
based on the material configuration of the connection.
eventually leading to leakage.
ou
a. 37° Flare (JIC) Thread - Steel
ry
de
or
to
om
MAE9130
t.c
en
TYPE/FITTING IDENTIFICATION Flats From

m
Thread ØA* ØB* [Ft-Lb] [Nm] Wrench

ip
Dash Size Resistance

Material Size
qu
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max (F.F.W.R)**
-E
2 5/16-24 0.28 7.00 0.31 7.75 6 7 7 8 9 10 --

nt
3 3/8-24 0.34 8.60 0.37 9.50 8 9 10 11 12 14 --

ou
4 7/16-20 0.39 10.00 0.44 11.10 13 14 14 18 19 19 1-1/2 to 1-3/4

sc
5 1/2-20 0.46 11.60 0.50 12.70 14 15 15 19 20 21 1 to 1-1/2

Di
6 9/16-18 0.51 13.00 0.56 14.30 22 23 24 30 31 33 1 to 1-1/2

STEEL FITTINGS
to
WITH STEEL 8 3/4-16 0.69 17.60 0.75 19.10 42 44 46 57 60 63 1-1/2 to 1-3/4

MATING
Go
10 7/8-14 0.81 20.50 0.87 22.20 60 63 66 81 85 89 1 to 1-1/2

COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 0.97 24.60 1.06 27.00 84 88 92 114 120 125 1 to 1-1/2
THREADS
14 1 3/16-12 1.11 28.30 1.19 30.10 100 105 110 136 142 149 1 to 1-1/2
16 1 5/16-12 1.23 31.30 1.31 33.30 118 124 130 160 168 176 3/4 to 1
20 1 5/8-12 1.54 39.20 1.63 41.30 168 176 185 228 239 251 3/4 to 1
24 1 7/8-12 1.80 45.60 1.87 47.60 195 205 215 264 278 291 3/4 to 1
32 2 1/2-12 2.42 61.50 2.50 63.50 265 278 292 359 377 395 3/4 to 1
NOTE: * ØA and ØB thread dimensions for reference only.

** Refer to Section 2.8.15, “FFWR and TFFT Methods.”, for FFWR procedure requirements.
2-42 31211388 6036, 6042, 8042, 10042, 10054, 12054

b. 37° Flare (JIC) Thread - Aluminum Brass
MAE9130
ts
ar
TYPE/FITTING IDENTIFICATION Flats From
rp
Thread ØA* ØB* [Ft-Lb] [Nm] Wrench
Dash Size Resistance
Material Size
ou
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max (F.F.W.R)**
ry
2 5/16-24 0.28 7.00 0.31 7.75 4 4 5 5 6 7 --
de
3 3/8-24 0.34 8.60 0.37 9.50 5 6 7 7 8 9 --
or
4 7/16-20 0.39 10.00 0.44 11.10 8 9 9 11 12 13 1-1/2 to 1-3/4
5 1/2-20 0.46 11.60 0.50 12.70 9 10 10 12 13 14 1 to 1-1/2
ALUMINUM/BRASS 6 9/16-18 0.51 13.00 0.56 14.30 to 14 15 16 19 20 21 1 to 1-1/2

om
FITTINGS OR
8 3/4-16 0.69 17.60 0.75 19.10 27 29 30 37 39 41 1-1/2 to 1-3/4
ALUMINUM/BRASS
t.c
MATING 10 7/8-14 0.81 20.50 0.87 22.20 39 41 43 53 56 58 1 to 1-1/2

COMPONENTS;
en
UN-LUBRICATED 12 1 1/16-12 0.97 24.60 1.06 27.00 55 57 60 74 78 81 1 to 1-1/2

m
THREADS 14 1 3/16-12 1.11 28.30 1.19 30.10 65 68 72 88 93 97 1 to 1-1/2

ip
16 1 5/16-12 1.23 31.30 1.31 33.30 77 81 84 104 109 114 3/4 to 1

qu
20 1 5/8-12 1.54 39.20 1.63 41.30 109 115 120 148 155 163 3/4 to 1
-E
24 1 7/8-12 1.80 45.60 1.87 47.60 127 133 139 172 180 189 3/4 to 1
nt
32 2 1/2-12 2.42 61.50 2.50 63.50 172 181 189 234 245 257 3/4 to 1
ou
sc

Di
to
Go
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-43

2.8.5 Assembly Instructions for 45° SAE Flare

Fittings
1. Inspect the flare for obvious visual squareness and
concentricity issues with the tube OD. Ensure that
surface is smooth, free of rust, weld and brazing splatter,
splits, dirt, foreign matter, or burrs. If necessary, replace
fitting or adapter.
NOTICE
ts
DO NOT force a misaligned or short hose/tube into
ar
alignment. It puts undesirable strain onto the joint
rp
eventually leading to leakage.
ou
2. Align tube to fitting.
ry
3. Tighten fitting by hand until hand tight.
de
NOTICE
or
The torque method should NOT be used on lubricated or
oily fittings. No lubrication or sealant is required. The to
om
lubrication would cause increased clamping force and
t.c
Torque fitting to value listed in below table while using the

en
Double Wrench Method outlined in this section.

m
Note: Torque values provided in below table are segregated

ip

qu
‘Aluminum/brass fittings or aluminum/brass mating

-E
components’ indicate either the following material

configurations:
nt
a. Steel fittings with aluminum or brass mating

ou
components
sc
b. Aluminum or brass fittings with steel mating

Di
components
c. Aluminum or brass fittings with aluminum or brass
to
mating components.
Go
2-44 31211388 6036, 6042, 8042, 10042, 10054, 12054

a. 45° Flare (SAE)
MAE9140
STEEL
ts
ar
TYPE/FITTING IDENTIFICATION TORQUE
rp
Thread ØA* ØB* [Ft-Lb] [Nm]
Dash Size
Material
ou
Size
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max
ry
4 7/16-20 0.39 9.90 0.44 11.10 13 14 14 18 19 19
de
STEEL FITTINGS
6 5/8-18 0.56 14.30 0.63 15.90 22 23 24 30 31 33
WITH STEEL MATING
or
COMPONENTS; 8 3/4-16 0.69 17.50 0.75 19.10 42 44 46 57 60 62
UN-LUBRICATED
THREADS 10 7/8-14 0.81 20.60 0.87
to
22.20 60 63 66 81 85 89
om
12 1 1/16-14 0.98 25.00 1.06 27.00 84 88 92 114 119 125
t.c

en
ALUMINUM BRASS
m

ip
Thread
qu
ØA* ØB* [Ft-Lb] [Nm]

Dash Size
Material Size
-E
nt
ALUMINUM/BRASS 4 7/16-20 0.39 9.90 0.44 11.10 8 9 9 11 12 12

ou
FITTINGS OR 6 5/8-18 0.56 14.30 0.63 15.90 14 15 15 19 20 20

sc
ALUMINUM/BRASS
MATING 8 3/4-16 0.69 17.50 0.75 19.10 27 29 30 37 39 41
Di
COMPONENTS;
UN-LUBRICATED 10 7/8-14 0.81 20.60 0.87 22.20 39 41 43 53 56 58
to
THREADS
12 1 1/16-14 0.98 25.00 1.06 27.00 55 58 61 75 79 83
Go
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-45

2.8.6 Assembly Instructions for O-Ring Face

Seal (ORFS) Fittings
1. Ensure proper o-ring is installed. If o-ring is missing
install per o-ring Installation (replacement). Refer to
Section 2.8.17, “O-ring Installation (Replacement),”, for
procedure.
2. Ensure that surface is smooth, free of rust, weld and
brazing splatter, splits, dirt, foreign matter, or burrs. If
necessary, replace fitting or adapter.
ts
ar
NOTICE
rp
ou
Care to be taken when lubricating o-ring. Avoid adding
oil to the threaded connection of the fitting. The
ry
de
or
3. Pre-lubricate the o-ring with hydraulic oil.
to
4. Place the tube assembly against the fitting body so that
the flat face comes in contact with the o-ring. Hand
om
thread the nut onto the fitting body.
5. Torque nut to value listed in below mentioned table
t.c
while using the Double Wrench Method. Refer to

en
Section 2.8.15, “FFWR and TFFT Methods,”, for

procedure if using the FFWR method.
m
Note: Torque values provided in below table are segregated

ip

qu
Aluminum/brass fittings or aluminum/brass mating

-E
components’ indicate either the following

nt
material configurations:
ou
a. Steel fittings with aluminum or brass mating

sc
components
Di
b. Aluminum or brass fittings with steel mating

components
to
c. Aluminum or brass fittings with aluminum or brass

mating components.
Go
2-46 31211388 6036, 6042, 8042, 10042, 10054, 12054

a. O-ring Face Seal (ORFS)
MAE9150
STEEL
ts
ar
rp
Thread
Dash ØA* ØB* [Ft-Lb] [Nm] Tube Swivel &
Size
ou
Material
Size Nuts Hose Ends
ry
4 9/16-18 0.51 13.00 0.56 14.20 18 19 20 25 26 27 1/4 to 1/2 1/2 to 3/4
de
6 11/16-16 0.63 15.90 0.69 17.50 30 32 33 40 43 45 1/4 to 1/2 1/2 to 3/4
8 13/16-16 0.75 19.10 0.81 20.60 40 42 44 55 57 60 1/4 to 1/2 1/2 to 3/4
or
STEEL FITTINGS
WITH 10 1-14 0.94 23.80 1.00 25.40 60 63 66 81 85 89 1/4 to 1/2 1/2 to 3/4
to
STEEL MATING
12 1 3/16-12 1.11 28.20 1.19 30.10 85 90 94 115 122 127 1/4 to 1/2 1/2 to 3/4
COMPONENTS;
om
UN-LUBRICATED 16 1 7/16-12 1.34 34.15 1.44 36.50 110 116 121 149 157 164 1/4 to 1/2 1/2 to 3/4
THREADS 20 1 11/16-12 1.59 40.50 1.69 42.90 150 158 165 203 214 224 1/4 to 1/2 1/2 to 3/4
t.c
24 2-12 1.92 48.80 2.00 50.80 230 242 253 312 328 343 1/4 to 1/2 1/2 to 3/4
en
32 2 1/2-12 2.43 61.67 2.50 63.50 375 394 413 508 534 560 1/4 to 1/2 1/2 to 3/4
m

ip
ALUMINUM/BRASS
qu
FLATS FROM
-E
WRENCH
nt
RESISTANCE
(F.F.W.R)**
ou
Thread
ØA* ØB* [Ft-Lb] [Nm]
sc
Dash Size Tube Swivel &

Material
Di
Size Nuts Hose Ends

to
4 9/16-18 0.51 13.00 0.56 14.20 12 13 13 16 18 18 1/4 to 1/2 1/2 to 3/4

Go
6 11/16-16 0.63 15.90 0.69 17.50 20 21 22 27 28 30 1/4 to 1/2 1/2 to 3/4

ALUMINUM/BRASS 8 13/16-16 0.75 19.10 0.81 20.60 26 28 29 35 38 39 1/4 to 1/2 1/2 to 3/4
FITTINGS OR
ALUMINUM/BRASS 10 1-14 0.94 23.80 1.00 25.40 39 41 43 53 56 58 1/4 to 1/2 1/2 to 3/4
MATING 12 1 3/16-12 1.11 28.20 1.19 30.10 55 58 61 75 79 83 1/4 to 1/2 1/2 to 3/4
COMPONENT;
16 1 7/16-12 1.34 34.15 1.44 36.50 72 76 79 98 103 107 1/4 to 1/2 1/2 to 3/4
UN-LUBRICATED
THREADS 20 1 11/16-12 1.59 40.50 1.69 42.90 98 103 108 133 140 146 1/4 to 1/2 1/2 to 3/4
24 2-12 1.92 48.80 2.00 50.80 12 13 13 16 18 18 1/4 to 1/2 1/2 to 3/4
32 2 1/2-12 2.43 61.67 2.50 63.50 20 21 22 27 28 30 1/4 to 1/2 1/2 to 3/4

6036, 6042, 8042, 10042, 10054, 12054 31211388 2-47

2.8.7 Assembly Instructions for DIN 24° Flare

Bite Type Fittings (MBTL and MBTS)
NOTICE
A non-square tube end can cause improperly seated
fittings and leakage.
6. Inspect the components to ensure free of
contamination, external damage, rust, splits, dirt,
ts
foreign matter, or burrs. Ensure tube end is visibly
ar
square. If necessary, replace fitting or tube.
rp
7. Lubricate thread and cone of fitting body or hardened
pre-assembly tool, as well as the progressive ring and
ou
nut threads.
ry
8. Slip nut and progressive ring over tube, assuring that
they are in the proper orientation.
de
9. Push the tube end into the coupling body.
or
10. Slide collet into position and tighten until finger tight.
to
Mark nut and tube in the finger-tight position. Tighten
nut to the number of flats listed while using the Double
om
Wrench Method. The tube must not turn with the nut.
t.c
en
m
ip
qu
-E
nt
ou
sc
Di
to
Go
2-48 31211388 6036, 6042, 8042, 10042, 10054, 12054

a. DIN 24° CONE (MBTL & MBTS)
MAE9160
ts
DIN 24° CONE FLARELESS BITE FITTING
ar
(WITH OR WITHOUT O-RING)
rp
Tube Thread Torque Flats From
ØA* ØB* C* ØD*
O.D. M Size Wrench
ou
Material Type [Ft-Lb] [Nm]
Resistance
ry
(mm) (Metric) (mm) (mm) (mm) (mm) Min Nom Max Min Nom Max (F.F.W.R)**
6 M12 x 1.5 10.50 12.00 7.00 6.20 1.5 to 1.75
de
8 M14 x 1.5 12.50 14.00 7.00 8.20 1.5 to 1.75
or
FFWR is the recommended method of
10 M16 x 1.5 14.50 16.00 7.00 10.20 fitting assembly. 1.5 to 1.75
to
DIN 12 M18 x 1.5 16.50 18.00 7.00 12.20 1.5 to 1.75
Torque values are application specific
24° CONE 15 M22 x 1.5 20.50 22.00 7.00 15.20 due to variability in the fitting supplier, 1.5 to 1.75
om
FLARELESS coating, lubrication, and other physical
BITE (MBTL) 18 M26 x 1.5 24.50 26.00 7.50 18.20 characteristic of the connection. 1.5 to 1.75
t.c
FITTING 22 M30 x 2 27.90 30.00 7.50 22.20 1.5 to 1.75

Consult Engineering on the
28 M36 x 2 33.90 36.00 7.50 28.20 generation of torque values for the 1.5 to 1.75
en
particular application.
35 M45 x 2 42.90 45.00 10.50 35.30 1.5 to 1.75
m
42 M52 x 2 49.90 52.00 11.00 42.30 1.5 to 1.75

ip
Torque
qu
STEEL Tube Thread Flats From

ØA* ØB* C* ØD*
FITTINGS WITH O.D. M Size [Ft-Lb] [Nm] Wrench
Type
-E
STEEL MATING Resistance

COMPONENTS (F.F.W.R)**
nt
(mm) (Metric) (mm) (mm) (mm) (mm) Min Nom Max Min Nom Max
ou
6 M14 x 1.5 12.50 14.00 7.00 6.20 1.5 to 1.75

FFWR is the recommended method of
8 M16 x 1.5 14.50 16.00 7.00 8.20 1.5 to 1.75
sc
fitting assembly.
10 M18 x 1.5 16.50 18.00 7.50 10.20 1.5 to 1.75
Di
DIN 12 M20 x 1.5 18.50 20.00 7.50 12.20 Torque values are application specific 1.5 to 1.75
to
24° CONE 14 M22 x 1.5 20.50 22.00 8.00 14.20 due to variability in the fitting supplier, 1.5 to 1.75
FLARELESS coating, lubrication, and other physical
Go
16 M24 x 1.5 22.50 24.00 8.50 16.20 characteristics of the connection. 1.5 to 1.75
BITE (MBTS)
FITTING 20 M30 x 2 27.90 30.00 10.50 20.20 1.5 to 1.75
25 M36 x 2 33.90 36.00 12.00 25.20 Consult Engineering on the 1.5 to 1.75
generation of torque values for the
30 M42 x 2 39.90 42.00 13.50 30.20 1.5 to 1.75
particular application.
38 M52 x 2 49.90 52.00 16.00 38.30 1.5 to 1.75
NOTE: * ØA, ØB,C, & ØD thread dimensions for reference only.

6036, 6042, 8042, 10042, 10054, 12054 31211388 2-49

2.8.8 Assembly Instructions for Bulkhead (BH)

Fittings
1. Ensure that threads and surface are free of rust, weld
and brazing splatter, splits, burrs or other foreign
material. If necessary, replace fitting or adapter.
2. Remove the locknut from the bulkhead assembly.
3. Insert the bulkhead side of the fitting into the panel or
bulkhead bracket opening.
4. Hand thread the locknut onto the bulkhead end of the
ts
fitting body.
ar
5. Torque nut onto fitting while using the Double Wrench
rp
Method.
ou
ry
de
or
to
om
t.c
en
m
ip
qu
-E
nt
ou
sc
Di
to
Go
2-50 31211388 6036, 6042, 8042, 10042, 10054, 12054

a. Bulkhead Fittings (BH) - INCH
MAE9170
ts
FASTENING JAM NUT
ar
FOR BULKHEAD CONNECTORS
rp
Thread Torque
Dash Size
ou
Material Type [Ft-Lb] [Nm]
Size
(UNF) Min Nom Max Min Nom Max
ry
4 9/16-18 15 16 17 20 22 23
de
6 11/16-16 25 27 28 34 37 38
or
8 13/16-16 55 58 61 75 79 83
O-RING FACE 10 1-14 85 90 94 115 122 127
SEAL (ORFS)
BULKHEAD
12 1 3/16-12 135
to 142 149 183 193 202
om
FITTING 14 1 5/16-12 170 179 187 230 243 254
16 1 7/16-12 200 210 220 271 285 298
t.c
20 1 11/16-12 245 258 270 332 350 366

en
24 2-12 270 284 297 366 385 403

m
Thread Torque
Dash
ip
Type Size [Ft-Lb] [Nm]

Size
qu
STEEL (UNF) Min Nom Max Min Nom Max

FITTINGS 3 3/8-24 8 9 9 11 12 12
-E
4 7/16-20 13 14 14 18 19 19
nt
5 1/2-20 20 21 22 27 28 30
ou
6 9/16-18 25 27 28 34 37 38
sc
8 3/4-16 50 53 55 68 72 75
Di
37° FLARE (JLIC) 10 7/8-14 85 90 94 115 122 127

BULKHEAD
12 1 1/16-12 135 142 149 183 193 202
to
FITTING
14 1 3/16-12 170 179 187 230 243 254
Go
16 1 5/16-12 200 210 220 271 285 298

20 1 5/8-12 245 258 270 332 350 366
24 1 7/8-12 270 284 297 366 385 403
32 2 1/2-12 310 326 341 420 442 462
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-51

b. Bulkhead Fittings (BH) - METRIC
MAE9180
ts
ar
FASTENING JAM NUT
FOR BULKHEAD CONNECTORS
rp
Connecting Thread Torque
ou
Material Type Tube O.D. M Size [Ft-Lb] [Nm]
ry
(mm) (metric) Min Nom Max Min Nom Max
6 M12 x 1.5 14 15 16 19 20 22
de
8 M14 x 1.5 17 18 19 23 24 26
or
10 M16 x 1.5 22 23 24 30 31 33
DIN 24° CONE

FLARELESS BITE
12
15
M18 x 1.5
M22 x 1.5
35
44 to37
47
39
50
47
60
50
64
53
68
om
(MBTL) BULKHEAD 18 M26 x 1.5 70 75 80 95 102 108
FITTING
t.c
22 M30 x 2 115 120 125 156 163 169

28 M36 x 2 150 157 164 203 213 222
en
35 M45 x 2 155 162 169 210 220 229

m
42 M52 x 2 220 230 240 298 312 325

ip
Connecting Thread Torque

qu
STEEL Tube O.D. M Size

Type [Ft-Lb] [Nm]
FITTINGS
-E
(mm) (metric) Min Nom Max Min Nom Max

nt
6 M14 x 1.5 17 15 16 23 20 22
ou
8 M16 x 1.5 22 18 19 30 24 26
sc
10 M18 x 1.5 35 23 24 47 31 33
Di
12 M20 x 1.5 40 35 37 54 47 50
DIN 24° CONE
FLARELESS BITE 14 M22 x 1.5 44 47 50 60 64 68
to
(MBTS) BULKHEAD 16 M24 x 1.5 70 75 80 95 102 108

FITTING
Go
20 M30 x 2 115 120 125 156 163 169

25 M36 x 2 150 157 164 203 213 222
30 M42 x 2 155 162 169 210 220 229
38 M52 x 2 220 230 240 298 312 325
2-52 31211388 6036, 6042, 8042, 10042, 10054, 12054

2.8.9 Assembly Instructions for O-Ring Boss

(ORB) Fittings
1. Inspect components to ensure that male and female
port threads are free of rust, splits, dirt, foreign matter,
or burrs.
2. Ensure proper o-ring is installed. If o-ring is missing
install per o-ring Installation (replacement). Refer to
Section 2.8.17, “O-ring Installation (Replacement),”, for
procedure.
ts
NOTICE
ar
rp
ou
ry
de
or
4. For non-adjustable and plugs, thread the fitting by hand
until contact.
5. For adjustable fittings, refer to Section 2.8.16, to
om
“Adjustable Stud End Assembly,”, for proper assembly.
6. Torque the fitting or nut to value while using the
t.c
Double Wrench Method.

en
a. The table headings identify the straight thread

m
o-ring port and the type on the other side of the

fitting. The torque will be applied to the straight
ip
thread o-ring port.

qu
b. Torque values are segregated based on the material

-E
configuration of the connection. ‘Aluminum/brass

fittings or aluminum/brass mating components’
nt
indicate either the following material

ou
configurations:
sc
• Steel fittings with aluminum or brass mating

components
Di
• Aluminum or brass fittings with steel mating

to
components
Go
• Aluminum or brass fittings with aluminum or brass

mating components.
7. Inspect to ensure the o-ring is not pinched and the
washer is seated flat on the counter bore of the port.
2-54 31211388 6036, 6042, 8042, 10042, 10054, 12054

a. O-ring Boss (ORB) - Table 1 of 6
MAE9190
HEX TYPE PLUGS & STUD ENDS
ts
WITH 37° (JIC) OR L SERIES DIN (MBTL) OPPOSITE END
ar
Torque
rp
Thread
ØA*
Material Dash Size Size [Ft-Lb] [Nm]
ou
(UNF) (in) (mm) Min Nom Max Min Nom Max
ry
2 5/16-24 0.31 7.93 (85) (90) (94) 10 10 11
de
3 3/8-24 0.37 9.52 (155) (163) (171) 18 18 19
4 7/16-20 0.44 11.11 22 23 24 29 31 33
or
5 1/2-20 0.50 12.70 23 25 26 32 34 35
STEEL FITTINGS
WITH STEEL
6
8
9/16-18
3/4-16
0.56
0.75
14.28
19.10 to 29
52
31
55
32
57
40
70
42
75
43
77
om
MATING
10 7/8-14 0.87 22.22 85 90 94 115 122 127
COMPONENTS;
t.c
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS
en
14 1 3/16-12 1.19 30.10 175 184 193 235 249 262

16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
m
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373

ip
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456

qu
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560

-E
Thread Torque
ØA*
nt

ou

sc
2 5/16-24 0.31 7.93 (55) (58) (61) 6 7 7

Di
3 3/8-24 0.37 9.52 (101) (106) (111) 11 12 13

4 7/16-20 0.44 11.11 14 15 16 19 20 22
to
5 1/2-20 0.50 12.70 15 16 17 20 22 23

Go
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 19 20 21 26 27 28

FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 34 36 37 46 49 50
MATING 10 7/8-14 0.87 22.22 55 58 61 75 79 83
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
NOTE: 1. * ØA thread OD dimension for reference only.

2. Removal torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque.
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-55

b. O-ring Boss (ORB) - Table 2 of 6
MAE9190
STUD ENDS
ts
WITH (ORFS) OR S ERIES DIN (MBTS) OPPOSITE END
ar
Torque
rp
Thread
ØA*
ou
ry
2 5/16-24 0.31 7.93 (85) (90) (94) 10 10 11
3 3/8-24 0.37 9.52 (155) (163) (171) 18 18 19
de
4 7/16-20 0.44 11.11 22 23 24 29 31 33
or
5 1/2-20 0.50 12.70 23 25 26 32 34 35
to
STEEL FITTINGS 6 9/16-18 0.56 14.28 29 31 32 40 42 43
WITH STEEL 8 3/4-16 0.75 19.10 52 55 57 70 75 77
om
MATING
10 7/8-14 0.87 22.22 85 90 94 115 122 127
COMPONENTS;
t.c
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
en
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298

m
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373

ip
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456

qu
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560

-E
Thread Torque
ØA*
nt

ou

2 5/16-24 0.31 7.93 (55) (58) (61) 6 7 7
sc
3 3/8-24 0.37 9.52 (101) (106) (111) 11 12 13

Di
4 7/16-20 0.44 11.11 14 15 16 19 20 22

to
5 1/2-20 0.50 12.70 15 16 17 20 22 23

ALUMINUM/BRASS 6 9/16-18 0.56 14.28 19 20 21 26 27 28
Go
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 34 36 37 46 49 50
MATING 10 7/8-14 0.87 22.22 55 58 61 75 79 83
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

2-56 31211388 6036, 6042, 8042, 10042, 10054, 12054

c. O-ring Boss (ORB) - Table 3 of 6
MAE9210
ts
ADJUSTABLE STUD END
ar
WITH 37° (JIC) OR L SERIES DIN (MBTL) OPPOSITE END
rp
Thread Torque
ØA*
ou
ry
2 5/16-24 0.31 7.93 (85) (90) (94) 10 10 11
de
3 3/8-24 0.37 9.52 (155) (163) (171) 18 18 19
or
4 7/16-20 0.44 11.11 22 23 24 29 31 33
5 1/2-20 0.50 12.70 23 25 26 32 34 35
STEEL FITTINGS 6 9/16-18 0.56 14.28
to 29 31 32 40 42 43
om
WITH STEEL 8 3/4-16 0.75 19.10 52 55 57 70 75 77
MATING
10 7/8-14 0.87 22.22 85 90 94 115 122 127
COMPONENTS;
t.c
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
en
THREADS 14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
m
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298

ip
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373

qu
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456

32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
-E
Thread Torque
nt
ØA*
ou

sc
2 5/16-24 0.31 7.93 (55) (58) (61) 6 7 7

Di
3 3/8-24 0.37 9.52 (101) (106) (111) 11 12 13

4 7/16-20 0.44 11.11 14 15 16 19 20 22
to
5 1/2-20 0.50 12.70 15 16 17 20 22 23

Go
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 19 20 21 26 27 28

FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 34 36 37 46 49 50
MATING 10 7/8-14 0.87 22.22 55 58 61 75 79 83
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

6036, 6042, 8042, 10042, 10054, 12054 31211388 2-57

d. O-ring Boss (ORB) - Table 4 of 6
MAE9220
ts
ADJUSTABLE STUD END
ar
WITH (ORFS) OR S SERIES DIN (MBTS) OPPOSITE END
rp
Thread Torque
ØA*
ou
ry
2 5/16-24 0.31 7.93 -- -- -- -- -- --
de
3 3/8-24 0.37 9.52 -- -- -- -- -- --
4 7/16-20 0.44 11.11 15 16 17 20 22 23
or
5 1/2-20 0.50 12.70 30 32 33 40 43 45
STEEL FITTINGS
WITH STEEL
6
8
9/16-18
3/4-16
0.56
0.75
14.28
19.10 to
35
60
37
63
39
66
46
80
50
85
53
89
om
MATING
10 7/8-14 0.87 22.22 100 105 110 135 142 149
COMPONENTS;
t.c
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS
en
14 1 3/16-12 1.19 30.10 175 184 193 235 249 262

16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
m
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373

ip
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456

qu
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560

-E
Thread Torque
ØA*
nt

ou

2 5/16-24 0.31 7.93 -- -- -- -- -- --
sc
3 3/8-24 0.37 9.52 -- -- -- -- -- --

Di
4 7/16-20 0.44 11.11 10 11 11 14 15 15

to
5 1/2-20 0.50 12.70 20 21 21 27 28 28

ALUMINUM/BRASS 6 9/16-18 0.56 14.28 23 24 24 31 33 33
Go
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 39 41 43 53 56 58
MATING 10 7/8-14 0.87 22.22 65 69 72 88 94 98
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

2-58 31211388 6036, 6042, 8042, 10042, 10054, 12054

e. O-ring Boss (ORB) - Table 5 of 6
MAE9230
TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS
ts
Thread Torque
ar
ØA*
rp
ou
2 5/16-24 0.31 7.93 (30) (32) (33) 3 4 4
3 3/8-24 0.37 9.52 (55) (58) (61) 6 7 7
ry
4 7/16-20 0.44 11.11 10 11 11 14 15 15
de
5 1/2-20 0.50 12.70 14 15 16 19 20 22
or
STEEL FITTINGS 6 9/16-18 0.56 14.28 34 36 38 46 49 52
WITH STEEL 8 3/4-16 0.75 19.10 60 63 66 80 85 89
MATING
COMPONENTS;
10 7/8-14 0.87 22.22 to 100 105 110 135 142 149
om
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
t.c
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298

en
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373

m
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456

ip
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560

qu
Thread Torque
ØA*
Size [Ft-Lb] [Nm]
-E
Material Dash Size

nt
2 5/16-24 0.31 7.93 (20) (21) (21) 2 2 2

ou
3 3/8-24 0.37 9.52 (36) (38) (40) 4 4 5

sc
4 7/16-20 0.44 11.11 6 7 7 8 9 9

Di
5 1/2-20 0.50 12.70 9 10 10 12 14 14

ALUMINUM/BRASS
to
6 9/16-18 0.56 14.28 22 24 25 30 33 34

FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 39 41 43 53 56 58
Go
MATING 10 7/8-14 0.87 22.22 65 69 72 88 94 98

COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

6036, 6042, 8042, 10042, 10054, 12054 31211388 2-59

f. O-ring Boss (ORB) - Table 6 of 6
MAE9240
ts
ZERO LEAK GOLD®
ar
HOLLOW HEX PLUGS
rp
Thread Torque
ØA*
ou
ry
2 5/16-24 0.31 7.93 2 3 4 3 4 5
de
3 3/8-24 0.37 9.52 3 4 5 4 5 7
4 7/16-20 0.44 11.11 7 8 9 9 11 12
or
5 1/2-20 0.50 12.70 9 10 11 12 14 15
STEEL FITTINGS WITH

6
8
9/16-18
3/4-16
0.56
0.75
14.28
19.10 to
11
28
12
30
13
32
15
38
16
41
18
43
om
STEEL MATING
COMPONENTS; 10 7/8-14 0.87 22.22 46 48 50 62 65 68
t.c
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 51 54 57 69 73 77

THREADS
14 1 3/16-12 1.19 30.10
en
16 1 5/16-12 1.31 33.30 Fitting size greater than -12 not typically specified on
m
Caterpillar applications.
20 1 5/8-12 1.63 41.30
ip
Consult specific service procedure if

24 1 7/8-12 1.87 47.60 encountered.
qu
32 2 1/2-12 2.50 63.50

-E
Thread Torque
ØA*
nt

ou

sc
2 5/16-24 0.31 7.93 2 3 4 3 4 5

3 3/8-24 0.37 9.52 3 4 5 4 5 7
Di
4 7/16-20 0.44 11.11 7 8 9 9 11 12

to
5 1/2-20 0.50 12.70 9 10 11 12 14 15

ALUMINUM/BRASS
Go
6 9/16-18 0.56 14.28 11 12 13 15 16 18

FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 28 30 32 38 41 43
MATING 10 7/8-14 0.87 22.22 46 48 50 62 65 68
COMPONENTS; 12 1 1/16-12 1.06 27.00 51 54 57 69 73 77
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10
16 1 5/16-12 1.31 33.30 Fitting size greater than -12 not typically specified on
Caterpillar applications.
20 1 5/8-12 1.63 41.30
Consult specific service procedure if
24 1 7/8-12 1.87 47.60 encountered.
32 2 1/2-12 2.50 63.50

2-60 31211388 6036, 6042, 8042, 10042, 10054, 12054

2.8.10 Assembly Instructions for Adjustable

Port End Metric Fittings
threads and surfaces are free of rust, splits, dirt, foreign
matter, or burrs.
2. If o-ring is not pre-installed, install proper size, taking
care not to damage it. Refer to Section 2.8.17, “O-ring
Installation (Replacement).”, for procedure.
NOTICE
ts
ar
rp
ou
ry
de
4. For non-adjustable fittings and plugs, thread the fitting
or
by hand until contact.
to
5. For adjustable fittings, refer to Section 2.8.16,
om
t.c
a. The table headings identify the Metric port and the

en
type on the other side of the fitting. The torque will

be applied to the Metric port.
m

ip

qu

-E
configurations:
nt

ou
components
sc

Di
components
to
mating components.
Go

2-62 31211388 6036, 6042, 8042, 10042, 10054, 12054

a. Metric Flat Face Port (MFF) L Series - Table 1 of 3
ts
ar
rp
MAE9260
MAE9250
ou
FORM A (SEALING WASHER) FORM B (CUTTING FACE)
ry
TYPE/FITTING STUD ENDS STUD ENDS
de
IDENTIFICATION WITH 37° (JIC) or L SERIES DIN (MBTL) WITH 37° (JIC) OR L SERIES DIN (MBTL)
OPPOSITE END OPPOSITE END
or
Thread Connecting Torque Torque
Material M Size Tube O.D [Ft-Lb] to [Nm] [Ft-Lb] [Nm]

om
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
t.c
M10x1 6 7 8 8 9 11 11 13 14 14 18 19 19
M12x1.5 8 15 16 17 20 22 23 22 23 24 30 31 33
en
M14x1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
m
STEEL FITTINGS
M16x1.5 12 33 35 36 45 47 49 48 51 53 65 69 72
ip
WITH STEEL
MATING M18x1.5 15 41 43 45 55 58 61 59 62 65 80 84 88
qu
COMPONENTS; M22x1.5 18 48 51 53 65 69 72 103 108 113 140 146 153

-E
UN-LUBRICATED
M27x2 22 66 70 73 90 95 99 140 147 154 190 199 209
THREADS
nt
M33x2 28 111 117 122 150 159 165 251 264 276 340 358 374
ou
M42x2 35 177 186 195 240 252 264 369 388 406 500 526 550
sc
M48x2 42 214 225 235 290 305 319 465 489 512 630 663 694
Di

to
Material M Size Tube O.D

[Ft-Lb] [Nm] [Ft-Lb] [Nm]
Go
M10x1 6 4 5 5 5 7 7 8 9 9 11 12 12
M12x1.5 8 10 11 11 14 15 15 14 15 16 19 20 22
ALUMINUM/BRASS
M14x1.5 10 17 18 19 23 24 26 21 22 23 28 30 31
FITTINGS OR M16x1.5 12 21 22 23 28 30 31 31 33 34 42 45 46
ALUMINUM/BRASS M18x1.5 15 27 28 29 37 38 39 38 40 42 52 54 57
MATING
COMPONENTS; M22x1.5 18 31 33 34 42 45 46 67 70 73 91 95 99
UN-LUBRICATED M27x2 22 43 45 47 58 61 64 91 96 100 123 130 136
THREADS
M33x2 28 72 76 79 98 103 107 163 171 179 221 232 243
M42x2 35 115 121 127 156 164 172 240 252 264 325 342 358
M48x2 42 139 146 153 188 198 207 302 318 332 409 431 450
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-63

b. Metric Flat Face Port (MFF) L Series - Table 2 of 3
ts
ar
MAE9280
rp
MAE9270
ou
ry
IDENTIFICATION WITH 37° (JIC) OR L SERIES DIN (MBTL) WITH 37° (JIC) OR L SERIES DIN (MBTL)
de
or
Material M Size Tube O.D

[Ft-Lb] to
[Nm] [Ft-Lb] [Nm]
om
t.c
M10x1 6 13 14 14 18 19 19 13 14 15 18 19 20
M12x1.5 8 18 19 20 25 26 27 18 19 20 25 26 28
en
M14x1.5 10 33 35 36 45 47 49 30 31 32 40 42 44
m
STEEL FITTINGS
WITH STEEL M16x1.5 12 41 43 45 55 58 61 41 43 45 55 58 61
ip
MATING M18x1.5 15 52 55 57 70 75 77 52 54 57 70 74 77
qu
COMPONENTS; M22x1.5 18 92 97 101 125 132 137 66 70 73 90 95 99

-E
UN-LUBRICATED M27x2 22 133 140 146 180 190 198 133 139 146 180 189 198
THREADS
nt
M33x2 28 229 241 252 310 327 342 229 240 252 310 326 341
ou
M42x2 35 332 349 365 450 473 495 332 348 365 450 473 495
sc
M48x2 42 398 418 438 540 567 594 398 418 438 540 567 594
Di

M Size Tube O.D
to
Material [Ft-Lb] [Nm] [Ft-Lb] [Nm]
(mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
Go
(UNF)
M10x1 6 8 9 9 11 12 12 8 9 9 11 12 12
M12x1.5 8 12 13 13 16 18 18 12 13 13 16 18 18
ALUMINUM/ M14x1.5 10 21 22 23 28 30 31 19 20 21 26 27 29
BRASS FITTINGS
OR ALUMINUM/ M16x1.5 12 27 28 29 37 38 39 26 28 29 36 38 39
BRASS M18x1.5 15 34 36 37 46 49 50 34 35 37 46 48 50
MATING M22x1.5 18 60 63 66 81 85 89 43 45 47 59 61 64
COMPONENTS; M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
UN-LUBRICATED
THREADS M33x2 28 149 157 164 202 213 222 149 157 164 202 213 222
M42x2 35 216 227 237 293 308 321 216 227 237 293 308 321
M48x2 42 259 272 285 351 369 386 259 272 285 351 369 386
2-64 31211388 6036, 6042, 8042, 10042, 10054, 12054

c. Metric Flat Face Port (MFF) L Series - Table 3 of 3
MAE9310
MAE9290 MAE9300
ts
ar
HIGH PRESSURE BANJO
BANJO FITTINGS FORM E (EOLASTIC
rp
TYPE/FITTING FITTINGS
WITH L SERIES DIN (MBTL) SEALING RING)
IDENTIFICATION WITH L SERIES DIN (MBTL)
OPPOSITE END HOLLOW HEX PLUGS
ou
OPPOSITE END
ry
Thread Connecting Torque Torque Torque
M Size Tube O.D
de
Material [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
or
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 13 14 14 18 19 19 13 14 14 18 19 19 9 10 10 12 14 14
M12x1.5 8 26 28 29 35 38 39 to
33 35 36 45 47 49 18 19 20 25 26 27
om
M14x1.5 10 37 39 41 50 53 56 41 43 45 55 58 61 26 28 29 35 38 39
STEEL FITTINGS
M16x1.5 12 44 46 48 60 62 65 59 62 65 80 84 88 41 43 45 55 58 61
t.c
WITH STEEL
MATING M18x1.5 15 59 62 65 80 84 88 74 78 81 100 106 110 48 51 53 65 69 72
en
COMPONENTS; M22x1.5 18 89 94 98 120 127 133 103 108 113 140 146 153 66 70 73 90 95 99
UN-LUBRICATED
m
M27x2 22 96 101 106 130 137 144 236 248 260 320 336 353 100 105 110 135 142 149
THREADS
ip
M33x2 28 -- -- -- -- -- -- 266 280 293 360 380 397 166 175 183 225 237 248
qu
M42x2 35 -- -- -- -- -- -- 398 418 438 540 567 594 266 280 293 360 380 397
M48x2 42 -- -- -- -- -- -- 516 542 568 700 735 770 266 280 293 360 380 397
-E
Torque Torque Torque

nt
Thread Connecting
M Size Tube O.D
ou
Material [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]

sc
Di
M10x1 6 8 9 9 11 12 12 8 9 9 11 12 12 6 7 7 8 9 9
M12x1.5 8 17 18 19 23 24 26 21 22 23 28 30 31 12 13 13 16 18 18
to
ALUMINUM/ M14x1.5 10 24 26 27 33 35 37 27 28 29 37 38 39 17 18 19 23 24 26
BRASS FITTINGS
Go
M16x1.5 12 29 30 31 39 41 42 38 40 42 52 54 57 27 28 29 37 38 39
OR ALUMINUM/
BRASS M18x1.5 15 38 40 42 52 54 57 48 51 53 65 69 72 31 33 34 42 45 46
MATING M22x1.5 18 58 61 64 79 83 87 67 70 73 91 95 99 43 45 47 58 61 64
COMPONENTS;
M27x2 22 62 66 69 84 89 94 153 161 169 207 218 229 65 69 72 88 94 98
UN-LUBRICATED
THREADS M33x2 28 -- -- -- -- -- -- 173 182 190 235 247 258 108 114 119 146 155 161
M42x2 35 -- -- -- -- -- -- 259 272 285 351 369 386 173 182 190 235 247 258
M48x2 42 -- -- -- -- -- -- 335 352 369 454 477 500 173 182 190 235 247 258
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-65

d. Metric Flat Face Port (MFF) S Series - Table 1 of 3
ts
ar
rp
MAE9320 MAE9330
ou
ry
IDENTIFICATION WITH (ORFS) OR S SERIES DIN (MBTS) WITH (ORFS) OR S SERIES DIN (MBTS)
de
or
Material M Size Tube O.D. [Ft-Lb]
to
[Nm] [Ft-Lb] [Nm]
om
M12x1.5 6 15 16 17 20 22 23 26 28 29 35 38 39
t.c
M14x1.5 8 26 28 29 35 38 39 41 43 45 55 58 61
en
M16x1.5 10 33 35 36 45 47 49 52 55 57 70 75 77
STEEL FITTINGS
m
M18x1.5 12 41 43 45 55 58 61 81 85 89 110 115 121

WITH STEEL
ip
MATING M20x1.5 14 41 43 45 55 58 61 111 117 122 150 159 165

qu
COMPONENTS; M22x1.5 16 48 51 53 65 69 72 125 132 138 170 179 187

UN-LUBRICATED
M27x2 20 66 70 73 89 95 99 199 209 219 270 283 297
-E
THREADS
M33x2 25 111 117 122 150 159 165 302 317 332 410 430 450
nt
M42x2 30 177 186 195 240 252 264 398 418 438 540 567 594
ou
M48x2 38 214 225 235 290 305 319 516 542 568 700 735 770
sc

Di
Material M Size Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm]

to
Go
M12x1.5 6 10 11 11 14 15 15 17 18 19 23 24 26
M14x1.5 8 17 18 19 23 24 26 27 28 29 37 38 39
ALUMINUM/ M16x1.5 10 21 22 23 28 30 31 34 36 37 46 49 50
BRASS FITTINGS
M18x1.5 12 27 28 29 37 38 39 53 56 58 72 76 79
OR ALUMINUM/
BRASS M20x1.5 14 27 28 29 37 38 39 72 76 79 98 103 107
MATING M22x1.5 16 31 33 34 42 45 46 81 86 90 110 117 122
COMPONENTS;
M27x2 20 43 45 47 58 61 64 129 136 142 175 184 193
UN-LUBRICATED
THREADS M33x2 25 72 76 79 98 103 107 196 206 216 266 279 293
M42x2 30 115 121 127 156 164 172 259 272 285 351 369 386
M48x2 38 139 146 153 188 198 207 335 352 369 454 477 500
2-66 31211388 6036, 6042, 8042, 10042, 10054, 12054

e. Metric Flat Face Port (MFF) S Series - Table 2 of 3
ts
ar
MAE9350
rp
MAE9340
ou
ry
de
IDENTIFICATION WITH (ORFS) OR S SERIES DIN (MBTS) WITH (ORFS) OR S SERIES DIN (MBTS)
or
Material M Size Tube O.D. [Ft-Lb]
to
[Nm] [Ft-Lb] [Nm]
om
M10x1 6 26 28 29 35 38 39 26 28 29 35 38 39
t.c
M12x1.5 8 33 35 36 45 47 49 41 43 45 55 58 61
en
M14x1.5 10 52 55 57 70 75 77 52 55 57 70 75 77
STEEL FITTINGS
m
M16x1.5 12 66 70 73 90 95 99 66 70 73 90 95 99
WITH STEEL
ip
MATING M18x1.5 15 92 97 101 125 132 137 92 97 101 125 132 137
qu
COMPONENTS; M22x1.5 18 100 105 110 135 142 149 100 105 110 135 142 149
UN-LUBRICATED
-E
M27x2 22 133 140 146 180 190 198 133 140 146 180 190 198
THREADS
M33x2 28 229 241 252 310 327 342 229 241 252 310 327 342
nt
M42x2 35 332 349 365 450 473 495 332 349 365 450 473 495
ou
M48x2 42 398 418 438 540 567 594 398 418 438 540 567 594
sc

Di
Material M Size Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm]

to
Go
M10x1 6 17 18 19 23 24 26 17 18 19 23 24 26
M12x1.5 8 21 23 23 29 31 32 27 28 29 37 38 39
ALUMINUM/ M14x1.5 10 34 36 37 46 49 50 34 36 37 46 49 50
BRASS FITTINGS
M16x1.5 12 43 45 47 58 61 64 43 45 47 58 61 64
OR ALUMINUM/
BRASS M18x1.5 15 60 63 66 81 85 89 60 63 66 81 85 89
MATING M22x1.5 18 65 69 72 88 94 98 65 69 72 88 94 98
COMPONENTS;
M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
UN-LUBRICATED
THREADS M33x2 28 149 157 164 202 213 222 149 157 164 202 213 222
M42x2 35 216 227 237 293 308 321 216 227 237 293 308 321
M48x2 42 259 272 285 351 369 386 259 272 285 351 369 386
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-67

f. Metric Flat Face Port (MFF) S Series - Table 3 of 3
MAE9310
MAE9290 MAE9300
ts
ar
HIGH PRESSURE BANJO
rp
TYPE/FITTING FITTINGS
WITH S SERIES DIN (MBTS) SEALING RING)
ou
IDENTIFICATION WITH S SERIES DIN (MBTS)
OPPOSITE END
ry
de
Material M Size Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
or
to
M10x1 6 26 28 29 35 38 39 33 35 36 45 47 49 -- -- -- -- -- --
M12x1.5 8 37 39 41 50 53 56 41 43 45 55 58 61 -- -- -- -- -- --
om
M14x1.5 10 44 46 48 60 62 65 59 62 65 80 84 88 -- -- -- -- -- --
STEEL FITTINGS
t.c
M16x1.5 12 59 62 65 80 84 88 74 78 81 100 106 110 -- -- -- -- -- --

WITH STEEL
M18x1.5 15 81 85 89 110 115 121 92 97 101 125 132 137 59 62 65 80 84 88
en
MATING
COMPONENTS; M22x1.5 18 89 94 98 120 127 133 100 105 110 135 142 149 -- -- -- -- -- --
m
UN-LUBRICATED
M27x2 22 100 105 110 135 142 149 236 248 260 320 336 353 -- -- -- -- -- --
ip
THREADS
M33x2 28 -- -- -- -- -- -- 266 280 293 360 380 397 -- -- -- -- -- --
qu
M42x2 35 -- -- -- -- -- -- 398 418 438 540 567 594 -- -- -- -- -- --

-E
M48x2 42 -- -- -- -- -- -- 516 542 568 700 735 770 -- -- -- -- -- --

nt

ou
Material M Size Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
sc
Di
M10x1 6 17 18 19 23 24 26 21 22 23 28 30 31 -- -- -- -- -- --
M12x1.5 8 24 26 27 33 35 37 27 28 29 37 38 39 -- -- -- -- -- --
to
ALUMINUM/
BRASS M14x1.5 10 29 30 31 39 41 42 38 40 42 52 54 57 -- -- -- -- -- --
Go
FITTINGS OR M16x1.5 12 38 40 42 52 54 57 48 51 53 65 69 72 -- -- -- -- -- --
ALUMINUM/ M18x1.5 15 53 56 58 72 76 79 60 63 66 81 85 89 38 40 42 52 54 57
BRASS
MATING M22x1.5 18 58 61 64 79 83 87 65 69 72 88 94 98 -- -- -- -- -- --
COMPONENTS; M27x2 22 65 69 72 88 94 98 153 161 169 207 218 229 -- -- -- -- -- --
UN-LUBRICATED M33x2 28 -- -- -- -- -- -- 173 182 190 235 247 258 -- -- -- -- -- --
THREADS
M42x2 35 -- -- -- -- -- -- 259 272 285 351 369 386 -- -- -- -- -- --
M48x2 42 -- -- -- -- -- -- 335 352 369 454 477 500 -- -- -- -- -- --
2-68 31211388 6036, 6042, 8042, 10042, 10054, 12054

2.8.11 Assembly Instructions for Metric ISO

6149 Port Assembly Stud Ends
matter, or burrs.
2. If o-ring is not pre installed, install proper size, taking
Installation (Replacement),”.
NOTICE
ts
ar
rp
ou
ry
de
or
to
om
t.c
a. The table headings identify the Metric port and the

en

be applied to the Metric port.
m

ip

qu

-E
configurations:
nt

ou
components
sc

Di
components
to
mating components.
Go

2-70 31211388 6036, 6042, 8042, 10042, 10054, 12054

a. Metric Pipe Parallel O-Ring Boss (MPP)
MAE9370 MAE9380
ts
MAE9360
ar
TYPE/FITTING STUD ENDS WITH 37° (JIC) OR L SERIES STUD ENDS WITH (ORFS) OR S SERIES
rp
IDENTIFICATION DIN (MBTL) OPPOSITE END DIN (MBTS) OPPOSITE END
ou
M Size Tube O.D.
ry
Material [Ft-Lb] [Nm] [Ft-Lb] [Nm]
de
M8 x 1 4 6 7 7 8 9 9 8 9 9 10 12 12
or
M10 x 1 6 11 12 12 15 16 16 15 16 17 20 22 23
M12 x 1.5 8 18 19 20 25 26 27 26 28 29 35 38 39
M14 x 1.5
M16 x 1.5
10
12
26
30
28
32
29
33
35
40 to38
43
39
45
33
41
35
43
36
45
45
55
47
58
49
61
om
STEEL FITTINGS M18 x 1.5 15 33 35 36 45 47 49 52 55 57 70 75 77
WITH STEEL M20 x 1.5 -- -- -- -- -- -- -- 59 62 65 80 84 88
t.c
MATING
M22 x 1.5 18 44 46 48 60 62 65 74 78 81 100 106 110
COMPONENTS;
en
UN-LUBRICATED M27 x 2 22 74 78 81 100 106 110 125 132 138 170 179 187
M30 x 2 -- 95 100 105 130 136 142 175 184 193 237 249 262
m
THREADS
M33 x 2 25 120 126 132 160 171 179 230 242 253 310 328 343
ip
M38 x 2 -- 135 142 149 183 193 202 235 247 259 319 335 351
qu
M42 x 2 30 155 163 171 210 221 232 245 258 270 330 350 366
-E
M48 x 2 38 190 200 209 260 271 283 310 326 341 420 442 462
M60 x 2 50 230 242 253 315 328 343 370 389 407 500 527 552
nt

ou
Material M Size Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]

sc
Di
M8 x 1 4 4 5 5 5 7 7 5 6 6 7 8 8
M10 x 1 6 7 8 8 9 11 11 10 11 11 14 15 15
to
M12 x 1.5 8 12 13 13 16 18 18 17 18 19 23 24 26
Go
M14 x 1.5 10 17 18 19 23 24 26 21 22 23 28 30 31
ALUMINUM/ M16 x 1.5 12 20 21 21 27 28 28 27 28 29 37 38 39
BRASS FITTINGS M18 x 1.5 15 21 22 23 28 30 31 34 36 37 46 49 50
OR ALUMINUM/ M20 x 1.5 -- -- -- -- -- -- -- 30 40 42 41 54 57
BRASS
M22 x 1.5 18 29 30 31 39 41 42 48 51 53 65 69 72
MATING
COMPONENTS; M27 x 2 22 48 51 53 65 69 72 81 86 90 110 117 122
UN-LUBRICATED M30 x 2 -- 62 65 68 84 88 92 114 120 125 155 163 169
THREADS M33 x 2 25 78 82 86 106 111 117 150 157 164 203 213 222
M38 x 2 -- 88 93 97 119 126 132 153 161 168 207 218 228
M42 x 2 30 101 106 111 137 144 150 159 168 176 216 228 239
M48 x 2 38 124 130 136 168 176 184 202 212 222 274 287 301
M60 x 2 50 150 157 164 203 213 222 241 253 265 327 343 359
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-71

2.8.12 Assembly Instructions for Adjustable

Port End (BSPP) Fittings
matter, or burrs.
2. If o-ring is not pre installed, install proper size, taking
Installation (Replacement).”, for instructions.
NOTICE
ts
ar
rp
ou
ry
de
or
to
“Adjustable Stud End Assembly.”, for proper assembly.
om
t.c
a. The table headings identify the BSPP port and the

en

be applied to the BSPP port.
m

ip

qu

-E
configurations:
nt

ou
components
sc

Di
components
to
mating components.
Go

2-72 31211388 6036, 6042, 8042, 10042, 10054, 12054

a. British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3
ts
MAE9390 MAE9400
ar
rp
FORM A**(SEALING WASHER) FORM B** (CUTTING FACE)
ou
TYPE/FITTING STUD ENDS WITH 37° (JIC) or STUD ENDS
IDENTIFICATION L SERIES DIN (MBTL) WITH 37° (JIC) OR L SERIES DIN (MBTL)
ry
de
Torque Torque
Connecting
or
BSPP
Tube O.D.
Material Thread [Ft-Lb] [Nm] [Ft-Lb] [Nm]
to
G Size
om
G 1/8A 6 7 8 8 9 11 11 13 14 14 18 19 19
G 1/4A 8 26 28 29 35 38 39 26 28 29 35 38 39
t.c
STEEL FITTINGS G 1/4A 10 26 28 29 35 38 39 26 28 29 35 38 39

en
WITH STEEL G 3/8A 12 33 35 36 45 47 49 52 55 57 70 75 77

MATING G 1/2A 15 48 51 53 65 69 72 103 108 113 140 146 153
m
COMPONENTS; G 1/2A 18 48 51 53 65 69 72 74 78 81 100 106 110

ip
UN-LUBRICATED G 3/4A 22 66 70 73 90 95 99 133 140 146 180 190 198

qu
THREADS G 1A 28 111 117 122 150 159 165 243 255 267 330 346 362
G 1-1/4A 35 177 186 195 240 252 264 398 418 438 540 567 594
-E
G 1-1/2A 42 214 225 235 290 305 319 465 489 512 630 663 694
nt
Connecting Torque Torque

ou
BSPP
Material Thread Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
sc
G Size
Di
G 1/8A 6 4 5 5 5 7 7 8 9 9 11 12 12
to
ALUMINUM/ G 1/4A 8 17 18 19 23 24 26 17 18 19 23 24 26
Go
BRASS FITTINGS G 1/4A 10 17 18 19 23 24 26 17 18 19 23 24 26

OR ALUMINUM/ G 3/8A 12 21 22 23 28 30 31 34 36 37 46 49 50
BRASS
G 1/2A 15 31 33 34 42 45 46 67 70 73 91 95 99
MATING
COMPONENTS; G 1/2A 18 31 33 34 42 45 46 48 51 53 65 69 72
UN-LUBRICATED G 3/4A 22 42 45 47 57 61 64 86 91 95 117 123 129
THREADS G 1A 28 72 76 79 98 103 107 158 166 174 214 225 236
G 1-1/4A 35 115 121 127 156 164 172 259 272 285 351 369 386
NOTE: ** Non typical for Straight Male Stud Fittings, reference only.
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-73

b. British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3
ts
MAE9420
ar
MAE9410
rp
ou
FORM A**(SEALING WASHER) FORM B** (CUTTING FACE)
TYPE/FITTING
ry
STUD ENDS WITH 37° (JIC) OR STUD ENDS WITH 37° (JIC) OR
IDENTIFICATION
L SERIES DIN (MBTL) OPPOSITE END L SERIES DIN (MBTL) OPPOSITE END
de
or
BSPP
Tube O.D.
to
G Size
om
G 1/8A 6 13 14 14 18 19 19 13 14 14 18 19 19
t.c
G 1/4A 8 26 28 29 35 38 39 26 28 29 35 38 39
STEEL FITTINGS G 1/4A 10 26 28 29 35 38 39 26 28 29 35 38 39
en
WITH STEEL G 3/8A 12 52 55 57 70 75 77 52 55 57 70 75 77

m
MATING G 1/2A 15 66 70 73 90 95 99 66 70 73 90 95 99
ip
COMPONENTS; G 1/2A 18 66 70 73 90 95 99 66 70 73 90 95 99
UN-LUBRICATED G 3/4A 22 133 140 146 180 190 198 133 140 146 180 190 198
qu
THREADS G 1A 28 229 241 252 310 327 342 229 241 252 310 327 342
-E
G 1-1/4A 35 332 349 365 450 473 495 332 349 365 450 473 495
nt
G 1-1/2A 42 398 418 438 540 567 594 398 418 438 540 567 594
ou

BSPP
Tube O.D.
sc

G Size
Di
G 1/8A 6 8 9 9 11 12 12 8 9 9 11 12 12
to
ALUMINUM/ G 1/4A 8 17 18 19 23 24 26 17 18 19 23 24 26
Go
BRASS FITTINGS G 1/4A 10 17 18 19 23 24 26 17 18 19 23 24 26

OR ALUMINUM/ G 3/8A 12 34 36 37 46 49 50 34 36 37 46 49 50
BRASS
G 1/2A 15 43 45 47 58 61 64 43 45 47 58 61 64
MATING
COMPONENTS; G 1/2A 18 43 45 47 58 61 64 43 45 47 58 61 64
UN-LUBRICATED G 3/4A 22 86 91 95 117 123 129 86 91 95 117 123 129
THREADS G 1A 28 149 157 164 202 213 222 149 157 164 202 213 222
G 1-1/4A 35 216 227 237 293 308 321 216 227 237 293 308 321
2-74 31211388 6036, 6042, 8042, 10042, 10054, 12054

c. British Standard Parallel Pipe Port (BSPP) L Series - Table 3 of 3
MAE9310
MAE9290 MAE9300
ts
ar
HIGH PRESSURE BANJO
rp
TYPE/FITTING FITTINGS WITH
WITH S SERIES DIN (MBTS) SEALING RING)
IDENTIFICATION S SERIES DIN (MBTS)
ou
OPPOSITE END
ry
BSPP Connecting
de
Material Thread Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
or
(mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/8A 6 13 14 14 18 19 19 13 14 14 18 19 19 10 11 11 13 15 15
G 1/4A 8 30 32 33 40 43 45 to
33 35 36 45 47 49 22 23 24 30 31 33
om
G 1/4A 10 30 32 33 40 43 45 33 35 36 45 47 49 22 23 24 30 31 33
STEEL FITTINGS
G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77 44 46 48 60 62 65
t.c
WITH STEEL
MATING G 1/2A 15 66 70 73 90 95 99 89 94 98 120 127 133 59 62 65 80 84 88
en
COMPONENTS; G 1/2A 18 66 70 73 90 95 99 89 94 98 120 127 133 59 62 65 80 84 88

m
UN-LUBRICATED
G 3/4A 22 92 97 101 125 132 137 170 179 187 230 243 254 103 108 113 140 146 153
THREADS
ip
G 1A 28 -- -- -- -- -- -- 236 248 260 320 336 353 148 156 163 200 212 221
qu
G 1-1/4A 35 -- -- -- -- -- -- 398 418 438 540 567 594 295 313.5 332 400 425 450
-E
G 1-1/2A 42 -- -- -- -- -- -- 516 542 568 700 735 770 332 349 365 450 473 495
nt

BSPP Connecting
ou
Material Thread Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
sc
Di
G 1/8A 6 8 9 9 11 12 12 8 9 9 11 12 12 6 7 7 8 9 9
G 1/4A 8 20 21 21 27 28 28 21 22 23 28 30 31 14 15 16 19 20 22
to
ALUMINUM/
BRASS G 1/4A 10 20 21 21 27 28 28 21 22 23 28 30 31 14 15 16 19 20 22
Go
FITTINGS OR G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50 29 30 31 39 41 42
ALUMINUM/ G 1/2A 15 43 45 47 58 61 64 58 61 64 79 83 87 38 40 42 52 54 57
BRASS
MATING G 1/2A 18 43 45 47 58 61 64 58 61 64 79 83 87 38 40 42 52 54 57
COMPONENTS; G 3/4A 22 60 63 66 81 85 89 111 117 122 150 159 165 67 70 73 91 95 99
UN-LUBRICATED G 1A 28 -- -- -- -- -- -- 153 161 169 207 218 229 96 101 106 130 137 144
THREADS
G 1-1/4A 35 -- -- -- -- -- -- 259 272 285 351 369 386 216 227 237 293 308 321
G 1-1/2A 42 -- -- -- -- -- -- 335 352 369 454 477 500 216 227 237 293 308 321
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-75

d. British Standard Parallel Pipe Port (BSPP) S Series - Table 1 of 3
ts
MAE9430
ar
MAE9440
rp
FORM A** (SEALING WASHER) FORM B** (CUTTING FACE)
ou
TYPE/FITTING
STUD ENDS WITH (ORFS) OR STUD ENDS WITH (ORFS) OR
IDENTIFICATION
ry
S SERIES DIN (MBTS) OPPOSITE END S SERIES DIN (MBTS) OPPOSITE END
de
BSPP Connecting Torque Torque
Tube O.D.
or
G Size (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/4A 6 26 28 29 35
to
38 39 41 43 45 55 58 61
om
G 1/4A 8 26 28 29 35 38 39 41 43 45 55 58 61
G 3/8A 10 33 35 36 45 47 49 66 70 73 90 95 99
t.c
STEEL FITTINGS
G 3/8A 12 33 35 36 45 47 49 66 70 73 90 95 99
WITH STEEL
en
MATING G 1/2A 14 48 51 53 65 69 72 111 117 122 150 159 165

COMPONENTS;
m
G 1/2A 16 48 51 53 65 69 72 96 101 106 130 137 144

UN-LUBRICATED
ip
G 3/4A 20 66 70 73 90 95 99 199 209 219 270 283 297

THREADS
qu
G 1A 25 111 117 122 150 159 165 251 264 276 340 358 374
G 1-1/4A 30 177 186 195 240 252 264 398 418 438 540 567 594
-E
G 1-1/2A 38 214 225 235 290 305 319 516 542 568 700 735 770
nt
BSPP Connecting Torque Torque

ou
Material Thread Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]

sc
G Size (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
Di
G 1/4A 6 17 18 19 23 24 26 27 28 29 37 38 39
G 1/4A 8 17 18 19 23 24 26 27 28 29 37 38 39
to
ALUMINUM/ G 3/8A 10 21 22 23 28 30 31 43 45 47 58 61 64
Go
BRASS FITTINGS
G 3/8A 12 21 22 23 28 30 31 43 45 47 58 61 64
OR ALUMINUM/
BRASS G 1/2A 14 31 33 34 42 45 46 72 76 79 98 103 107
MATING G 1/2A 16 31 33 34 42 45 46 62 66 69 84 89 94
COMPONENTS;
G 3/4A 20 43 45 47 58 61 64 129 136 142 175 184 193
UN-LUBRICATED
THREADS G 1A 25 72 76 79 98 103 107 163 171 179 221 232 243
G 1-1/4A 30 115 121 127 156 164 172 259 272 285 351 369 386
G 1-1/2A 38 139 146 153 188 198 207 335 352 369 454 477 500
2-76 31211388 6036, 6042, 8042, 10042, 10054, 12054

e. British Standard Parallel Pipe Port (BSPP) S Series - Table 2 of 3
ts
MAE9460
MAE9450
ar
rp
FORM E* (EOLASTIC SEALING RING) FORM G/H*** (O-RING W/ RETAINING
TYPE/FITTING STUD ENDS AND HEX TYPE PLUGS RING) STUD ENDS & ADJUSTABLE
ou
IDENTIFICATION WITH (ORFS) or S SERIES DIN (MBTS) STUD ENDS WITH (ORFS) OR
ry
OPPOSITE END S SERIES DIN (MBTS) OPPOSITE END
de
BSPP
Tube O.D.
or
G Size
G 1/4A 6 41 43 45 55 to58 61 26 28 29 35 38 39
om
G 1/4A 8 41 43 45 55 58 61 26 28 29 35 38 39
G 3/8A 10 59 62 65 80 84 88 52 55 57 70 75 77
t.c
STEEL FITTINGS
G 3/8A 12 59 62 65 80 84 88 52 55 57 70 75 77
en
WITH STEEL
MATING G 1/2A 14 85 90 94 115 122 127 66 70 73 90 95 99
m
COMPONENTS; G 1/2A 16 85 90 94 115 122 127 66 70 73 90 95 99

ip
UN-LUBRICATED
G 3/4A 20 133 140 146 180 190 198 133 140 146 180 190 198
THREADS
qu
G 1A 25 229 241 252 310 327 342 229 241 252 310 327 342
-E
G 1-1/4A 30 332 349 365 450 473 495 332 349 365 450 473 495
nt
G 1-1/2A 38 398 418 438 540 567 594 398 418 438 540 567 594
ou

BSPP
Tube O.D.
sc

G Size
Di
to
G 1/4A 6 27 28 29 37 38 39 17 18 19 23 24 26
G 1/4A 8 27 28 29 37 38 39 17 18 19 23 24 26
Go
ALUMINUM/ G 3/8A 10 38 40 42 52 54 57 34 36 37 46 49 50
BRASS FITTINGS
G 3/8A 12 38 40 42 52 54 57 34 36 37 46 49 50
OR ALUMINUM/
BRASS G 1/2A 14 55 58 61 75 79 83 43 45 47 58 61 64
MATING G 1/2A 16 55 58 61 75 79 83 43 45 47 58 61 64
COMPONENTS;
G 3/4A 20 86 91 95 117 123 129 86 91 95 117 123 129
UN-LUBRICATED
THREADS G 1A 25 149 157 164 202 213 222 149 157 164 202 213 222
G 1-1/4A 30 216 227 237 293 308 321 216 227 237 293 308 321
G 1-1/2A 38 259 272 285 351 369 386 259 272 285 351 369 386
NOTE: * Typical for Straight Male Stud Fittings

***Typical for Adjustable Fittings.
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-77

f. British Standard Parallel Pipe Port (BSPP) L Series - Table 3 of 3
MAE9290 MAE9300
ts
MAE9470
ar
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BANJO FITTINGS HIGH PRESSURE BANJO
TYPE/FITTING JIS/BSPP O-RING
WITH S SERIES DIN (MBTS) FITTINGS WITH S SERIES
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IDENTIFICATION ONLY
OPPOSITE END DIN (MBTS) OPPOSITE END
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BSPP Connecting
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Material Thread Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
or
G Size
G 1/4A 6 30 32 33 40 43 45 33
to
35 36 45 47 49
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G 1/4A 8 30 32 33 40 43 45 33 35 36 45 47 49
G 3/8A 10 48 51 53 65 69 72 52 55 57 70 75 77 Fitting type not typically
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STEEL FITTINGS
G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77 specified on Caterpillar
WITH STEEL
applications.
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MATING G 1/2A 14 66 70 73 90 95 99 89 94 98 120 127 133

COMPONENTS; G 1/2A 16 66 70 73 90 95 99 89 94 98 120 127 133
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Refer to the specific

UN-LUBRICATED
G 3/4A 20 92 97 101 125 132 137 170 179 187 230 243 254 procedure
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THREADS
G 1A 25 -- -- -- -- -- -- 236 248 260 320 336 353 in this Service Manual.
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G 1-1/4A 30 -- -- -- -- -- -- 398 418 438 540 567 594

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G 1-1/2A 38 -- -- -- -- -- -- 516 542 568 700 735 770

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BSPP Connecting
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Material Thread Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
sc
G Size
Di
G 1/4A 6 20 21 21 27 28 28 22 22 23 30 30 31
to
G 1/4A 8 20 21 21 27 28 28 22 22 23 30 30 31
ALUMINUM/
Go
G 3/8A 10 31 33 34 42 45 46 34 36 37 46 49 50 Fitting type not typically

BRASS FITTINGS
G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50 specified on Caterpillar
OR ALUMINUM/
G 1/2A 14 43 45 47 58 61 64 58 61 64 79 83 87 applications.
BRASS
MATING G 1/2A 16 43 45 47 58 61 64 58 61 64 79 83 87 Refer to the
COMPONENTS;
G 3/4A 20 60 63 66 81 85 89 111 117 122 150 159 165 specific procedure in
UN-LUBRICATED
G 1A 25 -- -- -- -- -- -- 153 161 169 207 218 229 this Service Manual.
THREADS
G 1-1/4A 30 -- -- -- -- -- -- 259 272 285 351 369 386
G 1-1/2A 38 -- -- -- -- -- -- 335 352 368 454 477 499
2-78 31211388 6036, 6042, 8042, 10042, 10054, 12054

2.8.13 Assembly Instructions for Flange

Connections (FL61 and FL62)
1. Ensure sealing surfaces are free of rust, splits, scratches,
dirt, foreign matter, or burrs.
2. Pre-lubricate the O-ring with hydraulic oil.
3. Position flange and clamp halves.
4. Place lock washers on bolt and bolt through clamp
halves.
5. Tighten all bolts by hand.
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6. Torque bolts in diagonal sequence in two or more
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increments to the torque listed.
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2-80 31211388 6036, 6042, 8042, 10042, 10054, 12054

a. Flange Code (FL61 & FL62) - Inch Fasteners
MAE9480
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STEEL 4-BOLT FLANGE SAE J518
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(INCH FASTENERS)
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Fastener Torque for Fastener Torque for
Inch Bolt
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Flange Flanges Equipped with Flanges Equipped with
Flange A* Thread GRADE 5 Screws GRADE 8 Screws
Type SAE Size
Size
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Dash [Ft-Lb] [Nm] [Ft-Lb] [Nm]
Size
or
(in) (mm) (in) (mm) (UNF) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.50 38.10 5/16-18 18 19 19 24 25 26 24 25 26 32 34 35
12 0.75 19 1.88 47.75 3/8-16 32 33 to
35 43 45 47 44 46 49 60 63 66
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16 1.00 25 2.06 52.32 3/8-16 32 33 35 43 45 47 44 46 49 60 63 66
20 1.25 32 2.31 58.67 7/16-14 52 54 57 70 74 77 68 71 75 92 97 101
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CODE 61 24 1.50 38 2.75 69.85 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
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SPLIT
32 2.00 51 3.06 77.72 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
FLANGE
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(FL61) 40 2.50 64 3.50 88.90 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
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48 3.00 76 4.19 106.43 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
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56 3.50 89 4.75 120.65 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
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64 4.00 102 5.13 130.30 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
80 5.00 127 6.00 152.40 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
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Inch Bolt Fastener Torque for Flanges Fastener Torque for Flanges
Flange Flange Equipped with GRADE 5 Screws Equipped with GRADE 8 Screws
A* Thread
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Type SAE Size

Size
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Size
(in) (mm) (in) (mm) (UNF) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
to
8 0.50 13 1.59 40.39 5/16-18 -- -- -- -- -- -- 24 25 26 32 34 35

Go
12 0.75 19 2.00 50.80 3/8-16 -- -- -- -- -- -- 44 46 49 60 63 66

CODE 62 16 1.00 25 2.25 57.15 7/16-14 -- -- -- -- -- -- 68 71 75 92 97 101
SPLIT
20 1.25 32 2.62 66.55 1/2-13 -- -- -- -- -- -- 111 116 122 150 158 165
FLANGE
(FL62) 20 1.25 32 2.62 66.55 -- -- -- -- -- -- -- -- -- -- -- -- --
24 1.50 38 3.12 79.25 5/8-11 -- -- -- -- -- -- 218 228 239 295 310 325
32 2.00 51 3.81 96.77 3/4-10 -- -- -- -- -- -- 332 348 365 450 473 495
NOTE: * A dimension for reference only.
6036, 6042, 8042, 10042, 10054, 12054 31211388 2-81

b. Flange Code (FL61 & FL62) - Metric Fasteners
MAE9480
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TYPE/FITTING STEEL 4-BOLT FLANGE SAE J518
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IDENTIFICATION (INCH FASTENERS)
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Inch Fastener Torque for Fastener Torque for
Bolt Flanges Equipped with Flanges Equipped with
Flange Flange Size
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A* Thread CLASS 8.8 Screws CLASS 10.9 Screws
Type SAE Size
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Size (in) (mm) (in) (mm) (Metric) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
or
8 0.50 13 1.50 38.10
12 0.75 19 1.88 47.75 M8 x 1.25 18 19 19 24 25 26 18 19 19 24 25 26
16 1.00 25 2.06 52.32 M10 x 1.5 37 39 41
to
50 53 55 37 39 41 50 53 55
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20 1.25 32 2.31 58.67 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
CODE 61 24 1.50 38 2.75 69.85 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
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SPLIT
32 2.00 51 3.06 77.72 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
FLANGE
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(FL61) 40 2.50 64 3.50 88.90 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101

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48 3.00 76 4.19 106.43 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101

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56 3.50 89 4.75 120.65 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
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64 4.00 102 5.13 130.30 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
80 5.00 127 6.00 152.40 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
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Inch Fastener Torque for Fastener Torque for

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Bolt Flanges Equipped with Flanges Equipped with

Flange Flange Size A* Thread
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Type SAE GRADE 5 Screws GRADE 8 Screws

Size
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Size (in) (mm) (in) (mm) (Metric) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
Di
8 0.50 13 1.59 40.39 M8 x 1.25 -- -- -- -- -- -- 24 25 26 32 34 35

to
12 0.75 19 2.00 50.80 M10 x 1.5 -- -- -- -- -- -- 52 54 57 70 74 77

CODE 62 16 1.00 25 2.25 57.15 M12 x 1.75 -- -- -- -- -- -- 96 101 105 130 137 143
Go
SPLIT
20 1.25 32 2.62 66.55 M12 x 1.75 -- -- -- -- -- -- 96 101 105 130 137 143
FLANGE
(FL62) 20 1.25 32 2.62 66.55 M14 x 2 -- -- -- -- -- -- 133 139 146 180 189 198
24 1.50 38 3.12 79.25 M16 x 2 -- -- -- -- -- -- 218 228 239 295 310 325
32 2.00 51 3.81 96.77 M20 x 2.5 -- -- -- -- -- -- 406 426 446 550 578 605
NOTE: * A dimension for reference only.
2-82 31211388 6036, 6042, 8042, 10042, 10054, 12054

2.8.14 Double Wrench Method

To prevent undesired hose or connector rotation, two
wrenches must be used; one torque wrench and one back
up wrench. If two wrenches are not used, inadvertent
component rotation may occur which absorbs torque and
causes improper joint load and leads to leaks. For hose
connections, the ‘layline’ printed on the hose is a good
indicator of proper hose installation. A twisted lay-line
usually indicates the hose is twisted.
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Double Wrench Method to Prevent Hose Twist
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6036, 6042, 8042, 10042, 10054, 12054 31211388 2-83

2.8.15 FFWR and TFFT Methods 2.8.16 Adjustable Stud End Assembly
1. FFWR (Flats from Wrench Resistance Method) For Adjustable Stud End Connections; the following
a. Tighten the swivel nut to the mating fitting until no assembly steps are to be performed:
lateral movement of the swivel nut can be detected; a. Lubricate the o-ring with a light coat of hydraulic oil.
finger tight condition.
b. Position #1 – The o-ring should be located in the
b. Mark a dot on one of the swivel hex nut flats and groove adjacent to the face of the backup washer.
another dot in line on the connecting tube adapter. The washer and o-ring should be positioned at the
c. Use the double wrench method per Appendix A, extreme top end of the groove as shown.
turn the swivel nut to tighten. The nut is to be c. Position #2 – Position the locknut to just touch the
rotated clockwise the number of hex flats. backup washer as shown. The locknut in this
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d. After the connection has been properly tightened, position will eliminate potential backup washer.
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mark a straight line across the connecting parts, not
covering the dots, to indicate the connection has 2.8.17 O-ring Installation (Replacement)
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been properly tightened.
Care must be taken when installing o-rings over threads
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FFWR Method
during replacement or installation. O-rings could become
nicked or torn. A damaged o-ring could lead to leakage
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problems.
1. Inspect o-ring for tears or nicks. If any are found replace
or
o-ring.
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2. Ensure proper o-ring to be installed. Many o-rings look
the same but are of different material, different
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hardness, or are slightly different diameters or widths.
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3. Use a thread protector when replacing o-rings on

MAE9500
fittings.
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2. TFFT (Turns from Finger Tight Method) 4. In ORB; ensure o-ring is properly seated in groove. On
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straight threads, ensure o-ring is seated all the way past

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a. Tighten the swivel nut to the mating fitting until no the threads prior to installation.
lateral movement of the swivel nut can be detected;
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finger tight condition. 5. Inspect o-ring for any visible nicks or tears. Replace if
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b. Mark a dot on one of the swivel hex nut flats and found.
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another dot in line on the connecting tube adapter.

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c. Use the double wrench method per Appendix A,

turn the swivel nut to tighten. The nut is to be
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rotated clockwise the number of turns.

Di
d. After the connection has been properly tightened,

mark a straight line across the connecting parts, not
to
covering the dots, to indicate the connection has

been properly tightened.
Go
2-84 31211388 6036, 6042, 8042, 10042, 10054, 12054

Need parts?
Section 3
Boom
Contents
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3.1 Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
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3.3 Boom System - Three Section (6036, 6042, 8042 & 10042) . . . . . . . . . . . . . . . . . . . . . . . . 3-4
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3.3.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
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3.4 Boom Assembly Maintenance (6036, 6042, 8042 & 10042) . . . . . . . . . . . . . . . . . . . . . . . 3-4
r
3.4.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
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3.4.2 Third Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
or
3.4.3 Second Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.4.4 First Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.4.5
3.4.6
to
First Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Second Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9
3-11
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3.4.7 Third Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
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3.4.8 Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3.5 Boom System - Four Section (10054 & 12054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
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3.5.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

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3.6 Boom Assembly Maintenance (10054 & 12054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

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3.6.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

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3.6.2 Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3.6.3 Third Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
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3.6.4 Second Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

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3.6.5 First Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

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3.6.6 First Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3.6.7 Second Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
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3.6.8 Third Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Di
3.6.9 Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

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3.6.10 Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

3.7 Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Go
3.7.1 Boom Chain Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

3.7.2 Inspection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.7.3 Expose Chains for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3.7.4 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3.7.5 Boom Chain Tension Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3.7.6 Boom Chain Tension Adjustment (6036, 6042, 8042 & 10042) . . . . . . . . . . . . . . . . 3-37
3.7.7 Boom Chain Tension Adjustment (10054 & 12054) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3.7.8 Extend Chains Removal and Replacement (6036, 6042, 8042 & 10042) . . . . . . . 3-44
3.7.9 Retract Chain Removal and Replacement (6036, 6042, 8042 & 10042) . . . . . . . . 3-45
3.7.10 Extend Chains Removal and Replacement (10054 & 12054 ) . . . . . . . . . . . . . . . . . 3-47
3.7.11 Retract Chain Removal and Replacement (10054 & 12054) . . . . . . . . . . . . . . . . . . 3-51
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-1

Boom
3.8 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

3.8.1 Wear Pad Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
3.8.2 Wear Pad Installation and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
3.9 Quick Coupler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
3.9.1 Quick Coupler Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
3.9.2 Quick Coupler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
3.10 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
3.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
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3-2 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
3.1 BOOM SYSTEM COMPONENT

TERMINOLOGY
The following illustrations identify the components that are
referred to throughout this section.
THREE SECTION BOOM (6036, 6042, 8042 & 10042)
FIRST BOOM
BOOM EXTEND SECOND BOOM
BOOM RETRACT SECTION
CHAINS SECTION
THIRD BOOM CHAIN
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SECTION
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BOOM PROXIMITY
SENSOR
or
EXTEND/RETRACT
CYLINDER
COMPENSATION
TILT CYLINDER
to LIFT/LOWER
CYLINDER
om
CYLINDER
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QUICK COUPLER
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FOUR SECTION BOOM (10054 & 12054)

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FOURTH BOOM SECOND & THIRD THIRD BOOM

SECTION EXTEND BOOM SECTION SECTION
FIRST BOOM
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EXTEND CHAINS SECOND BOOM

CHAIN SECTION
SECTION
FOURTH BOOM
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SECTION RETRACT SECOND & THIRD

CHAIN
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FOURTH BOOM BOOM SECTION

SECTION RETRACT CHAIN
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BOOM PROXIMITY
BOOM PROXIMITY SENSOR
SENSOR
EXTEND/RETRACT
CYLINDER
COMPENSATION
CYLINDER
TILT CYLINDER
LIFT/LOWER
CYLINDER
MH4351
QUICK COUPLER
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-3

Boom
3.2 SAFETY INFORMATION
WARNING WARNING
NEVER weld or drill the boom unless approved in writing
DO NOT service the machine without following all safety
by the manufacturer. The structural integrity of the boom
precautions as outlined in Section 1, “Safety Practices”, of
will be impaired if subjected to any repair involving
this manual.
welding or drilling.
3.3 BOOM SYSTEM - THREE SECTION 3.4.1 Boom Removal
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(6036, 6042, 8042 & 10042)
1. Remove any attachment from quick coupler assembly.
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3.3.1 Boom System Operation Note: When removing a complete boom assembly use a hoist
or crane with a minimum lift capacity of 8000 lb (3628,7 kg).
ur
The three section boom assembly consists of first, second
yo
and third boom section assemblies with double top boom Note: If replacing the third section boom, remove the quick
extend chains and a single retract chain. Boom extension and coupler from the third section. Refer to Section 3.9, “Quick
r
retraction is accomplished via hydraulic power and chain Coupler”.
de
movement. 2. Park the machine on a hard, level surface, level the
or
As the Extend/Retract hydraulic cylinder, which is anchored machine, fully retract the boom, lower the boom, place
at the rear of the second boom section and the rear of the the transmission in (N) NEUTRAL, engage the park brake
first boom section, begins to extend, it forces the second to
and shut the engine OFF.
om
boom section out of the first boom section. 3. Place a Do Not Operate Tag on both ignition key switch
The second and third boom sections are connected by and steering wheel.
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extend and retract chains. These chains are routed around 4. Open the engine rear and side engine doors. Allow the
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sheaves on the second boom section. As the second boom system fluids to cool.
section is forced out, the extend chain pulls the third boom
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5. Move the attachment tilt joystick in both directions to

section out of the second boom section.
relieve any trapped pressure in the attachment tilt
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As hydraulic pressure is applied to the retract port on the system. If the machine is equipped with auxiliary
qu
Extend/Retract cylinder, the second boom section is pulled controls, move the auxiliary hydraulic joystick in both
-E
back into the first boom section, and retract chain pulls the directions to relieve any trapped pressure in the
third boom section back into the second section. auxiliary hydraulic system.
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This mechanical linkage formed by the chains and

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6. Properly disconnect the battery. Refer Section 9.8,

supporting hardware extends and retracts the second and “Battery”, for procedure.
sc
third boom sections at the same rate.

7. Label, disconnect and cap the hydraulic hoses at the
Di
The first boom section does not extend or retract, but lifts rear of the boom. Cap all fittings to keep dirt and debris
and lowers via action of the lift/lower cylinder. from entering the hydraulic system.
to
8. Label and disconnect the boom proximity sensor at the

3.4 BOOM ASSEMBLY MAINTENANCE
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rear of the boom.

(6036, 6042, 8042 & 10042)
9. Remove the pin from the rod end of the compensation
These instructions must be completed in sequence. The third cylinder being careful not to drop the cylinder. Lower
boom section must be removed before removing the second the cylinder onto the frame rails.
boom section. The third and second boom section must be 10. Remove the pin from the rod end of the lift/lower
removed at one time before removing the first boom section. cylinders. Lower the cylinders onto the frame rails.
Before beginning, conduct a visual inspection of the 11. Confirm that the boom assembly is balanced with the
machine and work area, and review the task about to be sling and remove the boom assembly pivot pin.
undertaken. Read, understand and follow these instructions. 12. Lift the boom assembly from the machine and lower
onto suitable supports.
3-4 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
3.4.2 Third Boom Section Removal

1 2
Note: If replacing the third section boom, remove the quick
coupler from the third section. Refer to Section 3.9, “Quick
Coupler”.
2. Park the machine on a hard, level surface, level the
machine, fully retract the boom, lower the boom, place
the transmission in (N) NEUTRAL, engage the park brake
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3. Place a Do Not Operate Tag on both ignition key switch
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and steering wheel.
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4. Open the engine rear and side engine doors. Allow the
system fluids to cool.
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MH2841
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11. Remove the stack clamps (1) and hose clamp support
relieve any trapped pressure in the attachment tilt bracket (2) to the left side of the third boom section.
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system. If the machine is equipped with auxiliary
controls, move the auxiliary hydraulic joystick in both
or
directions to relieve any trapped pressure in the
auxiliary hydraulic system.
6. Label, disconnect and cap the hoses attached to the to
om
attachment tilt cylinder. Cap all fittings to keep dirt and
debris from entering the hydraulic system.
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7. If the machine is equipped with auxiliary hydraulics, 3

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label, cap and remove the hoses from the bulkhead

fittings.
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8. If replacing the third boom section with a new boom

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section: Remove the female coupler, male nipple and

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bulkhead fittings from the bulkhead plate inside the

-E
boom head.
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9. Remove the rear cover from the boom.

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10. If equipped with Auxiliary hydraulics, inside the third

boom section, loosen, but DO NOT remove the
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capscrews securing the left side wear pad and hose MH0871
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clamp support bracket to the top of the third boom

section. 12. Pull the free ends of the hydraulic hoses (3) from the
to
inside the third boom section and out of the rear of the
boom. Allow the hoses to hang from the rear of the
Go
boom.
13. Remove the top and side wear pads and spacers to the
inside of the second boom section. Label and tag each
set of wear pads being removed.
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-5

Boom
4 6
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7
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MH0912
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14. At the rear of the boom, measure the amount of threads MH2551
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protruding beyond each locknut (4) and record the
Note: Record the location of the shoulder bolt (6) to ensure
measurement for reassembly. Remove the two locknuts
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correct installation.
and flat washers holding both extend chain clevis’ to
the anchor plate on the first boom section. 16. At the rear of the boom, locate the retract chain (7) on
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the right side of the boom. In front of the retract chain
or
sheave, locate the shoulder bolt which holds the retract
chain to the anchor plates on the third boom section.
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Remove the locknut from the shoulder bolt. Allow the
om
retract chain to hang out the rear of the boom.
Note: If replacing the third boom section with a new boom
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5 section, the quick coupler assembly and the Attachment Tilt

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cylinder should be removed at this time. Refer to Section 3.9,

“Quick Coupler”. If the third boom section is not to be replaced,
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the quick coupler assembly and Attachment Tilt cylinder can

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remain in place.
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17. Using a sling or suitable support, pull the third boom

-E
MH0921
section straight out of the second boom section.
Reposition the slings as needed so the third boom
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15. At the front of the second boom section, pull both section balances when removed from the second boom
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extend chains (5) out from between the second and section. Set the boom section down on a hard, level
third boom sections. The extend chains can remain surface. Support the boom as needed to prevent it from
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anchored between the yoke plates on the first boom tipping over.
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section. Loop both chains over the top of the chain 18. At the rear of the third boom section, remove the
sheave and lay the chains on top of the boom.
to
remaining wear pads, shims and hardware. Label and

tag each set of wear pads being removed.
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19. Inspect all wear pads for wear. Refer to Section 3.8,
“Boom Wear Pads”.
3-6 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
3.4.3 Second Boom Section Removal 7. Remove hose reel side plate, lower left side wear pad
and shims. Label and tag each set of wear pads being
1. At the front of the first boom section, remove the top,
removed.
bottom and side wear pads to the inside of the boom.
Label and tag each set of wear pads being removed. 8. Pull the hose reel, with hoses, out the back of the
second boom section. Allow the hose reel assembly to
2. Remove the capscrews and lockwashers holding the
slide down the hoses and rest it on the floor.
center wear pad spacer mount to the front of the first
boom section. Label and tag each set of wear pads 9. Label and remove the hoses from the hose reel. The
being removed. center bolt can remain in place to hold the hose reel and
side plates together.
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10
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MH1451
MH1021 to
10. Label, disconnect and cap the hydraulic hoses from the
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bottom tube assemblies at the mounting plate (10).
3. At the rear of the second boom section, remove the
11. Pull the hose ends out from between the second and
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capscrew and lockwasher holding the retract chain

sheave pin (8) to the mounting plate inside the boom. first boom sections and out the rear of the boom.
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4. Remove the retract chain sheave pin from the mount 12. Using a suitable sling or support, secure the front of the
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and the retract chain sheave. Remove the retract chain Extend/Retract cylinder.
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sheave from the second boom section.

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5. Inspect the bushings inside the sheave. Replace the

bushings if there are any signs of wear. Inspect the pin
-E
for wear or damage. Replace the pin if showing signs of

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wear.
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to
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11
MH1051
9
13. Remove the retaining ring from one side of the
Extend/Retract cylinder rod end mounting pin (11).
MH1501
14. Using a sling or suitable support, pull the second boom
section straight out of the first boom section.
6. At the rear of the second boom section, remove the Reposition the slings as needed so the second boom
hose reel assembly (9), lower wear pad and spacer. section balances when removed from the first boom
Reassemble the capscrews, lockwashers and flat section. Set the second boom section down on blocks
washers to hold the lower wear pad in place for second on a hard, level surface.
boom section removal.
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-7
Boom
15. Remove the remaining wear pads. Label and tag each
set of wear pads being removed.
16. Inspect all wear pads for wear. Refer to Section 3.8, 14
MH1131
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4. Label, disconnect and cap the hydraulic hoses from the
12
bulkhead fittings on the mounting plate (14). Remove
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the tubes from the bulkhead fittings.
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5. At the rear right side of the boom, label, disconnect and
cap the boom Extend/Retract hoses from the bulkhead
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fittings on the mounting plate. Cap the fittings to keep
dirt and debris from entering the hydraulic system.
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MH1091
or
17. Remove the extend chain sheave (12).
16
3.4.4 First Boom Section Removal
to
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1. Use a suitable overhead lifting device and sling
attached to the Lift/Lower cylinder; remove slack from 15
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the sling.
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MH1151
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6. Remove the tube clamps (15) and clamp covers to the

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Extend and Retract tubes under the boom.

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7. At the rear right side of the boom, label, disconnect and

cap the Extend and Retract tubes (16) from the
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bulkhead fittings. Cap the fittings to keep dirt and

to
13
MH1111
Go
2. At the underside of the boom, locate the retract chain

locknut (13). Measure the amount of threads protruding
beyond the locknut and record that measurement for
reassembly of the chain. Remove the locknut and flat
washer.
3. Remove the retract chain by pulling it out through the
17
rear of the boom. Place the retract chain on a clean
surface.
MH1201
3-8 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
8. Label, disconnect and cap the hydraulic hoses attached 15. Lower the base end of the Extend/Retract cylinder and
to both compensation cylinders (17). Cap all fittings to remove the rod end of the cylinder from the retainer at
keep dirt and debris from entering the hydraulic system. the front of the boom. Place the Extend/Retract cylinder
9. Support the compensation cylinder on the right side of on a clean, flat surface.
the machine. Remove the rod end pins securing the 16. At the front of the first boom section, remove rubber
cylinder in position. Move the cylinder to a clean, flat bumper to the Extend/Retract cylinder retainer. Inspect
surface. Repeat this procedure for the left side the rubber bumper. If it is in good condition, the rubber
compensation cylinder. bumper can be reused. If the bumper is showing signs
of cracking or deterioration, it should be replaced.
17. Remove the two yoke plates to the mount at the front of
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the boom. Inspect the yoke plates for wear or distortion.
If any wear or distortion is detected, both plates must
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be replaced. If no wear is detected, the plates can
remain assembled to the extend chain clevis.
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18
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3.4.5 First Boom Section Installation
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1. On the rear of the boom, assemble the extend and
MH1221
retract bulkhead fittings to the mounting plate on the
10. Remove the boom proximity sensor (18) from the right
side boom pivot mounting plate.
to
right side. Insert the fittings from the bottom up and
om
secure in place with the bulkhead fitting nuts on the top
11. Securely block up or support the right Lift/Lower side. Tighten securely. Repeat this procedure for the
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cylinder. Remove the rod end pin. Repeat this procedure attachment tilt fittings on the left side.
for the left Lift/Lower cylinder.
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Note: Keep the caps on the threaded ends of the fittings to

protect the threads from damage and to keep dirt and debris
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from entering the hydraulic system.

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19 2. If equipped with auxiliary hydraulics, assemble the

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auxiliary hydraulic bulkhead fittings to the mounting

-E
plate on the left side. Insert the fittings from the bottom
up into the outer set of holes and secure in place with
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the bulkhead fitting nuts on the top side. Tighten

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securely.
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3. Using a sling, position the extend/retract cylinder to its

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MH1241 original orientation under the boom.

12. Remove the boom pivot pins (19) to the frame. While 4. Coat the base end of the cylinder with anti-seize
to
removing the pins, note the location and quantity of compound. Insert the base end cylinder pin through
shims between the outer boom and frame.
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both mounting ears and the base end of the Extend/

13. Using a sling or suitable support, carefully lift the first Retract cylinder. Secure the pin in place with a retaining
boom section away from the machine. Set the boom ring on each side of the pin.
section down on a hard, level surface. Support the 5. Lift the rod end of the Extend/Retract cylinder enough
boom as required to allow removal of the Extend/ to insert the threaded stud on the rubber bumper into
Retract cylinder from the underside of the boom. the hole in the Extend/Retract cylinder retainer. Secure
14. Use a hoist and slings to support the Extend/Retract the rubber bumper in place with a locknut. Tighten
cylinder. At the base end of the cylinder, remove a securely. Lower the rod end of the Extend/Retract
retaining ring from one side of the cylinder base end cylinder, and allow it to rest on the rubber bumper.
pin.
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-9

Boom
6. Using a suitable hoist and slings, lift the boom assembly 11. Use a hoist or suitable support to position the right side
and position the boom on the frame. Align the compensation cylinder to its original orientation onto
mounting plates on the frame between the mounting the lower cylinder mount. Coat the entire
hubs on each side of the boom assembly. Lower the Compensation cylinder pin with anti-seize compound.
boom assembly until the holes in the boom assembly Insert the pin through the rod end of the cylinder and
and the mounting plates align. the self-aligning bearing. Secure with lockbolt. Repeat
7. On the end of the boom pivot pin, closest to the procedure for left side Compensation cylinder.
capscrew hole, mark the capscrew mounting hole 12. Install the boom proximity sensor on the right side
location. Coat the entire pin with anti-seize compound. mounting plate. With the boom properly shimmed,
8. Insert the pivot pin from the outside of the boom position the boom assembly all the way to the right
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assembly, making sure the marks for the capscrew side.
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mounting hole stay in line with the capscrew mounting B
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holes in the boom mounting hub.
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20 MH1391
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13. Insert the boom proximity sensor through the hole in

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the right side mounting plate. Install the jam nut onto
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the boom proximity sensor on the inside of the plate.

Adjust the inner and outer jam nuts on the sensor until
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the gap (B) between the sensor and the boom is

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0.12 in. (3 mm). Torque the inside jam nut to

-E
MH1381 36 lb-in. (4,1 Nm), to hold the sensor in position.

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9. Shim the boom as required using the shims (20) to

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maintain a 0.10” (2,5 mm) maximum gap (A) between

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the boom mounting hub and the self aligning bearing 16

in the frame. If an additional shim is required to
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maintain the maximum gap, the extra shim MUST be 15

to
inserted on the right side of the boom.

10. Align the rod end of the right Lift/Lower cylinder with
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the self-aligning bearing on the boom assembly. Coat

the entire Lift/Lower cylinder pin with anti-seize
compound. Insert the pin through the rod end of the
cylinder and the self-aligning bearing. Secure with lock
bolt. Repeat procedure with left Lift/Lower cylinder.
MH1151
14. Install the Extend and Retract tubes (16) to the inside
bulkhead fitting and the Extend/Retract cylinder.
15. Install the Extend and Retract tube clamp halves (15).
16. Uncap and connect the hydraulic hoses and attach to
their appropriate cylinder locations.
3-10 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
17. Install the Extend and Retract and Auxiliary (if 3.4.6 Second Boom Section Installation
equipped) tube assemblies to their appropriate
bulkhead fittings. Secure with tube clamps.
22
18. Uncap and connect the previously labeled attachment
tilt and auxiliary (if equipped) hydraulic hoses to their
appropriate bulkhead fittings.
8
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MH1481
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1. At the rear of the second boom section, assemble the
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retract chain sheave (22) to the mounting ears on the
right side of the boom. Place the sheave between the
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ears and insert the sheave pin (8) from the left side.
21
or
Align the hole in the pin retainer plate with the
threaded hole in the left ear. Secure the pin.
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2. Apply grease to the grease fitting in the pin. Spin the
om
sheave by hand to ensure the sheave spins freely on the
MH1461 pin and to distribute grease evenly.
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19. Inside the rear of the boom, slide the threaded clevis
end (21) of the retract chain down the right side of the
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boom. Guide the threaded part of the clevis out

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through the hole in the tab on the bottom of the boom.

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Pull threaded part of clevis all the way through tab.

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20. Coat the entire threaded portion of the clevis with

multi-purpose grease. Install a flat washer and locknut
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onto the clevis. Thread the nut onto the clevis until the
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threads are flush with the top of the nut.

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21. Install the bottom wear pads to the first boom section 9
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with the previously used hardware.

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MH1501
to
3. Install the hose reel assembly (9), left side and bottom
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wear pads to the rear of the second boom section.

4. Install the boom side and top wear pads.
5. Grease the sections of the boom in areas where the
wear pads will slide.
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-11

Boom
6. Before installing the second boom section into the first 3.4.7 Third Boom Section Installation
boom section, place a string (heavy enough to pull the
attachment tilt and auxiliary hydraulic hoses) down the
0
inside of the boom. Allow the string to hang out the rear 6.0 )
19 8 cm
(49
of the boom. Pull the other end out the opening on the
left side of the boom where the hoses will exit the
boom. Position the strings all the way to the left side of
the first boom section.
7. Using a suitable sling, carefully slide the second boom
section into the first boom section. Leave enough room MH1401
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at the front of the boom to install the center wear pad.
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8. Install the center wear pad mount and wear pad to the 1. Stretch the attachment tilt and auxiliary (if equipped)
hoses out straight on a flat surface. Measure from the
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bottom front of the first boom section.
male end of each hose back 196 in. (498 cm) and apply
9. Install the side and top wear pads to the front of the first
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tape around each hose at that point. The tape is for
boom section. proper tensioning of the hoses during reassembly of the
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hose clamps.
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2. Slide the elbow ends of the hoses down the third boom
section and out the boom head. Be careful not to cross
or
the hoses as you pull them out. Secure the hoses in
place with hose clamps. DO NOT tighten the hose
to
clamps at this time.
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12
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2
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MH1091
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10. Install the double extend chain sheave (12) to the front
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of the second boom section.

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11. With the sling still in place, install the rod end of the
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Extend/Retract cylinder, pin and retaining ring.

12. Install the front, bottom wear pads in the second boom
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1
section.
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to
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MH1631
3. Install the hose clamp support bracket (2) and top left
side wear pad to the third boom section (Auxiliary
hydraulics only).
4. Position the attachment tilt and auxiliary hydraulic
hoses with the edge of the tape at the hose clamps (1).
Hold the hoses in this position, and tighten the hose
clamps.
3-12 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
5. Install the top, bottom and side wear pads to the rear of
the third boom section. If the machine is equipped with
auxiliary hydraulics, the top left wear pad is already
installed.
5
9
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MH1651
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MH1691
6. Lay the two extend chains (5) on the top of the third
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boom section with the threaded clevis ends toward the 12. Assemble the hoses to the hose reel (9) at the rear of the
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rear of the boom. Coat the threads on each clevis with boom.
or
multi-purpose grease and insert the clevis’ through the
Note: Keep the hoses in the same order as they come from the
holes in the anchor plate. Install a washer and locknut
hose clamps. DO NOT allow the hoses to cross.
onto each clevis. Tighten the locknut enough so the
threads are even with the top of the locknut. to
13. Tie the strings (positioned inside the first boom section)
om
7. At the rear of the third boom section, place the male to the male end of the hydraulic hoses coming off the
bottom of the hose reel assembly.
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ends of the hydraulic hoses in the third boom section to

prevent damage while installing the third boom section 14. Working from the front of the boom, pull each hose
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into the second boom section. through the boom assembly through the opening at
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8. Grease the sections of the boom in areas where the the bottom of the first boom section.
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wear pads will slide. 15. Remove the strings from the hoses.
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9. Using a suitable sling, carefully slide the third boom

section into the second boom section. Leave enough
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room at the front of the boom to install the remaining

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wear pads.
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10. Install the top and side wear pads to the inside of the
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second boom section.

10
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11. Pull the male ends of the hydraulic hoses out the rear of
the third boom section. Stretch the hoses out straight
to
behind the machine.

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MH1451
16. At the front of the first boom section, assemble the hose
assemblies and tube assemblies to the mounting
plate (10).
Note: Where the hose assemblies come out of the outer boom,
lubricate the radius in the first boom section with soap and
water to allow proper tensioning of hoses.
17. Place the retract chain up around the retract chain
sheave on the right side of the boom. Stretch the chain
forward and place the clevis between the two anchor
plates. Align the hole in the clevis with the second hole
from the rear of the anchor plates.
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-13
Boom
18. Insert the shoulder bolt from the top down and secure 3.4.8 Boom Installation
in place with a locknut.
24
23
2. Using suitable slings, balance the boom assembly, lift
and guide the boom assembly into place. Align the
frame pivot bores with the boom assembly pivot bores.
Install the boom pivot pin.
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SH1871
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19. Assemble the two extend chains to the mount if the controls, move the auxiliary hydraulic joystick in both
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yoke plates (23) were removed from the extend chains.
Secure in place with a locknut. Tighten the locknut auxiliary hydraulic system.
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securely; but the yoke plates must pivot freely. 4. Refer to Section 2.6, “Threadlocking Compound”, for all
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20. Align the holes in the yoke plates with the hole in the thread locking requirements.
mount on the first boom section. Coat the shoulder 5. With the sling still in place, install the rod end of the
or
bolt (24) with anti-seize compound and insert the Compensation cylinder, pin and bolt. Torque lock bolt to
shoulder bolt through the yoke plates and the mount
to
100 - 110 lb-ft (135 - 149 Nm).
on the boom. Secure in place with a locknut. Tighten
6. With the sling still in place, install the rod end of each
om
the locknut securely; but the yoke plates must pivot
lift/lower cylinder, pin and bolt. Torque lock bolt to
freely.
200 - 215 lb-ft (271 - 291 Nm).
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21. Install the quick coupler and attachment tilt cylinder to

7. Uncap and connect the hydraulic hoses at the rear of
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the front of the boom. Refer to Section 3.9.2, “Quick

the boom.
Coupler Installation”.
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8. Connect the boom proximity sensor at the rear of the

22. If necessary, install the auxiliary hydraulic fittings to the
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boom.
front of the boom.
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9. Recheck wear pad gaps to ensure they meet the

23. Uncap and connect the previously labeled hoses to the
minimum gap requirement. Shim as necessary.
-E
attachment tilt cylinder.

10. Ensure that the boom chains are properly adjusted.
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24. Properly connect the battery. Refer Section 9.8,

Refer to Section 3.7.6, “Boom Chain Tension Adjustment
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“Battery”, for procedure.

(6036, 6042, 8042 & 10042)”.
25. Remove the Do Not Operate Tags from both ignition
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key switch and steering wheel.
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26. Start the engine and operate all boom functions several
to
times. Check the chain tension again and adjust as

times. Check for leaks, and check the hydraulic fluid at
necessary. Check for leaks, and check the hydraulic fluid
Go
the reservoir; add fluid if required.

level in the tank; add fluid if required.
13. Lower the boom assembly and shut engine OFF.
27. Clean up all debris, hydraulic fluid, etc., in, on, near and
around the machine. 14. Remove Do Not Operate Tags from both ignition key
switch and steering wheel.
28. Install the rear cover to the boom.
29. Close and secure the engine rear and side engine doors.
around the machine.
3-14 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
3.5 BOOM SYSTEM - FOUR SECTION 3.6.1 Boom Removal

(10054 & 12054) While the boom sections can be separated from each other
on the machine, it is more efficient to remove the complete
3.5.1 Boom System Operation boom assembly from the machine and place it on suitable
supports for separation.
The four section boom consists of the fourth, third, second
and first boom assemblies with double intermediate boom Note: When removing a complete boom assembly use a hoist
extend chains, a single inner boom extend chain, a single or crane with a minimum lift capacity of 8000 lb (3628,7 kg).
inner boom retract chain and a single intermediate boom 1. Remove any attachment from quick coupler assembly.
retract chain.
Note: If replacing the fourth section boom, remove the quick
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As the Extend/Retract hydraulic cylinder, which is anchored
coupler from the fourth section. Refer to Section 3.9, “Quick
ar
at the front of the second boom section, and the rear of the
Coupler”.
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first boom section begins to extend, it forces the second
boom section out of the first boom section. 2. Park the machine on a hard, level surface, level the
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The fourth, third, second and first boom sections are machine, fully retract the boom, lower the boom, place
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connected by extend and retract chains. These chains are
routed around sheaves on the third and second boom and shut the engine OFF.
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sections. As the second and third boom sections are forced 3. Place a Do Not Operate Tag on both ignition key switch
out, the extend chain pulls the fourth boom section out of and steering wheel.
or
the third. 4. Open the engine rear and side engine doors. Allow the
As hydraulic pressure is applied to the retract port on the
Extend/Retract cylinder, the third boom section is pulled to
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back into the fourth boom section, and the retract chain pulls relieve any trapped pressure in the attachment tilt
the third and fourth boom sections back into the second
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boom section. controls, move the auxiliary hydraulic joystick in both
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This mechanical linkage formed by the chains and directions to relieve any trapped pressure in the
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supporting hardware, extends and retracts the second, third auxiliary hydraulic system.
and fourth boom sections at the same rate.
ip

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The first boom section does not extend or retract, but lifts “Battery”, for procedure.
and lowers via action of the Lift/Lower cylinders. 7. Label, disconnect and cap the hydraulic hoses at the
-E
rear of the boom. Cap all fittings to keep dirt and debris
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3.6 BOOM ASSEMBLY MAINTENANCE from entering the hydraulic system.

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(10054 & 12054) 8. Label and disconnect the boom proximity sensor at the
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rear of the boom.

These instructions must be completed in sequence. The
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fourth boom section must be removed before removing the 9. Remove the pin from the rod end of the compensation
third boom section. The third boom section must be cylinder being careful not to drop the cylinder. Lower
to
removed before removing the second boom section.The the cylinder onto the frame rails.
fourth, third and second boom section must be removed at
Go
10. Remove the pin from the rod end of the lift/lower
one time before removing the first boom section. cylinders. Lower the cylinders onto the frame rails.
Before beginning, conduct a visual inspection of the 11. Confirm that the boom assembly is balanced with the
machine and work area, and review the task about to be sling and remove the boom assembly pivot pin.
undertaken. Read, understand and follow these instructions. 12. Lift the boom assembly from the machine and lower
onto suitable supports.
WARNING
NEVER weld or drill the boom unless approved in writing
by the manufacturer. The structural integrity of the boom
will be impaired if subjected to any repair involving
welding or drilling.
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-15

Boom
3.6.2 Fourth Boom Section Removal

12054
Note: If replacing the fourth section boom, remove the quick
coupler from the fourth section. Refer to Section 3.9, “Quick
Coupler”.
the transmission lever in (N) NEUTRAL, engage the park
brake and shut the engine OFF.
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and steering wheel.
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MAE40540
yo
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10. For 12054, remove hydraulic hoses from bottom tube
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assemblies. Cap the hose ends.
or
6. Label, disconnect and cap the hoses attached to the to
om
attachment tilt cylinder. Cap all fittings to keep dirt and
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7. If the machine is equipped with auxiliary hydraulics,

en
label, cap and remove the hoses from the bulkhead

fittings. 2
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If replacing the fourth boom section with a new boom

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section: Remove the female coupler, male nipple and

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bulkhead fittings from the bulkhead plate inside the

boom head.
-E
8. Remove the rear cover from the boom.

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10054
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MAE40550
sc
11. Label and remove the hydraulic hoses from the hose
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reel (2).
to
Go
MH1451
9. At the front of the first boom section, label and remove

the hydraulic hoses from the bottom tube assemblies at
the mounting plate (1). Cap the hose ends.
3-16 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
10054 4
10054
5
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pa
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MH1781
MH1791
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12054
4
or
12054
5
to 6
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3
m
ip
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MAE40830
MAE40560
sc
12. At the rear of the boom, locate the fourth boom section 17. At the front of the boom, disconnect the fourth boom
Di
extend chain locknut (3). Measure the amount of section extend chain clevis (5) from the anchor plates
threads protruding beyond the locknut and record the on the second boom section. Pull the extend chain
to
measurement for reassembly. clevis from between the plates and lay over the front of
the fourth boom section.
Go
13. Loosen, but DO NOT remove the locknut.

14. At the rear of the boom, locate the third boom section 18. Remove the extend chain sheave (6).
extend chain locknuts (4). Measure the amount of 19. Remove the top and side wear pads on the inside of the
threads protruding beyond each locknut and record the third boom section. Label and tag each set of wear pads
measurements for reassembly. being removed.
15. Loosen, but DO NOT remove the locknuts.
16. Return to the cab, start the engine and extend the
boom approximately 2 in. (51 mm). Retract the boom
slightly until there is slack in the fourth boom section
extend chain. Shut the engine OFF.
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-17

Boom
Note: Record the location of the shoulder bolt to ensure correct

installation.
10054
8
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9
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MAE40570
MH4071
or
20. At the rear of the boom, remove the hose reel
assembly (2). This requires removal of the bottom and
side wear pads. Reinstall the wear pads for second
boom section removal. to
12054
om
8
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7
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9
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MAE40580
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21. Inside the third boom section, remove the hose clamps
and hose clamp support bracket (7).
to
22. Return to the cab, start the engine and fully retract the
Go
boom slowly. Shut the engine OFF.

MAE40600
23. At the rear of the boom, remove the shoulder bolt (8) to
the fourth boom section retract chain (9). Let the chain
hang out the rear of the boom.
3-18 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
12054
11
10
MH1861
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24. Remove the two capscrews and lockwashers holding
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the hose carrier support (10) and the lower wear pad to
the third boom section.
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MAE41850
25. Pull the hose carrier support with hose carrier attached
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toward the rear of the boom. Reinstall the capscrews 28. At the rear of the boom section, remove the extend
and lockwashers to hold the wear pad in place. chain clevis (11) from the extend chain clevis anchor.
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DO NOT fully tighten the capscrews. 29. At the rear of the fourth boom section, remove the
or
26. Remove the hose carrier support from the hose carrier. remaining wear pads, shims and hardware. Label and
tag each set of wear pads being removed.
to
Note: If replacing the fourth boom section with a new boom
section, the quick coupler assembly and the Attachment Tilt 30. Inspect all wear pads for wear. Refer to Section 3.8,
om
cylinder should be removed at this time. Refer to Section 3.9, “Boom Wear Pads”.
“Quick Coupler”.
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27. Using a sling or suitable support, pull the fourth boom 10054
en
section straight out of the third boom section.

Reposition the slings as needed so the fourth boom
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section balances when removed from the third boom

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section. Set the boom section down on a hard, level

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surface. Support the boom as needed to prevent it from

12
-E
tipping over.
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10054
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11
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MH1901
to
12054
Go
MH1871
12
MAE40610
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-19

Boom
31. Inside the boom section, remove the hardware securing

the hose carrier (12) to the bottom of the boom.
32. On each side of the boom, remove the hardware
securing the rear of the hose carrier guide in place.
10054
14
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13
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MH1961
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MH1911
36. Remove the hose carrier assembly (14) from the boom
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by carefully pulling both the upper and lowers portions
12054 through the rear of the boom at the same time.
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37. Carefully slide the hose channel assembly out of the
or
rear of the boom.
3.6.3 to Third Boom Section Removal

om
1. At the front of the second boom section, remove the
top and side wear pads. Label and tag each set of wear
t.c
pads being removed.

en
10054 15
m
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13
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MAE40640
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33. Loosen, but DO NOT remove the hardware holding the

front of the hose carrier guide and the top wear
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pad (13) to each side of the boom.

Di
34. Tilt the back of the hose carrier guide up. Label all hoses
to
and their orientations. Pull the hoses from the channels

inside the boom. Lay the hoses out behind the boom.
Go
MH1991
35. After the hoses are removed, remove the hose carrier
guide by pulling the guide out the rear of the boom.
3-20 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
9. Remove the remaining wear pads, shims and hardware.

12054 Label and tag each set of wear pads being removed.
15
3.6.4 Second Boom Section Removal

1. At the front of the first boom section, remove the top,
side and bottom wear pads. Label and tag each set of
wear pads being removed.
ts
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rp
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17
ry
MAE40560
2. Remove the shoulder bolt (15) holding the yoke plates
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to the mount at the front of the first boom section.
or
3. Remove the extend chain sheave pin and sheave on the
third boom section.
to
om
MH2121
2. Remove the retract chain sheave by removing chain

t.c
16
sheave pin (17) from the inside of the second boom
en
section.
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3. Using a suitable sling or support, secure the front of the

Extend/Retract cylinder.
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4. Remove the retaining ring from one side of the

Extend/Retract cylinder rod end mounting pin.
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MH2011
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4. Remove the locknuts (16) holding the threaded clevis of

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the extend chains to the anchor bracket on the rear of

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5. Pull both extend chains out from the front of the boom.
Go
6. At the rear of the third boom section, remove the retract

chain sheave.
7. Remove the shoulder bolt. Let the retract chain hang 18
out the rear of the boom. MH2171
8. Using a sling or suitable support, pull the third boom
5. On the left side of the first boom section, remove the
section straight out of the second boom section.
boom extend interlock proximity sensor (18) and
Reposition the slings as needed so the third boom
mounting bracket.
section balances when removed from the second boom
section. Set the boom section down on a hard, level
surface. Support the boom as needed to prevent it from
tipping over.
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-21

Boom
6. Using a sling or suitable support, pull the second boom 3.6.5 First Boom Section Removal
section straight out of the first boom section.
1. Attach a suitable overhead lifting device and sling to
Reposition the slings as needed so the second boom
the Lift/Lower cylinder, and remove slack in the sling.
section balances when removed from the first boom
section. While pulling the second boom section out of 2. Securely support the first boom section.
the first boom section, guide the retract chain into the 3. Remove all wear pads, shims and hardware. Label and
rear of the boom. Set the boom section down on a hard, tag each set of wear pads being removed.
level surface. Support the boom as needed to prevent it
from tipping over.
7. Remove the remaining wear pads, shims and hardware.
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Label and tag each set of wear pads being removed.
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to
20
MH1111
om
4. At the underside of the boom, remove the retract chain
t.c
locknut (20). Measure the amount of threads protruding

beyond the locknut and record the measurement for
en
reassembly of the chain.

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19 5. Remove the retract chain by pulling it out the rear of the

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MH2141 boom.
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9. At the underside of the second boom section, remove

the locknut (19) from the retract chain clevis. Pull the
-E
21
retract chain out of the boom through the rear of the
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boom.
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sc
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to
MH1131
Go
6. Label, disconnect and cap the attachment tilt and

auxiliary (if equipped) hydraulic hoses on the mounting
plate (21).
7. Label, disconnect and cap the attachment tilt and
auxiliary (if equipped) hydraulic tubes from the
bulkhead fittings.
8. Label, disconnect and cap the Extend/Retract hydraulic
hoses from the bulkhead fittings.
3-22 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
22
23 25
ts
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rp
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MAE40670
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9. Label, disconnect and cap the Extend/Retract hydraulic MAE41810
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tubes (22) from the bulkhead fittings. Remove the tube 12. On the right side boom pivot mounting plate, remove
clamps (23). the boom proximity sensor (25).
or
13. With the boom securely supported, block the Lift/Lower
to
cylinders. Remove the lockbolts from the rod end of the
cylinders and lower the cylinders onto the machine.
om
t.c
24
en
26
m
ip
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MH1201
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10. Label, disconnect and cap the hydraulic hoses attached

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to the compensation cylinders (24).

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11. Use a hoist and a sling to hold the left compensation

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cylinder in position. Remove the lockbolt from the

compensation cylinder rod end mounting pin. Remove
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the locknut from the base end of compensation

to
cylinder. Lift the compensation cylinder away from the MAE41840

machine. Repeat procedure for the right compensation
Go
cylinder. 14. Remove the boom pivot pins (26) and lockbolts.
15. Using a sling or suitable support, carefully lift the first
boom section away from the machine. Set the boom
section down on a hard, level surface. Support the
boom as required to allow removal of the
Extend/Retract cylinder from the underside of the
boom.
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-23

Boom
A
17. Use a hoist and slings to support the Extend/Retract
cylinder.
18. Remove the retaining rings from the ends of the
Extend/Retract cylinder.
19. Remove the rubber bumper from the Extend/Retract 27
cylinder retainer. Inspect the rubber bumper. If it is in
good condition, the rubber bumper can be reused. If
the bumper is showing signs of cracking or
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deterioration, it should be replaced.
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20. Remove the Extend/Retract cylinder from the boom.
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3.6.6 First Boom Section Installation
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1. Using a suitable hoist and sling, position the Extend/
Retract cylinder with the port elbows facing down.
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Place the rod end of the cylinder through the cylinder
retainer at the front of the boom.
or
2. Coat the base end of the cylinder with anti-seize
compound. Insert the base end cylinder pin through
both mounting ears and the base end of the Extend/ to
om
Retract cylinder. Secure the pin in place with a retaining MAE41830
ring on each side of the pin.

t.c
7. Shim the boom as required using the shims (27) to

3. Lift the rod end of the Extend/Retract cylinder enough maintain a 0.02-0.06 in. (0.5-1.5 mm) maximum gap (A)
en
to insert the threaded stud on the rubber bumper into between the boom mounting hub and the self aligning
bearing in the frame. If an additional shim is required to
m
the hole in the Extend/Retract cylinder retainer. Secure

the rubber bumper in place with a new locknut. Tighten maintain the maximum gap, the extra shim MUST be
ip
securely. Lower the rod end of the Extend/Retract inserted on the right side of the boom.
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cylinder, and allow it to rest on the rubber bumper. 8. Align the rod end of the right Lift/Lower cylinder with
-E
4. Using a suitable hoist and slings, lift the boom assembly the self-aligning bearing on the boom assembly. Coat
nt
and position the boom on the frame. Align the the entire Lift/Lower cylinder pin with anti-seize
mounting plates on the frame between the mounting compound. Insert the pin through the rod end of the
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hubs on each side of the boom assembly. Lower the cylinder and the self-aligning bearing. Secure with lock
sc
boom assembly until the holes in the boom assembly bolt. Repeat procedure with left Lift/Lower cylinder.
Di
and the mounting plates align. 9. Use a hoist or suitable support to position the right side
5. On the end of the boom pivot pin, closest to the compensation cylinder to its original orientation onto
to
capscrew hole, mark the capscrew mounting hole the lower cylinder mount. Coat the entire
Compensation cylinder pin with anti-seize compound.
Go
location. Coat the entire pin with anti-seize compound.

Insert the pin through the rod end of the cylinder and
6. Insert the pivot pin from the outside of the boom
the self-aligning bearing. Secure with lockbolt. Repeat
assembly, making sure the marks for the capscrew
procedure for left side Compensation cylinder.
mounting hole stay in line with the capscrew mounting
holes in the boom mounting hub. 10. Install the boom proximity sensor on the right side
mounting plate. With the boom properly shimmed,
position the boom assembly all the way to the right
side.
3-24 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
16. Uncap and connect the previously labeled attachment

B tilt and auxiliary (if equipped) hydraulic hoses to their
appropriate bulkhead fittings.
ts
ar
rp
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ry
28
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or
MAE41820
MH1461
11. Insert the boom proximity sensor through the hole in

the right side mounting plate. Install the jam nut onto to
17. Inside the rear of the boom, slide the threaded clevis
om
end (28) of the retract chain down the right side of the
the boom proximity sensor on the inside of the plate. boom. Guide the threaded part of the clevis out
Adjust the inner and outer jam nuts on the sensor until
t.c
through the hole in the tab on the bottom of the boom.

the gap (B) between the sensor and the boom is Pull threaded part of clevis all the way through tab.
en
0.12 in. (3 mm). Torque the inside jam nut to

36 lb-in (4,1 Nm), to hold the sensor in position. 18. Coat the entire threaded portion of the clevis with
m
multi-purpose grease. Install a flat washer and locknut

ip
onto the clevis. Thread the nut onto the clevis until the
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threads are flush with the top of the nut.

19. Install the bottom wear pads to the first boom section
-E
with the previously used hardware.

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22
sc
23
Di
to
Go
MAE40670
12. Install the Extend and Retract tubes (22) to the inside
bulkhead fitting and the Extend/Retract cylinder.
13. Install the Extend and Retract tube clamp halves (23).
14. Uncap and connect the previously labeled hydraulic
hoses and attach to their appropriate cylinder locations.
15. Install the extend and retract and auxiliary
(if equipped) tube assemblies to their appropriate
bulkhead fittings. secure with tube clamps.
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-25
Boom
3.6.7 Second Boom Section Installation inside of the boom. Allow the string to hang out the rear
of the boom. Pull the other end out the opening on the
left side of the boom where the hoses will exit the
boom. Position the strings all the way to the left side of
the first boom section.
7. Using a suitable sling, carefully slide the second boom
17 section into the first boom section. Leave enough room
at the front of the boom to install the center wear pad.
10054
ts
ar
rp
MH2261
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29
1. At the rear of the second boom section, assemble the
ry
retract chain sheave to the mounting ears on the right
side of the boom. Place the sheave between the ears
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and insert the chain sheave (17) from the left side. Align
or
the hole in the pin retainer plate with the threaded hole
in the left ear. Secure the pin.
2. Apply grease to the grease fitting in the pin. Spin the to
om
sheave by hand to ensure the sheave spins freely on the MH2211
pin and to distribute grease evenly.
t.c
12054
en
m
ip
qu
-E
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2
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sc
Di
to
Go
MAE40570
29
MAE41800
3. Install the hose reel assembly (2), left side and bottom
wear pads to the rear of the second boom section. 8. Install the center wear pad mount (29) and wear pad to
4. Install the boom side and top wear pads of the second the bottom front of the first boom section.
boom section. 9. Install the side and top wear pads to the front of the first
5. Grease the sections of the boom in areas where the boom section.
wear pads will slide. 10. Install the double extend chain sheave to the front of
6. Before installing the second boom section into the first the second boom section.
boom section, place a string (heavy enough to pull the 11. With the sling still in place, install the rod end of the
attachment tilt and auxiliary hydraulic hoses) down the Extend/Retract cylinder, pin and retaining ring.
3-26 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
12. Install the front, bottom wear pads in the second boom 4. Install the bottom front wear pads.
section. 10054
31
ts
ar
rp
MH2301
18
ou
MH2171
ry
12054
13. On the left side of the first boom section, reassemble
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the boom extend interlock sensor (18) with mounting
bracket. Secure in place with the previously used 31
or
hardware. Tighten securely.
to
14. Secure the boom extend interlock sensor wire to the
attachment tilt tubes under the boom with new tie
om
wraps.
t.c
3.6.8 Third Boom Installation

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1. Install the bottom, side and top wear pads to the rear of
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17 MAE40710
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5. Lay the two extend chains (31) on the top of the third
-E
boom section with the threaded clevis ends toward the

nt
rear of the boom. Coat the threads on each clevis with

30 multi-purpose grease and insert the clevis’ through the
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threads are even with the top of the locknut.
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to

Go
MH2021
7. Using a suitable sling, carefully slide the third boom
section into the second boom section. Leave enough
2. At the rear of the third boom section, assemble the room at the front of the boom to install the remaining
retract chain sheave (30) to the mounting ears on the wear pads.
left side of the boom. Place the sheave between the ears 8. Install the top and side wear pads to the inside of the
and insert the sheave pin (17) from the right side. Line second boom section.
up the hole in the pin retainer plate with the threaded
hole in the right ear. Secure the pin. 9. Place the two extend chains up through the double
sheave mounting bracket on the front of the second
3. Apply grease to the grease fitting in the pin. Spin the boom section.
sheave by hand to ensure the sheave spins freely on the
pin and to distribute grease evenly.
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-27

Boom
10. Assemble the two extend chains to the mount if the 13. Place the retract chain around the retract chain sheave
yoke plates were removed from the extend chains. on the right side of the boom. Stretch the chain forward
Secure in place with a locknut. Tighten the locknut and place the clevis between the two anchor plates.
securely; but the yoke plates must pivot freely. Align the hole in the clevis with the hole location
11. Install the double extend chain sheave. Apply grease to recorded in the removal procedure. Insert the shoulder
the sheave. Turn the sheave by hand to distribute the bolt and locknut, tighten securely.
grease evenly.
10054 3.6.9 Fourth Boom Section Installation
15
0
6.0 )
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19 8 cm
(49
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to MH2381
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MH1991
1. Lay the hose carrier assembly out flat on a level surface.
t.c
Stretch the four male ends of the hoses out straight

12054
15 from the hose carrier assembly. Measure from the male
en
end of each hose back toward the hose carrier assembly

m
196 in. (498 cm) and apply tape around each hose at
that point. The tape is for proper tensioning of the hoses
ip
during reassembly of the hose clamps.

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2. Insert the hose channel assembly into the rear of the

-E
fourth boom section. Slide the hose channel assembly

nt
into the boom and line up the holes for the side wear
pads.
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3. Install the side, bottom and top wear pads.

sc
10054
Di
11
to
Go
MAE40560
12. Align the holes in the yoke plates with the hole in the
mount on the first boom section. Coat the shoulder bolt
with anti-seize compound and insert the shoulder
bolt (15) through the yoke plates and the mount on the
boom. Secure in place with a locknut. Tighten the
MH2441
locknut securely; but the yoke plates must pivot freely.
3-28 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
12054
11
33
ts
ar
MAE40720
rp
4. Lay the two extend chains (11) on the top of the fourth
boom section with the threaded clevis ends toward the
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rear of the boom. Coat the threads on each clevis with
ry
multi-purpose grease and insert the clevis’ through the
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threads are even with the top of the locknut
or
Note: The hose carrier only folds one way; DO NOT force it. MH2471
DO NOT twist the hose carrier while folding.
to
8. Rotate the back of the hose guide up toward the top of
om
the fourth boom section as far as it will go. Tighten the
rear wear pad mounting capscrews enough to hold the
t.c
hose guide.
en
9. With the hose guide tilted up in the back, insert the

female ends of the two left side hoses (from the hose
m
carrier) one at a time over the top of the angled

ip
32
guide (33) on the front side of the hose guide. Push the
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hoses into the hose channel on the left side of the

-E
fourth boom section and down to the front of the boom

section. Repeat this procedure for the two right side
nt
hoses into the hose channel on the right side of the

ou
boom.
sc
MH2411 10. Insert a capscrew through the hole in the fourth boom
section. Secure the hose guide in place with a flat
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5. Fold the hose carrier assembly in half, ensure the female

washer and locknut.
ends (32) of the hoses are on the bottom, and carefully
to
slide the folded hose carrier into the fourth boom 11. Run the hose carrier out and in by hand to check for
interference.
Go
section.
6. Line up the lower mounting holes in the hose carrier Note: DO NOT allow the hydraulic hoses to cross inside the
assembly with the holes in the bottom of the fourth boom.
boom section. Secure with the previously used
12. At the front of the boom, pull the previously labeled
hardware.
hydraulic hoses out the opening in the back of the
7. Lift the upper part of the hose carrier assembly and boom head. Let the hoses hang out of the boom head.
place the hose carrier guide under the hose carrier with
the angled guides toward the front. Slide the hose
guide into the fourth boom section, and place the front
notches onto the rear wear pad mounting capscrew. Be 14. Using a suitable sling, lift the fourth boom section.
sure the notch in the side of the hose guide is under the While guiding the hoses into the third boom section,
flat washer on each side of the boom. carefully slide the fourth boom section into the front of
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-29

Boom
10054 15
10
MH1861
ts
15. Reassemble the hose carrier support to the hose carrier
ar
on the right side. Install the hose carrier support (10)
and lower wear pad with the previously used hardware.
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16. Place the retract chain up around the retract chain
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sheave on the left side of the boom. Stretch the chain
ry
forward and place the clevis between the two anchor
plates. Line up the hole in the clevis with the anchor MH2521
de
plate hole location recorded during removal.
or
17. Insert the shoulder bolt and secure in place with a
locknut. Tighten the locknut. 12054
15
18. Install the side and top wear pads.
to
om
19. Place the fourth boom section extend chain sheave (6)
between the mounts at the front of the third boom
t.c
section. Insert the sheave pin through the mounts and 6

the sheave. Secure in place with the previously used
en
hardware.
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20. After the sheave is assembled, apply a good grade of

ip
multi-purpose grease to the grease fitting at the end of

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the pin. Turn the sheave by hand to distribute grease

evenly.
-E
21. Place the fourth boom section extend chain up and

nt
around the sheave at the front of the third boom

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section.
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Di
MAE41910
to
22. Place the extend chain clevis between the mounting

plates at the front of the second boom section. Coat the
Go
shoulder bolt (15) with anti-seize compound and insert

through the plates and clevis. Secure the shoulder bolt
in place with a locknut. Tighten securely, but the chain
clevis should pivot freely.
Note: Keep the four hoses in line as they come out of the hose
carrier assembly at the rear of the boom. DO NOT allow the
hoses to cross.
23. Install the hose clamp support bracket and top left side
wear pad.
3-30 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
24. Position the hydraulic hoses with the edge of the tape at 29. At the front of the first boom section, assemble the hose
the hose clamps. Hold the hoses in this position, and assemblies and tube assemblies to the mounting
tighten the hose clamps. plate (1).
12054
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2
pa
ur
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MAE40540
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MAE40550 30. For 12054, assemble the hydraulic hoses to bottom tube
or
25. Assemble the hoses to the hose reel (2) at the rear of the assemblies.
boom.
to
Note: Where the hose assemblies come out of the outer boom,
lubricate the radius in the first boom section with soap and
om
26. Tie the strings (positioned inside the first boom section
during installation) to the male end of the hydraulic water to allow proper tensioning of hoses.
t.c
hoses coming off the bottom of the hose reel assembly. 31. Install the quick coupler and attachment tilt cylinder to
27. Working from the front of the boom, pull each hose the front of the boom. Refer to Section 3.9.2, “Quick
en
through the boom assembly through the opening at Coupler Installation”.

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the bottom of the first boom section. 32. Uncap and connect the previously labeled hoses to the
ip
28. Remove the strings from the hoses. attachment tilt cylinder.
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10054 33. Properly connect the battery. Refer Section 9.8,

-E

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34. Remove Do Not Operate Tags from both ignition key

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1 times. Check the chain tension again and adjust as

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necessary. Check for leaks, and check the hydraulic fluid

level in the tank; add fluid if required.
to
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around the machine.

MH1451
37. Install the rear cover to the boom.
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-31

Boom
3.6.10 Boom Installation

2. Using suitable slings, balance the boom assembly, lift
and guide the boom assembly into place. Align the
frame pivot bores with the boom assembly pivot bores.
Install the boom pivot pin.
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ar
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ry
4. Refer to Section 2.6, “Threadlocking Compound”, for all
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threadlocking requirements.
5. With the sling still in place, install the rod end of the
or
Compensation cylinder, pin and bolt. Torque lock bolt.
6. With the sling still in place, install the rod end of each
lift/lower cylinder, pin and bolt. Torque lock bolt. to
om
7. Uncap and connect the hydraulic hoses at the rear of
t.c
the boom.
8. Connect the boom proximity sensor at the rear of the
en
boom.
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9. Recheck wear pad gaps to ensure they meet the

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minimum gap requirement. Shim as necessary.

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10. Ensure that the boom chains are properly adjusted.

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Refer to Section 3.7.7, “Boom Chain Tension Adjustment

(10054 & 12054)”.
nt

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sc
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times. Check for leaks, and check the hydraulic fluid at

the reservoir and add fluid if required.
to
13. Lower the boom assembly and shut engine OFF.

Go

around the machine.
3-32 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
3.7 BOOM EXTEND AND RETRACT Following are some examples of dynamic shock loading
which can impose abnormal loads above the endurance limit
CHAINS
of a leaf chain.
• High velocity movement of load, followed by
3.7.1 Boom Chain Inspection sudden, abrupt stops.
• Carrying loads in suspension over irregular surfaces
WARNING such as railroad tracks, potholes, and rough terrain.
Worn pins, stretched or cracked links or corrosive • Attempting to “inch” loads which are beyond the
rated capacity of the machine.
environments can cause chain failure. A chain failure
ts
could result in uncontrolled boom movement, loss of The above load cycles and environmental conditions make it
ar
load or machine instability. impossible to predict chain life. It is therefore necessary to
conduct frequent inspections until replacement life can be
rp
Under normal operating conditions the boom extend chains predicted.
will need to be inspected every 250 hours of operation. The
ou
retract chains need to be exposed and inspected every 1000 The boom chain’s normal life expectancy can be expressed
as a maximum percent of elongation. This is generally 3%.
ry
hours of operation. Environmental conditions and dynamic
impulse/shock loads can drastically affect normal operating As the chain flexes back and forth over the sheave, the
bearing joints (pins and inside link plates) gradually incur
de
conditions and require more frequent inspection intervals.
wear due to articulation.
or
Environments in which material handling machines operate
can vary widely from outdoor moisture to temperature to 3.7.2 Inspection Guidelines
to
mildly corrosive or highly corrosive industrial atmospheres,
in addition to abrasive exposures such as sand and grit. 1. Park the machine on a firm, level surface, raise the boom
om
Some effects can be as follows: to a horizontal (level) position, place the transmission in
(N) NEUTRAL, engage the park brake switch.
• Moisture - Corrosive rusting reduces chain strength
t.c
by pitting and cracking. 2. Fully extend the boom until the extend chain is taut.
en
Shut the engine off.

• Temperature - Low temperature reduces chain
strength by embrittlement. Going in and out of 3. The extend chains will be visible for inspection with the
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cold storage results in moisture from condensation. machine in this state.

ip
4. While doing the chain inspection, check all chain clevis

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• Chemical Solutions or Vapors - Corrosive attack on

the chain components and/or the mechanical ends for distortion or cracking and sheaves for bearing
-E
connections between the chain components. wear or grooving from the chain.
Cracking can be (and often is) microscopic. Going
nt
from microscopic cracking to complete failure can 5. Inspect the retract chains every 1000 hours of
ou
be either abrupt or may require an extended period operation.

of time. 6. Inspect the chains for the following conditions:
sc
• Abrasives - Accelerated wearing and scoring of the

Di
articulating members of the chain (pins an d

to
plates), with a corresponding reduction in chain

strength. Due to the inaccessibility of the bearing
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surfaces (pin surfaces and plate apertures), wear

and scoring are not readily noticeable to the naked
eye.
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-33

Boom
Edge Wear Distorted or Battered Link Plates
85
1 2
MZ1463
MZ1466
Check the chain for wear on the link plate edges caused
ts
by running back and forth over the sheave. The
ar
maximum reduction of material should not exceed 5%.
Distorted or battered link plates (5) on a leaf chain can cause
Measure and compare to a normal link plate height by
rp
tight joints and prevent flexing.
measuring a portion of chain that does not run over the
sheave. If the measured plate height (1) is 5% less than Turning or Protruding Pins
ou
the normal plate height (2), discard and replace the
Highly loaded chain, operating with inadequate
ry
chain.
lubrication can generate abnormal frictional forces
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Elongation between pin and link plates. When chain is allowed to
operate in this condition, a pin or series of pins, can
It is important to measure the chain in the section that
or
begin to twist out of a chain, resulting in failure.
moves over the sheaves because it receives the most
to
frequent articulation. Measuring the chain near its clevis
terminals could give an inaccurate reading. The ends of
om
the chains, near the clevis terminal, will not have flexed 7
as frequently, if at all, as the middle of the chains. 6
t.c
It is best to measure in 12 pin increments from pin 8

center to pin center. For example, if the links are one
en
MZ1465
inch from pin center to pin center, the distance should
m
be 12 in. (305 mm). If the links are 3/4 in. (19,0 mm) Examine the pin head rivets to determine if the “VEE”
ip
apart, the distance after 12 pins should be 9 in. flats are still in correct alignment (6). Chain with
(228,6 mm). rotated/displaced heads (7) or abnormal pin
qu
protrusion (8) should be replaced immediately.

4
-E
DO NOT attempt to repair the chain by welding or

3
nt
driving the pin(s) back into the chain. Once the press fit
integrity between outside plates and pins has been
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altered, it cannot be restored.

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Any wear pattern on the pin heads or the sides of the

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link plates indicates misalignment in the system. This

condition damages the chain as well as increases
to
frictional loading and should be corrected.

Go
MY1360
If the distance measured (3) is 3% greater than the

normal length (4), discard and replace the chain.
3-34 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
Cracked Plates 3.7.3 Expose Chains for Inspection

Inspect the chains very carefully, front and back as well
as side to side, for any evidence of cracked plates. If any c. Extend Chains
one crack is discovered, the chain should be replaced in 1. Park the machine on a firm, level surface. Place the
its entirety. transmission in (N) NEUTRAL, engage the park brake
It is important, however to determine the cause of the switch and raise the boom to a horizontal (level)
crack before installing a new chain so the condition position.
does not repeat itself. 2. Fully extend the boom and shut the engine OFF.
The types of cracks are: The extend chains will be visible for inspection with the
machine in this state.
ts
• Fatigue Cracking -
9
ar
Fatigue cracks (9) are a While doing the chain inspection, check all chain clevis ends
result of repeated cyclic for distortion or cracking and sheaves for bearing wear or
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loading beyond the MZ1467 grooving from the chain.
chain’s endurance limit.
ou
If during the inspection, any chain is found to be damaged or
• Stress Corrosion stretched, the chain must be replaced. It is recommended
ry
Cracking - The outside
that when any chain is replaced, that all the chains and
link plates are
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particularly MZ1468
clevises be replaced at the same time.
10
or
susceptible to stress
corrosion cracking (10). d. Retract Chains
• Corrosion Fatigue Cracking - Corrosion fatigue

cracks are very similar to fatigue cracks in
to
The retract chains are only partially visible through the rear
of the boom with all the sections retracted. It is possible to
om
appearance. Corrosion fatigue is the combined see a section of the retract chain as the boom is slowly
action of an aggressive environment and cyclic extended. If there is ANY question that one or all the retract
t.c
stress. chains are damaged, the boom should be removed and

en
Other Modes of Failure disassembled with the retract chains being inspected and
replaced if necessary.
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• Ultimate Strength Failure -

ip
These types of failures are Note: DO NOT attempt to repair a chain. Replace a stretched
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caused by overloads far in 11 or damaged chain with a new part. Always replace both the
excess of the design load. MZ1469 chain and the clevis. It is recommended that when any chain is
-E
Either fractured plates (11) or 12 replaced, that all chains and clevis’ be replaced at the same
nt
enlarged holes (12) can occur. time.

If either of these failures
ou
MZ1470
occurs, the chain should be
replaced immediately.
sc
Di
• Tight Joints -
All joints in
to
the chain
should flex
Go
freely. Tight
joints (13) 13 MZ1471
resist flexing.
If the problem is caused by dirt or foreign substance
packed in the joints, clean and lubricate thoroughly
before re-installing the chain.
If the problem is caused by corrosion and rust or bent
pins, replace the chain.
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-35

Boom
3.7.4 Chain Lubrication 3.7.5 Boom Chain Tension Check

After inspection and before being returned to service, 1. Make sure the attachment is attached to the boom head
chains must be lubricated. Refer to Section 2.3, “Fluid & before doing the tension check.
Lubricant Capacities”, for proper lubricant.
2. Park the machine on level ground. Place the
The lubricant must penetrate the chain joint to prevent transmission in (N) NEUTRAL, engage the parking brake
wear. Applying lubricant to the external surfaces will switch and level the boom.
prevent rust, but the chains should be articulated to make
sure the lubricant penetrates to the working surfaces 3. Slowly, fully extend the boom and retract it about
between the pins and links. halfway. Fully extend the boom, then retract it
2 in. (51 mm) (one inch per section). Turn the
To prepare the chain for lubrication, the chain plates should engine OFF.
ts
be brushed with a stiff brush or wire brush to clear the space
ar
between the plates so that lubricant can penetrate to the 14
rp
working surfaces.
Lubricant may be applied with a narrow paint brush or
ou
directly poured on, but the chain should be well flooded
with lubricant and the boom should be extended and
ry
retracted to be sure that the lubricant penetrates to the
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working surfaces. All surplus lubricant should be wiped
away from the external surfaces. DO NOT use a solvent for
or
this wiping operation.
to
Regular application of lubricant is necessary to make sure
that all working surfaces are adequately lubricated. In
om
extremely dusty conditions, it may be necessary to lubricate
the chains more often. Refer to Section 2.4, “Service and
t.c
Maintenance Schedules”, and Section 2.5, “Lubrication

Schedules”, for detailed information.
en
Lubrication of chains on machines working consistently in

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extreme hot or cold conditions requires special

ip
consideration. It is important that a reputable lubrication OA0493
specialist or a JLG distributor be consulted for guidance.

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4. Measure the sag (14) in each of the double boom

-E
extend chains between the bottom of the extend chains

and the top of the second boom section at their closest
nt
point. For 6036, 6042, 8042, 10042, 10054 & 12054

ou
acceptable boom chain sag is between

1.5 in. (38 mm) and 2.5 in. (64 mm). For the 10054 &
sc
12054, also measure the sag of the single extend chain

Di
between the bottom of the extend chain and the top of

the third boom section at it’s closest point. Acceptable
to
boom chain sag is between 2.85 in. (72 mm) and 3.85 in.
Go
(98 mm).
If the measurement is either less than, or greater
than the range given, the boom chains need to be
adjusted. Continue with Section 3.7.6, “Boom Chain
Tension Adjustment (6036, 6042, 8042 & 10042)” or
Section 3.7.7, “Boom Chain Tension Adjustment
(10054 & 12054)”, to adjust the chain system.
5. Start the engine, retract the boom completely and turn
the engine OFF.
3-36 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
3.7.6 Boom Chain Tension Adjustment

(6036, 6042, 8042 & 10042)
Note: Always perform Section 3.7.5, “Boom Chain Tension
Check” before adjusting the boom chain tension.
18
15
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ar
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16
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OA0513
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3. If there is no adjustment left on the extend chains,
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tighten the retract chain locknut (18) at the front on the
underside of the outer boom.
or
4. Recheck chain tension. Refer to Section 3.7.5, “Boom
to
OH0241 Chain Tension Check”.
om
1. Adjust the two boom extend chains (15).
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19
en
m
ip
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17
-E
nt
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MH1752
MA9451
If the chain sag measurement (14) is less than
sc
1.5 in. (38 mm), tighten the two extend chain

5. Further chain adjustment can be achieved by loosening
Di
adjustment locknuts (17). If the chain sag measurement

is more than 2.5 in. (64 mm), loosen the two extend all three chain locknuts and moving the rear retract
to
chain adjustment locknuts. chain clevis (19) from the original mounting hole in the
anchor plate to the next hole.
Go
2. Tighten or loosen the two extend chain adjustment This is only acceptable when boom chain sag cannot be
locknuts located at the rear of the boom. Be sure that acquired and the chain elongation measurement is still
each extend chain maintains the same tension. less than 12.36 in. (313 mm). Follow the instructions in
Equal chain tension can be checked by the position of Section 3.7.6, a. “Component/Assembly Verification
the yoke (16) on the outer boom. The front of the yoke (6036, 6042 & 8042)”.
should be parallel with the front edge of the outer
boom. 6. Recheck chain tension. Refer to Section 3.7.5, “Boom
Chain Tension Check”.
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-37

Boom
a. Component/Assembly Verification b. Component/Assembly Verification (10042)

(6036, 6042 & 8042) 22
22
21
21
20
20
ts
ar
rp
OH1091
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OH1091
The third (20) to second (21) boom section separation
ry
The third (20) to second (21) boom section separation should be checked when assembling new boom sections or
should be checked when assembling new boom sections or chains, or when the rear retract chain clevis has been moved
de
chains, or when the rear retract chain clevis has been moved forward on the anchor plate.
or
forward on the anchor plate. Measure the separation (22) between the third and second
Measure the separation (22) between the third and second boom section top plates. The distance should be at least
boom section top plates. The distance should be at least to
18.38 in. (467 mm) and not greater than 22.38 in. (568 mm)
om
8.5 in. (216 mm) and not greater than 11 in. (279 mm) with with the boom fully retracted and the chains properly
the boom fully retracted and the chains properly tensioned. tensioned. A distance of less than 18.38 in. (467 mm) could
t.c
A distance of less than 8.5 in. (216 mm) could result in result in interference and cause damage to boom
interference and cause damage to boom components. components.
en
If the distance is less than 8.5 in. (216 mm) or greater than If the distance is less than 18.38 in. (467 mm) or greater than
m
11 in. (279 mm): 22.38 in. (568 mm):

ip
1. Verify that the retract chain clevis (19) is not mounted in 1. Verify that the retract chain clevis (19) is not mounted in
qu
the last hole in the anchor plate. the last hole in the anchor plate.
-E
2. Make sure that the chain system is properly tensioned. 2. Make sure that the chain system is properly tensioned.
Refer to Section 3.7.5, “Boom Chain Tension Check”. Refer to Section 3.7.5, “Boom Chain Tension Check”.
nt
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3. To increase the separation distance: Loosen the 3. To increase the separation distance: Loosen the
retract chain locknut (18) on the bottom of the boom retract chain locknut (5) on the bottom of the boom
sc
one or two turns and tighten the two extend chain one or two turns and tighten the two extend chain
Di
locknuts equally the same number of turns. A minimum locknuts equally the same number of turns. A minimum
of one full thread on the clevis must protrude beyond of one full thread on the clevis must protrude beyond
to
the collar of the locknut. the collar of the locknut.

Go
4. To decrease the separation distance: Loosen the 4. To decrease the separation distance: Loosen the
extend chain locknuts at the rear of boom equally one extend chain locknuts at the rear of boom equally one
or two turns and tighten the retract chain locknut (18) or two turns and tighten the retract chain locknut (18)
the same number of turns. A minimum of one full the same number of turns. A minimum of one full
thread on the clevis must protrude beyond the collar of thread on the clevis must protrude beyond the collar of
the locknut. the locknut.
5. Install the rear boom cover. 5. Install the rear boom cover.
6. If the third to second boom separation distance cannot If the third to second boom separation distance cannot be
be achieved, contact your local JLG service distributor. achieved, contact your local JLG service distributor.
3-38 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
3.7.7 Boom Chain Tension Adjustment

(10054 & 12054) 12054 17
a. Outer Boom Chains Tension Adjustment

Note: Always perform Section 3.7.5, “Boom Chain Tension
Check” before adjusting the boom extend chain tension.
14
rts
pa
ur
yo
MAE40780
r
de
1. Adjust the two third boom section extend chains.
or
1.5 in. (38 mm), tighten the two extend chain
to
adjustment locknuts (17).
If the chain sag measurement (14) is more than
om
2.5 in. (63,5 mm), loosen the two extend chain
OA0493
adjustment locknuts (17).
t.c
10054
en
17 10054
m
ip
qu
-E
nt
ou
sc
Di
to
16
Go
MH1781
OH0552
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-39

Boom
12054
19
rts
pa
MA9451
ur
16 5. Further chain adjustment can be achieved by loosening
yo
all three chain locknuts and moving the rear retract
chain clevis (19) from the original mounting hole in the
r
de
or
This is only acceptable when boom chain sag cannot be
acquired and the chain elongation measurement is still
to
less than 12.36 in. (313 mm). Follow the instructions in
Section 3.7.7, b. “Component/Assembly Verification
om
(10054 & 12054)”.
t.c
MAE40760
2. Tighten or loosen the two extend chain adjustment Chain Tension Check”.
en
locknuts (17) located at the rear of the boom. Be sure

m
that each extend chain maintains the same tension. b. Component/Assembly Verification (10054 & 12054)
ip
Equal chain tension can be checked by the position of The third to second boom section separation should be
qu
the yoke (16) on the first boom section. The front of the checked when assembling new boom sections or chains, or
yoke should be parallel with the front edge of the outer when the rear retract chain clevis has been moved forward
-E
boom. on the anchor plate.

nt
10054 22
ou
sc
Di
18
to
21
Go
20
OH2862
OA0513

tighten the retract chain locknut (18) at the front on the
underside of the boom.
Chain Tension Check”.
3-40 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
12054 12054 17
22
21
20
ts
ar
MAE40770
rp
Measure the separation between the third (20) and
second (21) section boom top plates. The distance (22)
ou
should be at least 8.5 in (216 mm) and not greater than
ry
11 in. (279 mm) with the boom fully retracted and the chains
MAE40780
properly tensioned. A distance of less than 8.5 in. (216 mm)
de
could result in interference and cause damage to boom 3. To increase the separation distance: Loosen the
components. retract chain locknut (18) on the bottom of the boom
or
If the distance is less than 8.5 in. (216 mm) or greater than one or two turns and tighten the two extend chain
to
11 in. (279 mm): locknuts (17) equally the same number of turns. A
minimum of one full thread on the clevis must protrude
om
1. Verify that the retract chain clevis is not mounted in the beyond the collar of the locknut.
last hole in the anchor plate.
4. To decrease the separation distance: Loosen the
t.c
2. Make sure that the chain system is properly tensioned. extend chain locknuts (17) at the rear of boom equally
Refer to Section 3.7.5, “Boom Chain Tension Check”.
en
one or two turns and tighten the retract chain locknut

10054 (18) the same number of turns. A minimum of one full
m
17 thread on the clevis must protrude beyond the collar of

ip
the locknut.
qu
Note: If the third to second boom section separation distance

-E
cannot be achieved, contact your local authorized service

distributor.
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sc
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to
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MH1781
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-41

Boom
c. Inner Boom Chain Tension Adjustment

(10054 & 12054) 12054
Note: Always perform the Section 3.7.5, “Boom Chain Tension

Check” before adjusting the fourth boom section extend chain
tension.
14
ts
17
ar
rp
ou
ry
MAE40780
de
5. Adjust the fourth boom section extend chain:
or
2.85 in. (72 mm), tighten the extend chain adjustment
to
locknut (17).
om
OA0493
If the chain sag measurement (14) is more than
3.85 in. (98 mm), loosen the extend chain adjustment
10054
t.c
17 locknut (17).
en
m
ip
qu
18
-E
nt
ou
sc
Di
to
MH1781
Go
OH0661

tighten the retract chain locknut (18) on the bottom of
the second boom section several turns.
3-42 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
7. Recheck chain tension. Refer to Section 3.7.5, “Boom 9. Recheck chain tension. Refer to Section 3.7.5, “Boom
Chain Tension Check”. Chain Tension Check”.
10054
d. Component/Assembly Verification (10054 & 12054)
The fourth to third boom section separation should be
checked when assembling new boom sections or chains, or
19 when the rear retract chain clevis has been moved forward
on the anchor plate.
22
rts
pa
ur
r yo
de
MH4071
or
24
23 MAE41950
12054
to
Measure the separation between the third (23) and
om
fourth (24) boom section top plates. The distance (22) should
19 be at least 13.75 in. (349 mm) and not greater than
t.c
14.25 in. (362 mm) with the boom fully retracted and the
chains properly tensioned. A distance of less than
en
13.75 in. (349 mm) could result in interference and cause

m
damage to boom components.

ip
If the distance is less than 13.75 in. (349 mm) or greater than
qu
14.25 in. (362 mm):

1. Verify that the retract chain clevis is not mounted in the
-E
last hole in the anchor plate.

nt
2. Make sure that the chain system is properly tensioned.

ou
Refer to Section 3.7.5, “Boom Chain Tension Check”.

sc
Di
to
Go
MAE40600
8. Further chain adjustment can be achieved by loosening

both chain locknuts and moving the rear retract chain
clevis (19) from the original mounting hole in the
This is only acceptable when boom chain sag cannot be
acquired and the chain elongation measurement is still
less than 12.36 in. (313 mm). Follow the instructions in
Section 3.7.7, d. “Component/Assembly Verification
(10054 & 12054)”.
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-43

Boom
3. To increase the separation distance: Loosen the 6. Remove and replace the extend chains one at a time.
retract chain locknut on the bottom of the second Remove the right side locknut and flat washer, holding
boom section one or two turns and tighten the extend the clevis to the anchor plate.
chain locknut the same number of turns. A minimum of 25
one full thread on the clevis must protrude beyond the
collar of the locknut.
4. To decrease the separation distance: Loosen the
extend chain locknut at the rear of boom one or two
turns and tighten the retract chain locknut on the
bottom of the second boom section the same number
SH1811
ts
of turns. A minimum of one full thread on the clevis
ar
must protrude beyond the collar of the locknut. 7. At the front of the boom, remove the capscrew (25) and
locknut holding the right side extend chain clevis to the
rp
Note: If the fourth to third boom section separation distance
cannot be achieved, contact your local authorized service yoke plates. Replace the capscrew if damaged or worn.
ou
distributor.
ry
3.7.8 Extend Chains Removal and
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Replacement
(6036, 6042, 8042 & 10042) 26
or
transmission in (N) NEUTRAL, engage the parking brake
switch, level the boom and shut the engine OFF. to
om

t.c
and steering wheel.

MH6510
en

“Battery”, for procedure. 8. At the rear of the boom, attach one end of a wire to the
m
4. Remove the boom rear cover. threaded clevis (26) on the right side extend chain using
ip
a threaded eye or a flat washer tack welded to a

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capscrew. The outside diameter of the eye or flat washer

must be smaller than the diameter of the threads on the
-E
clevis.
nt
9. Have an assistant pull the chain from the front of the

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boom while guiding the wires into the boom from the
17
sc
rear. Remove the wire from the clevis, but not from
inside the boom.
Di
10. Inspect wear and condition of the booms, chains, clevis’,

to
chain sheaves, Extend/Retract cylinder, chain rods,

MH1752 clevis anchors and all mounting hardware. Replace any
Go
5. At the rear of the boom, locate the extend chain worn or damaged parts. DO NOT attempt to make any
locknuts (17). Record the amount of threads extending repairs to the chain.
beyond both the locknuts. These measurements will be Note: Chains and clevis’ are wear items and experience the
the starting point for adjustment of the extend chains same stress. DO NOT attempt to repair a chain. Replace a
after installation. stretched or damaged chain with a new part. Always replace
both the chain and the clevis’.
11. Coat the threads of the threaded clevis with
multi-purpose grease.
12. Lay the new extend chain on top of the first boom
section with the threaded clevis toward the front of the
boom.
3-44 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
13. Attach the wire to the threaded clevis of the new extend 24. Properly connect the battery. Refer Section 9.8,
chain using a threaded eye or a flat washer tack welded “Battery”, for procedure.
to a capscrew. The outside diameter of the eye or flat 25. Remove the Do Not Operate Tags from both ignition
washer must be smaller than the diameter of the key switch and steering wheel.
threads on the clevis.
3.7.9 Retract Chain Removal and Replacement
(6036, 6042, 8042 & 10042)
switch, level the boom and shut the engine OFF.
ts
27 2. Place a Do Not Operate Tag on both ignition key switch
ar
and steering wheel.
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28
4. Remove the boom rear cover.
ry
de
or
29
SH1852
to 18
om
14. Pull the extend chain forward and place over the right
side of the chain sheave (27). Guide the wire and the
t.c
threaded clevis under the chain sheave, and between

the top of the third boom section (28) and the second
en
boom section (29).

m
15. Have an assistant guide the extend chain into the front
ip
of the boom, while pulling on the wire from the rear of

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the boom. Guide the threaded clevis into the hole in the
anchor plate. OA0513
-E
16. Assemble the flat washer and locknut to the threaded 5. At the front underside of the boom, record the amount
nt
clevis. Thread the locknut until the threads are flush of threads extending beyond the locknut (18). This
ou
with the top of the nut. measurement will be the starting point for adjustment
of the boom retract chain.
sc
17. Pull the anchor clevis up around the double chain

sheave and position the clevis between the yoke plates. 6. At the front underside of the boom, loosen the locknut
Di
18. Coat the capscrew with anti-seize compound. Insert the far enough that it can be removed by hand.
to
capscrew through the yoke plates and clevis and secure

in place with a locknut. Tighten securely; but the chain
Go
must pivot freely.

19. Remove the wire from the clevis.
20. Repeat this procedure for the left side extend chain. 30
21. At the rear of the boom, tighten the two locknuts on the
extend chain clevis’ until the amount of threads
protruding beyond each locknut is the same as the
measurement recorded during removal of the chains.
22. Check and adjust boom chain tension. Refer to
Section 3.7.5, “Boom Chain Tension Check”.
23. Install the boom rear cover. MA9441
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-45

Boom
7. Attach a wire or string (30) to the threaded clevis with a 14. From the rear of the boom, have an assistant push the
threaded eye or a flat washer tack welded to a threaded clevis end of the chain under the chain sheave
capscrew. The outside diameter of the eye or flat and down between the second and first boom sections.
washer must be smaller than the diameter of the Pull the front clevis using the string or wire. Keep the
threads on the clevis. The wire or string will be used to chain to the right side of the boom, push the threaded
pull the chain back through the boom during clevis down to the tab at the front underside of the first
reassembly. boom section.
8. Remove the locknut and flat washer holding the retract 15. Have an assistant guide the threaded end of the clevis
chain threaded clevis to the mounting tab. through the hole in the tab.
Note: Record the location of the shoulder bolt to ensure correct 16. Remove the string or wire from the end of the clevis.
rts
installation. 17. Reassemble the flat washer and locknut onto the
pa
threaded clevis. Tighten the locknut until the threaded
31
end of the clevis is flush with the top of the locknut.
ur
18. At the rear of the boom, place the retract chain up and
yo
over the chain sheave. Place the clevis between the two
anchor plates.
r
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19. If re-installing a used chain, insert the saved shoulder
bolt, in the same position in the plates and clevis
or
recorded during removal.
to
20. If installing a new chain, line up the hole in the clevis
with the second hole from the rear of the anchor plates.
om
Insert the shoulder bolt, saved during removal of the
old chain.
t.c
MH2551
21. Secure the shoulder bolt in place with a locknut.
en
9. At the rear of the boom, locate the two retract chain Tighten the locknut securely.
anchor plates holding the retract chain to the third
m
22. Tighten the locknut on the retract chain clevis until the
boom section just in front of the retract chain sheave.
ip
amount of threads protruding beyond the locknut is the

Remove the locknut and shoulder bolt (31) holding the
same as the measurement recorded during removal of
qu
retract chain clevis to the anchor plates. The two anchor

the retract chain.
plates can remain in place on the third boom section.
-E
23. Check and adjust retract chain tension. Refer to Section

10. From the rear of the boom, pull the retract chain out of
nt
3.7.5, “Boom Chain Tension Check”.

the rear of the boom.
ou
24. Install the boom rear cover.

11. Inspect wear and condition of the booms, chains, clevis’,
sc
chain sheaves, Extend/Retract cylinder, chain rods, clevis 25. Properly connect the battery. Refer Section 9.8,
Di
anchors and all mounting hardware. Replace a worn or

damaged chain. DO NOT attempt to make any repairs 26. Remove the Do Not Operate Tags from both ignition
to
to the chain. key switch and steering wheel.

Go
Note: Chains and clevis’ are wear items and experience the
same stress. DO NOT attempt to repair a chain. Replace a
stretched or damaged chain with a new part. Always replace
both the chain and the clevis’.
12. Remove the string from the old chain and attach it to
the new clevis.
13. Coat the threads of the threaded clevis with
multi-purpose grease.
3-46 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
3.7.10 Extend Chains Removal and 6. Remove and replace the boom extend chains one at a
Replacement (10054 & 12054) time. Remove the right side locknut and flat washer
holding the right side chain clevis to the anchor plate.
a. Second and Third Boom Section Extend Chains 25
Removal and Replacement
and steering wheel.
rts
SH1811
7. At the front of the first boom section, remove the
pa
capscrews (25) and locknuts holding the extend chain
4. Remove the boom rear cover. clevis’ to the yoke plates.
ur
10054
8. Inspect the capscrews for signs of wear or damage.
yo
17
Replace with new capscrews if damaged or worn.
r
9. At the front of the second boom section, remove the
de
capscrew and lockwasher holding the extend chain
or
sheave pin to the sheave mount bracket. Remove the
pin from the mount bracket and the extend chain
to
sheave. Remove the extend chain sheave from the
mount.
om
t.c
en
26
m
ip
MH1781
qu
12054 17
-E
nt
MH6510
ou
10. At the rear of the boom, attach one end of a wire to the
sc
threaded clevis (26) on the right side extend chain with

a threaded eye or a flat washer tack welded to a
Di
capscrew. The outside diameter of the eye or flat

to
washer must be smaller than the diameter of the

Go
11. Have an assistant pull the chain from the front of the
boom while guiding the wire into the boom from the
rear. Remove the wire from the clevis, but not from
inside the boom.
12. Coat the threads of the threaded clevis with multi-
MAE40780
purpose grease.
5. At the rear of the boom, locate the extend chain 13. Lay the new extend chain on top of the first boom
locknuts (17). Record the amount of threads extending section with the threaded clevis toward the front of the
beyond the locknuts. This measurement will be the boom.
starting point for adjustment of the extend chains after
installation.
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-47

Boom
14. Attach the wire to the threaded clevis of the new extend 23. Coat the capscrews with anti-seize compound. Insert the
chain using a threaded eye or a flat washer tack welded capscrews through the yoke plates and clevis’ and
to a capscrew. The outside diameter of the eye or flat secure in place with locknuts. Tighten each locknut
washer must be smaller than the diameter of the securely, but the chain clevis’ must pivot freely.
threads on the clevis. 24. At the rear of the boom, tighten the two locknuts on the
chain clevis’ until the amount of threads protruding
beyond each locknut is the same as the measurement
recorded during removal of the extend chains.
25. Check and adjust the retract chain tension. Refer to
ts
ar
32
rp
ou
ry
de
b. Fourth Boom Section Extend Chains Removal and
Replacement
or
MH2601
to
om
15. Pull the extend chain forward and place in between the
chain sheave mounts. Guide the wire (32) and the 2. Place a Do Not Operate Tag on both ignition key switch
t.c
threaded clevis into the boom by placing the threaded and steering wheel.
clevis between the top of the third boom section and 3. Properly disconnect the battery. Refer Section 9.8,
en
the second boom section. “Battery”, for procedure.

m
16. Have an assistant guide extend chain into the front of 4. Remove the boom rear cover.
ip
the boom while pulling the wire and threaded clevis 10054
qu
toward the rear of the boom. Guide the threaded clevis 33

into the hole in the anchor plate.
-E
17. Place the flat washer onto the threaded end of the
nt
threaded clevis and assemble the locknut. Thread

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locknut onto the threaded clevis until the threads are

flush with the top of the nut.
sc
Di
18. Remove the wire from the clevis.

19. Repeat this procedure for the left side extend chain.
to
20. After both of the chains are replaced inside the boom,
Go
assemble the double sheave to the mount at the front

of the second boom section.
21. Place the double extend chain sheave between the
MH1781
mounts and under the extend chains at the front of the
second boom section. Insert the sheave pin through the
mounts and the double sheave. Line up the mounting
hole in the sheave pin with the threaded hole in the
sheave mount and secure in place with the capscrew
and the lockwasher. Tighten securely.
22. Pull the anchor clevis’ up around the double chain
sheave and position the clevis’ one at a time between
the yoke plates.
3-48 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
12054 12054
34
33
ts
ar
rp
ou
MAE40790 35
ry
5. At the rear of the boom, locate the extend chain
de
locknut (33). Record the amount of threads extending
beyond the locknut. This measurement will be the MAE40560
or
starting point for adjustment of the extend chain after
7. At the front of the boom, disconnect the extend chain
installation.
6. Remove the locknut and flat washer holding the extend to
clevis from the anchor plates on the second boom
section. Remove the locknut holding the shoulder
om
chain clevis to the anchor plate on the boom. bolt (34) to the anchor plates. Pull the extend chain
clevis from between the plates and lay over the front of
t.c
10054 the fourth boom section (35).

en
34 8. Remove the locknut and capscrew holding the extend

chain sheave to the front of the third boom section.
m
ip
9. Inspect the sheave pin for corrosion or damage. If the

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pin is damaged, it should be replaced. Minor corrosion

can be repaired with fine emery cloth. Save the chain
-E
sheave, pin and capscrew.

nt
ou
sc
26
Di
to
35
Go
MH1791
MH6510
10. At the rear of the boom, attach one end of a wire to the
threaded clevis (26) on the extend chain with a
threaded eye or a flat washer tack welded to a
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-49

Boom
11. Have an assistant pull the chain from the front of the 16. Have an assistant guide the extend chain into the front
boom while guiding the wire into the boom from the of the boom while pulling the wire and threaded clevis
rear. Remove the wire from the clevis, but not from into the hole in the anchor plate.
inside the boom. 17. Place the flat washer onto the threaded end of the
12. Coat the threads of the threaded clevis with threaded clevis and assemble the locknut. Thread the
multi-purpose grease. locknut onto the threaded clevis until the threads are
13. Lay the new extend chains on top of the fourth boom flush with the top of the nut.
section with the threaded clevis toward the front of the 18. Remove the wire from the clevis.
boom. 19. After the chain is replaced inside the boom, assemble
14. Attach the wire to the threaded clevis of the new extend the sheave to the mount at the front of the third boom
ts
chain with a threaded eye or a flat washer tack welded section.
ar
to a capscrew. The outside diameter of the eye or flat 20. Place the extend chain sheave between the mounts at
rp
washer must be smaller than the diameter of the the front of the third boom section. Insert the sheave
ou
pin through the mounts and the sheave. Secure in place
10054 with the capscrew, saved, and a locknut. Tighten
ry
securely.
de
21. After the sheave is assembled, apply a good grade of
multi-purpose grease to the grease fitting at the end of
or
the pin. Turn the sheave by hand to distribute the
grease evenly.
to
22. Pull the extend chain up and around the sheave at the
om
front of the third boom section.
23. Place the extend chain clevis between the mounting
t.c
plates at the front of the third boom section. Coat the

en
saved shoulder bolt with anti-seize compound and

insert through the plates and clevis. Secure the shoulder
m
bolt in place with a locknut. Tighten securely, but the

ip
35 chain clevis should pivot freely.

qu
36 24. At the rear of the boom, tighten the locknut on the

MH5731
-E
extend chain clevis until the amount of threads

nt
protruding beyond the locknut is the same as the

12054 measurement recorded during removal of the extend
ou
chain.
sc
25. Check and adjust the extend chain tension. Refer to

Di

to

Go

36
35
MAE41880
15. Pull the extend chains forward and place in between the
chain sheave mounts. Guide the wire and the threaded
clevis into the boom by placing the threaded clevis
between the third boom section (36) and the top of the
fourth boom section (35).
3-50 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
3.7.11 Retract Chain Removal and Replacement Note: Record the location of the shoulder bolt to ensure correct
(10054 & 12054) installation.
c. Third Boom Section Retract Chain Removal and 31

Replacement
and steering wheel.
rts
pa
ur
MH2551
yo
8. At the rear of the boom, locate the two retract chain
r
anchor plates. Remove the locknut and shoulder bolt
de
(31) holding the retract chain clevis to the anchor
or
plates. The two anchor plates can remain in place on the
18 third boom section.
to
9. From the rear of the boom, pull the boom retract chain
om
out of the rear of the boom.
10. Disconnect the string or wire from the retract chain
t.c
clevis, and allow it to hang out the rear of the boom.

en
11. Coat the threads of the threaded clevis with multi-

purpose grease.
m
12. At the rear of the boom, attach the string or wire to the
ip
new retract chain threaded clevis end with a threaded

qu
OA0513
eye or a flat washer tack welded to a capscrew. The
-E
5. At the front underside of the boom, locate the retract outside diameter of the eye or flat washer must be
chain locknut (18). Record the amount of threads smaller than the diameter of the threads on the clevis.
nt
extending beyond the locknut. This measurement will 13. From the rear of the boom, have an assistant push the
ou
be the starting point for adjustment of the retract chain threaded clevis end of the new retract chain under the
sc
after installation. chain sheave and down between the second and first
Di
6. At the front underside of the fourth boom section, boom sections, while pulling the retract chain through
remove the locknut and flat washer holding the retract the boom using the previously attached string or wire.
to
chain threaded clevis to the mounting tab. Keep the retract chain to the right side of the boom,
push and pull the threaded clevis down to the tab at the
Go
7. Attach a wire or string to the threaded clevis with a

front underside of the boom.
threaded eye or a flat washer tack welded to a
threads on the clevis. The wire or string will be used to
pull the chain back through the boom during
reassembly.
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-51

Boom
6. At the front underside of the boom, locate the retract

chain locknut. Record the amount of threads extending
beyond the locknut. This measurement will be the
starting point for adjustment of the retract chain after
installation.
18
ts
ar
37
rp
ou
MH2561
ry
14. Reassemble the flat washer and a locknut (37) onto the
de
threaded clevis. Tighten the locknut until the threaded
end of the clevis is flush with the top of the locknut.
or
15. At the rear of the boom, place the retract chain up and
to
OH0661
over the chain sheave. Place the clevis between the two
anchor plates. Line up the hole in the clevis with the 7. Loosen the locknut (18) on the retract chain clevis.
om
anchor plate hole position recorded during removal. DO NOT remove the locknut at this time, but loosen the
nut as far as possible to gain as much slack as possible in
t.c
16. Insert the shoulder bolt through the plates and clevis
and secure in place with a locknut. Tighten the locknut the retract chain.
en
securely. 8. Return to the operator cab, start the engine and slowly
m
17. Check and adjust the retract chain tension. Refer to retract the boom all the way back, and then extend the
boom approximately 1 in. (25 mm) or just until all the
ip

tension on the retract chain is relieved. Shut the engine
qu

OFF.
-E

“Battery”, for procedure. Note: Record the location of the shoulder bolt to ensure correct
nt
installation.
ou
10054
sc
38
Di
d. Fourth Boom Section Retract Chain Removal and

Replacement
to

Go

and steering wheel.
MH2671
5. Start the engine and extend the boom until the retract
chain adjustment nut on the bottom of the second
boom section is visible. Shut the engine OFF.
3-52 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
12. Remove the locknut and flat washer holding the

12054 38 threaded clevis on the retract chain to the tab in the
second boom section.
26
rts
pa
MH6510
ur
13. Attach a wire to the end of the retract chain clevis (26)
yo
with a threaded eye or a flat washer tack welded to a
r
de
threads on the clevis. The wire must be long enough to
or
pull the clevis and chain through the boom. The wire
must be heavy enough to pull the weight of the entire
MAE40600
to
chain back through the boom during the reassembly.
om
14. From the rear of the boom, using the wire attached to
9. At the rear of the boom, locate the two retract chain
the rear anchor clevis, pull the retract chain through the
anchor plates (38). The two anchor plates can remain in
t.c
middle of the two center hoses on the chain reel and

place on the fourth boom section.
over the top of the chain reel and out of the rear of the
en
10. Pull the retract chain clevis toward the rear of the boom, boom.
through the middle of the two center hoses on the
m
15. Remove the wire still attached from the clevis on the old
chain reel and over the top of the chain reel. Let the
ip
chain.
clevis end of the retract chain hang out the rear of the
qu
boom. Use a piece of wire that is approximately 16. Install the wire still attached, to the new chain clevis.
-E
6 feet (1,8 m) long and tie it to the clevis end of the 17. Coat the threads of the threaded clevis on the new chain
retract chain. This wire will be used to guide the chain with multi-purpose grease.
nt
back into the boom when the boom is extended to

ou
expose the other end for removal. 39

sc
11. Have an assistant start the engine and slowly extend the 40
boom. Guide the retract chain with the wire attached
Di
into the back of the boom. Extend the boom until the
to
retract chain adjustment nut on the lower left side of

the second boom section can be accessed and
Go
removed. Turn the engine OFF.

41 MH6021
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-53

Boom
18. From the front of the boom, have an assistant pull on 25. Remove the wire from the anchor clevis at the rear of
the tow wire while guiding the chain clevis between the the boom. Place the retract chain up and over the chain
two center hoses of the hose reel and under the chain sheave in front of the hose reel assembly. Place the
sheave (39), on the left side of the boom and down the clevis between the two anchor plates. Line up the hole
boom between the third (40) and second (41) boom in the clevis with the anchor plate hole position
sections. Keep the retract chain lined up squarely with recorded during removal.
the chain sheave and help feed the retract chain in while 10054
pulling on the wire from the front of the boom. 31
ts
ar
rp
ou
ry
42
de
or
MH5991
MH2671
19. Guide the threaded end of the clevis through the hole in
the tab (42) on the second boom section. to
12054
om
31
20. Remove the wire from the end of the clevis.
t.c
21. Place the flat washer onto the threaded clevis. Assemble
en
a locknut onto the threaded clevis. Turn the locknut

only 2 or 3 turns onto the clevis to allow assembly of the
m
other end of the retract chain.

ip
22. At the front of the boom, disconnect the extend chain

qu
clevis from the anchor plates on the second boom

section. Remove the locknut holding the shoulder bolt
-E
to the anchor plates. Pull the extend chain clevis from

nt
between the plates and lay over the front of the fourth
ou
boom section.
sc
23. Return to the operator compartment and start the

engine and slowly retract the boom. To avoid having the
Di
retract chain becoming entangled, keep tension on the

to
chain coming out the back of the boom. Retract the

boom as far as possible with the Extend/Retract
Go
cylinder. Turn the engine OFF.

24. The fourth boom section will not retract completely and
must be manually pushed in. To avoid having the retract
MAE40600
chain becoming entangled, keep tension on the chain
coming out the back of the boom while the fourth 26. Insert the shoulder bolt (31) through the plates and
boom section is pushed in. clevis and secure in place with a locknut. Tighten the
locknut securely.
Note: Care should be taken not to push the fourth boom
section in too far. If the fourth boom section is pushed in too far 27. Pull the extend chain up and around the sheave at the
it could damage the hose reel at the back of the boom. front of the third boom section.
3-54 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
28. Place the extend chain clevis between the mounting 3.8 BOOM WEAR PADS
plates at the front of the third boom section. Coat the
shoulder bolt with anti-seize compound and insert The wear pads on this machine are flat rectangular wear pads
through the plates and clevis. Secure the shoulder bolt with metal inserts.
in place with a locknut. Tighten securely, but the chain
clevis should pivot freely. 3.8.1 Wear Pad Inspection
29. Return to the operator compartment and start the 1
engine. Slowly extend the boom to gain access to the
retract chain adjustment nut on the lower left side of
the second boom section. Shut the engine OFF. 1
ts
30. Tighten the adjustment nut until the threads of the MZ7680
ar
threaded clevis are flush with the top edge of the nut.
rp
This will be a starting point for adjustment of the fourth 1. Park the machine on level ground. Place the
boom section retract chain. transmission in (N) NEUTRAL, engage the parking brake
ou
31. Check and adjust the retract chain tension. Refer to
ry
Section 3.7.5, “Boom Chain Tension Check”. 2. Inspect all wear pads for wear. If the angle indicators (1)
on the ends of the wear pads are not visible, or show
de
uneven wear, they should be replaced. Always replace
33. Properly connect the battery. Refer Section 9.8, pads as a set.
or
switch and steering wheel. to
om
t.c
en
m
ip
2
qu
-E
nt
MZ7661
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3. Measure all side and top wear pads for proper clearance.
sc
0.02 - 0.059 in. (0.5 - 1.5mm) between the wear pad and
the next boom section (2) is acceptable.
Di
4. Shim each wear pad to within the above measurement

to
if required.
Go
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-55

Boom
3.8.2 Wear Pad Installation and Lubrication • The length of the wear pad bolt depends on the
number of shims, spacers and washers being used.
The boom has been factory lubricated for proper wear pad
• The bolt length can be ±0.004 in. (±1,0 mm) (A) from the
break-in and will normally require minor future lubrication.
face of the insert.
However, after replacing any wear pad(s), or prolonged
periods of inoperation, lubrication of the boom wear • The bolt length should be determined by measuring
the distance from the face of the insert to the face of the
surfaces with Schaffer 200S Silver Streak grease is
boom (B) including any spacer, shim(s) and washer(s).
recommended to keep the boom wear surfaces lubricated
properly. • One or two hardened washers are to be used on each
wear pad bolt except where noted otherwise.
Lubrication of the boom wear surfaces is also recommended DO NOT use more than two hardened washers.
when the machine is stored, to help prevent rusting. • Use only one hardened washer if mounting bolts are
ts
The following wear pad procedure must be followed to recessed.
ar
insure the proper wear pad installation: • Torque wear pad bolts as required.
rp
• Maintain a total boom section clearance (2) of • Lubricate the face and pockets of each wear pad after
ou
0.02 - 0.059 in. (0.5 - 1.5mm) both the horizontal and being installed.
vertical directions Boom Section Wear Pad Pathway Lubrication:
ry
• Clean and lightly grease all wear pad pathways with
5
de
Mystik Tetrimoly grease.
or
• Clean and lightly grease the hose carrier guide bar
pathways with Mystik Tetrimoly grease.
4
3 to
om
t.c
en
m
MAQ0420
ip
• A spacer (3) must be used before any shim (4) is used.

qu
• A shim (4) must be inserted between the spacer (3) and

-E
wear pad support plate, block or boom section (5).

• The number of shims can vary at each shim point.
nt
• The bottom wear pads must be shimmed equally on

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each side.
sc
A
Di
to
B
Go
MD1130
3-56 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
3.9 QUICK COUPLER 4. Support the quick coupler assembly. Remove the bolt
(2) and nut (1) securing the quick coupler to the boom
Note: The following procedure covers all styles of quick head. Remove the pin (4) from the quick coupler
couplers. assembly.
5. Inspect the above pins for nicks or surface corrosion.
3.9.1 Quick Coupler Removal Use fine emery cloth to fix minor nicks or corrosion. If
1. Remove any attachment. Refer to Operation & Safety damaged or if it cannot be repaired the pin must be
Manual for detailed removal instructions. replaced.
2. Lower boom, tilt forward to access coupler pin, set park
3.9.2 Quick Coupler Installation
brake and turn off engine.
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6036, 6042, 8042, 10042 & 10054 1. Refer to Section 2.6, “Threadlocking Compound” for all
ar
thread locking requirements.
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2. Assemble the quick coupler to the boom head. Line up
the quick coupler between the mounts on the boom
ou
head. The quick coupler should be centered in the
ry
boom head.
1
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3. Coat the quick coupler head pin (4) with an anti-seize
4 compound. Insert the quick coupler head pin through
or
2 the quick coupler and boom head. Secure with the
previously removed bolt (2) and nut (1).
3 to
4. Align the quick coupler with the rod end tilt cylinder
om
and insert the tilt cylinder pin (3). Secure with the
previously removed bolt (2) and nut (1).
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5. Install any attachment. Refer to Operation & Safety

en
2 Manual for detailed installation instructions.

1
MAQ1580
m
ip
12054
qu
2
-E
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Di
1
2
to
4
Go
3 MAE40820
3. Remove the lock bolt (2) and nut (1) securing the tilt
cylinder rod end pin (3) to the quick coupler assembly.
Remove the rod end pin (3).
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-57

Boom
3.10 FORKS
Forks should be cleaned and inspected prior to being
attached to carriage. If the following criteria is not met, forks
must be removed from service immediately.
Daily Inspection
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6
pa
7 5 4
ur
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2
1
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11
or
10 8
to
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9 MH6460
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6. Inspect forks (1) for cracks, paying special attention to

en
heel (2) and mounting tubes (3).

m
7. Inspect forks for broken or bent tips (4) and twisted

ip
blades (5) and shanks (6).

qu
Yearly Inspection
-E
1. Straightness of the upper face of blade (5) and the front

face of shank (6) should not exceed 0.5 percent of the
nt
length of blade or height of shank.

ou
2. Angle (7) between upper face of blade and front face of

sc
shank should not exceed 93 degrees.

Di
3. Thickness of blade (10) and shank (11) should not be

reduced to 90 percent of original thickness.
to
4. Ensure fork length (9) is adequate for intended loads.

Go
5. Fork markings should be legible, re-stamp if required.

6. Compare fork tips (8) when mounted on a carriage.
Maximum difference in height of fork tips is 3 percent of
the length of the blade (10).
3-58 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom
3.11 TROUBLESHOOTING
This section provides an easy reference guide covering the
most common problems that occur during operation of the
boom.
Problem Cause Remedy

1. Boom will not extend or retract 1. Broken hydraulic hose(s) or 1. Locate break, replace hose(s) or
tube(s) and/or connections tube(s), tighten connections.
ts
leaking.
ar
2. Extend/retract hydraulic system 2. Refer to Section 8.5.2, “Pressure
rp
not operating properly. Specifications”.
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3. Faulty extend/retract cylinder. 3. Repair cylinder. Refer to
Section 8.9.1, “General Cylinder
ry
Instructions”.
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4. Broken chains or anchors 4. Replace chains as needed
or
2. Boom shifts to right or left when 1. Boom side wear pads improperly 1. Shim wear pads to correct gap.
to
extending. shimmed or worn. Replace wear pads as needed.
Refer to Section 3.8, “Boom Wear
om
Pads”.
t.c
3. Excessive pivot pin noise and/or 1. Insufficient lubrication. 1. Lubricate at regular intervals.
wear. Refer to Section 2.5, “Lubrication
en
Schedules”. Replace worn pins as

m
needed.
ip
2. Worn bearing(s). 2. Replace bearing(s) and lubricate

qu
at regular intervals Refer to

Section 2.5, “Lubrication
-E
Schedules”.
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4. Excessive Compensation 1. Insufficient lubrication. 1. Lubricate at regular intervals.

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cylinder pivot pin noise and/or Refer to Section 2.5, “Lubrication

sc
wear. Schedules”.Replace worn pins as

Di
needed.
to
2. Worn bushing(s). 2. Replace bushing(s) and lubricate

at regular intervals.
Go
5. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes 1. Locate break, replace hose(s) or
and/or connection leaks. tube(s), tighten connections.
2. Lift/lower hydraulic system not 2. Refer to Section 8.5.2, “Pressure

operating properly. Specifications”.
3. Faulty lift/lower cylinder. 3. Repair cylinder. Refer to Section

8.9, “Hydraulic Cylinders”.
4. Seized boom pivot pin bearing. 4. Replace bearing.
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-59

Boom

6. Drooping chain, or jerky boom 1. Chain(s) tension not properly 1. Adjust chain(s).
extend or retract functions. adjusted.
2. Chain(s) stretched or binding. 2. Replace chains as needed. Refer to

Section 3.7, “Boom Extend and
Retract Chains”.
3. Wear pads loose, contaminated, 3. Replace wear pad. Refer to

excessively worn or damaged. Section 3.8, “Boom Wear Pads”.
ts
ar
4. Contaminated, corroded or rusted 4. Remove contamination and/or
wear pad sliding surfaces. corrosion from wear pad sliding
rp
surfaces and lubricate. If the
ou
surfaces cannot be reconditioned,
replace the boom section(s).
ry
5. Extend/Retract hydraulic system 5. Refer to Section 8.5.2, “Pressure
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not operating properly. Specifications”.
or
6. Damaged boom section. 6. Replace the damaged boom
section. Refer to Section 3.4,
to “Boom Assembly Maintenance
om
(6036, 6042, 8042 & 10042)”.
7. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes 1. Locate break, replace hose(s) or
t.c
and/or connection leaks. tube(s), tighten connections.

en
2. Lift/Lower hydraulic system not 2. Refer to Section 8.5.2, “Pressure

m

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3. Faulty Lift cylinder. 3. Repair cylinder. Refer to

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-E
Instructions”.
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4. Seized boom pivot pin bushing. 4. Replace bushing.

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8. Excessive Lift/Lower cylinder 1. Insufficient lubrication. 1. Lubricate at regular intervals.

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pivot pin noise and/or wear. Refer to Section 2.4, “Service and
Di
Maintenance Schedules”. Replace

worn pins as needed. Refer to
to

Instructions”.
Go
2. Worn self-aligning bushing(s). 2. Replace bushing(s) and lubricate

at regular intervals. Refer to
Section 2.5, “Lubrication
Schedules”.
3-60 31211388 6036, 6042, 8042, 10042, 10054, 12054

Boom

9. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and correct
as needed. Refer to Section 3.8,
2. Rapid cycle times with heavy 2. Reduce cycle times.

loads.
3. Contaminated, corroded or rusted 3. Remove contamination and/or

wear pad sliding surfaces. corrosion from wear pad sliding
rts
surfaces and lubricate. If the
surfaces cannot be reconditioned,
pa
replace the boom section(s).
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4. Operating in extremely dusty/ 4. Clean equipment frequently.
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abrasive conditions.
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10. Auxiliary hydraulics will not 1. Auxiliary hydraulic system not 1. Refer to Section 8.5.2, “Pressure
de
operate. operating properly. Specifications”.
or
11. Excessive chain wear. 1. Improper chain adjustment. 1. Adjust to correct tension. Refer to
Section 3.7.1, “Boom Chain
to Inspection”. Replace chains as
om
needed.
2. Chain sheave(s) not properly 2. Lubricate chain sheave. (Refer to

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lubricated. Section 2.4, “Service and

en
Maintenance Schedules”.
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3. Chain sheave(s) not rotating 3. Lubricate chain sheave. Refer to

ip
freely. Section 2.4, “Service and

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Maintenance Schedules”. Repair

or replace chain sheave(s) as
-E
needed.
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4. Improper chain lubrication. 4. Lubricate at regular intervals.

ou
Refer to Section 2.4, “Service and

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Maintenance Schedules”. Replace

chains as needed.
Di
to
Go
6036, 6042, 8042, 10042, 10054, 12054 31211388 3-61

Need parts?
Section 4
Cab
Contents
rts
4.1 Operator Cab Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
pa
4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.1 Operator Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
ur
4.2.2 Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
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4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
r
4.3.1 Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
de
4.3.2 Steering Column and Steering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
or
4.3.3 Service Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.4 Throttle Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.5
4.3.6
to
Joystick Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary/Frame Level Lever Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6
4-7
om
4.3.7 Windshield Wiper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
t.c
4.3.8 Heater System (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.3.9 Heater and A/C System (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
en
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

m
4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

ip
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-E
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to
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6036, 6042, 8042, 10042, 10054, 12054 31211388 4-1

Cab
4.1 OPERATOR CAB COMPONENT

TERMINOLOGY
To understand the safety, operation and maintenance
information presented in this section, it is necessary that the
operator/mechanic be familiar with the names and locations
of the major assemblies of the machine cab. The following
illustration identifies the components that are referred to
throughout this section.
ts
ar
HEATER AND A/C
AUXILIARY HYDRAULIC (10042, 10054 & 12054 only)
CONTROLS (OPTIONAL)
rp
CONTROL LEVER
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BOOM CONTROL/
TILT JOYSTICK
STEERING WHEEL
ry
de
INSTRUMENT PANEL
or
to
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OUTRIGGER
CONTROLS
PARK BRAKE (IF EQUIPPED)
t.c
SWITCH
en
TRANSMISSION
CONTROL LEVER
m
ip
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IGNITION
SWITCH
-E
FRAME LEVEL
CONTROL LEVER
nt
ou
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to
SERVICE BRAKE
PEDAL
Go
ACCELERATOR
PEDAL
MAE41190
4-2 31211388 6036, 6042, 8042, 10042, 10054, 12054

Cab
4.2 OPERATOR CAB 4.3 CAB COMPONENTS
4.3.1 Steering Wheel

WARNING
a. Steering Wheel Removal
precautions as outlined in Section 1, “Safety Practices”, 1. Park machine on a firm, level surface, level machine,
section of this manual. fully retract boom, lower boom, place transmission in
(N) NEUTRAL, engage park brake and shut engine OFF.
4.2.1 Operator Cab Safety 2. Place a Do Not Operate Tag on both ignition key switch
rts
and steering wheel.
WARNING 3. Open engine covers. Allow system fluids to cool.
pa
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The protection offered by this ROPS/FOPS will be “Battery”, for procedure.
impaired if subjected to any modification or structural
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1
damage, at which time replacement is necessary.
ROPS/FOPS must be properly installed using fasteners of
r
de
correct size and grade, and torqued to their specified 3
value.
or
WARNING to
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DO NOT weld, grind, drill, repair or modify the cab in any
t.c
way. Any modification or damage to cab structural

components requires cab replacement.
en
2
4
m
4.2.2 Serial Number Plate MAE4620

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The cab serial number plate is located on the left side of the 5. Carefully pry horn button (1) out of steering wheel (2).
qu
cab, behind the seat. Information specified on the serial 6. Remove horn wire (3) from back of horn button.
number plate includes the cab model number, the cab serial
-E
number and other data. Write this information down in a 7. Mark steering wheel and shaft to ensure proper
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convenient location to use in cab correspondence. installation. Remove nut (4) securing the steering
wheel (2) to splined steering column shaft.
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8. Use a steering wheel puller to remove steering wheel (2)

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from splined shaft.

Di
b. Steering Wheel Installation

to
1. Install steering wheel (2) onto splined steering column

Go
shaft.
2. Secure steering wheel with nut (4). Torque as required.
3. Connect the previously remove horn connectors (3).
4. Press the horn button (1) onto steering wheel.
6. Close and secure engine covers.
7. Remove Do Not Operate Tag from ignition key switch
and steering wheel.
6036, 6042, 8042, 10042, 10054, 12054 31211388 4-3

Cab
4.3.2 Steering Column and Steering Valve Note: DO NOT disassemble the steering valve. The steering
valve is not serviceable and must be replaced in its entirety, if
a. Steering Valve Removal defective.
1. Park the machine on a firm, level surface, level the
b. Steering Valve Installation
the transmission in (N) NEUTRAL, engage the parking 1. Install the steering column and steering valve, by
brake and turn the engine OFF. inserting them through the lower dash panel opening.
2. Place a Do Not Operate Tag on both ignition key switch Position steering valve in the cab to its original
and steering wheel. orientation. Secure the steering valve and column with
the previously used hardware.
rts
Torque to 13 lb-ft (18 Nm).
pa
Note: ALWAYS use new o-rings when servicing the machine.
“Battery”, for procedure. 2. Install new o-rings into the fittings. Lubricate the o-rings
ur
5. Remove the lower dash panel. with clean hydraulic oil.
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3. Uncap and connect the previously labeled load sense
2
hose to the steering valve.
r
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4. Install new o-rings into the steering valve fittings. Lubricate
or
the o-rings with clean hydraulic oil.
6
10 5. Uncap and connect the remaining previously labeled
to
four hoses to the steering valve.
om
9
6. Connect the horn button wire to the cab wiring harness.
5 7. Install the travel select lever, connect the instrument
t.c
panel harness connector, install the steering wheel

en
assembly. Torque the steering wheel nut to

50 lb-ft (68 Nm).
m

ip
7 “Battery”, for procedure.

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-E
8
and steering wheel.
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10. Start the engine and check the operation of steering

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system. Check for hydraulic fluid leaks. Check the

hydraulic fluid level in the tank and add fluid as
sc
MZ8450
required.
Di
11. Install the left, right and lower dash panels.

6. Remove the steering wheel (2), disconnect the
to
instrument panel harness connector (5), disconnect and 12. Close and secure the engine rear and side engine doors.
Go
remove the travel select lever (6).

c. Steering Test
7. Label, disconnect and cap the four hoses (7) from the
side of the steering valve (8). Cap the fittings on the Conduct a pressure check of the steering hydraulic circuits at
steering valve. Label, disconnect and plug the load sense the main control valve. Refer to Section 8.5.1, “Pressure
hose at the front of the steering valve. Cap the fitting on Checks and Adjustments”.
the steering valve.
8. Disconnect the horn button wire from the cab wiring
harness.
9. Support the bottom of the steering valve, and remove
the four capscrews and lockwashers (9). Remove the
steering valve (8) through the lower dash panel
opening. Remove the steering column (10).
4-4 31211388 6036, 6042, 8042, 10042, 10054, 12054

Cab
4.3.3 Service Brake Pedal d. Service Brake Pedal Installation

1. Position the service brake pedal in its mounting location
a. Brake Valve Removal
within the cab.
Refer to Section 8.8.2, “Service Brake Valve”, for removal 2. Insert the two brake pedal pivots into mounting
information. locations on the service brake pedal.
b. Brake Valve Installation 3. Install the service brake pedal with the previously used
hardware.
Refer to Section 8.8.2, “Service Brake Valve”, for installation
4. Be sure the brake pedal has the correct range of motion.
information.
Secure pivot pin with bolt and lockwasher.
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c. Service Brake Pedal Removal 5. Adjust the service brake switch as needed.
ar
1. Park the machine on a firm, level surface, level the 6. Install the lower dash panel.
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machine, fully retract the boom, lower the boom, place 7. Properly connect the battery. Refer Section 9.8,
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the transmission in (N) NEUTRAL, engage the parking “Battery”, for procedure.
brake and turn the engine OFF. 8. Remove Do Not Operate Tag from ignition key switch
ry
2. Place a Do Not Operate Tag on both ignition key switch and steering wheel.
de
and steering wheel. 9. Close and secure the engine rear and side engine doors.
or
to
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5. Remove the lower dash panel.
t.c
en
m
ip
11
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-E
nt
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Di
to
Go
MAE4430
6. Remove four bolts (11) securing the service brake pedal

to the cab.
7. Remove the service brake pedal from the cab.
6036, 6042, 8042, 10042, 10054, 12054 31211388 4-5

Cab
4.3.4 Throttle Pedal 4.3.5 Joystick Assembly

These removal and installation instructions apply to the
a. Throttle Pedal Removal
hydraulic joystick.
machine, fully retract the boom, lower the boom, place a. Joystick Assembly Removal
the transmission in (N) NEUTRAL, engage the parking
brake and turn the engine OFF.
2. Place a Do Not Operate Tag on both ignition key switch the transmission in (N) NEUTRAL, engage the parking
and steering wheel. brake and turn the engine OFF.
ts
ar
and steering wheel.
rp
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4. Remove the console panel in the cab.
ry
16
de
17
or
14 15
13
to
om
t.c
18
en
12 MZ8470
m
4. Remove the bolts (12) securing the throttle pedal (14)

ip
to the cab floor (13).

qu
5. Disconnect the electrical harness connector from the

back side of the throttle pedal.
-E
6. Remove the throttle pedal assembly from the cab.

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b. Throttle Pedal Installation

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1. Position the throttle pedal in its mounting location

Di
within the cab. MZ8490
2. Reconnect the wire harness plug to the backside of the

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Note: Label all hydraulic hoses to ensure correct installation.

throttle pedal.
Go
3. Secure the throttle pedal in place with previously used 5. Label, disconnect and cap the hydraulic hoses (15)
hardware. attached to joystick (16).
4. Properly connect the battery. Refer Section 9.8, 6. Disconnect the tilt function electrical connector.
“Battery”, for procedure. 7. Lift the joystick’s rubber sleeve (17), remove the
5. Remove Do Not Operate Tag from ignition key switch bolts (18) securing the boom joystick to the cab.
and steering wheel. 8. Remove the joystick assembly.
4-6 31211388 6036, 6042, 8042, 10042, 10054, 12054

Cab
b. Joystick Assembly Installation

1. Secure the joystick to the cab with the previously used
hardware. 19
2. Connect the tilt function electrical connector.
3. Uncap and connect the previously removed hydraulic
hoses to the joystick.
5. Test the joystick function:
rts
• Move the joystick handle rearward, activating the boom
pa
lift function. The boom should RISE.
• Move the joystick handle forward, activating the boom
ur
lower function. The boom should LOWER.
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• Move the joystick handle to the right, activating the 20
boom extend function. The boom should EXTEND.
r
de
• Move the joystick handle to the left, activating the
or
boom retract function. The boom should RETRACT.
• Move the joystick switch rearward, activating the
to
MZ8480
attachment tilt function. The boom should TILT UP.
om
Note: Record the location, and label all cables to ensure correct
• Move joystick switch forward, activating attachment tilt
function. The boom should TILT DOWN. installation.
t.c
6. Install console panel in the cab. 5. Remove the knob on each control lever (19).
en
7. Remove Do Not Operate Tag from ignition key switch 6. Loosen and remove the three bolts (20) securing the
control levers.
m
and steering wheel.

ip
6036, 6042 - 85 hp (63 kW)

4.3.6 Auxiliary/Frame Level Lever Assemblies
qu
These removal and installation instructions apply to the

-E
frame level and auxiliary hydraulic joysticks.

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a. Lever Assembly Removal

sc

Di

to
brake and turn the engine OFF.

Go
and steering wheel.

3. Properly disconnect the battery. Refer Section 9.8, 21
“Battery”, for procedure. 22 MAQ1390
4. Remove the console panel in the cab.
6036, 6042, 8042, 10042, 10054, 12054 31211388 4-7

Cab
6036 (74hp), 6042 (74hp), 8042, 10042, 10054, 12054 2. Mark the location of the adjusting nuts (26) on the main
control valve end of the control cable.
3. Loosen lock nut (27) and remove clevis.
4. Remove adjusting nuts (26) and washers (28).
c. Cable Installation
1. Install one adjusting nut (26), and washer (28) on the
control cable (23).
21 2. Install control cable mount (22) onto the control cable
rts
(23).
pa
3. Install washer (28), nut (26) and lock nut (27) onto the
22 MAE41230
control cable (23).
ur
DO NOT tighten the adjusting nuts at this time.
7. Remove the clip and anchor pin (21). Retain the clip and
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anchor pin for installation. 4. Connect control cable (23) at the lever control:
8. Loosen and remove the two bolts (22), and remove the a. Push the control lever and install the control cable.
r
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control cable mount or bracket/control cable. b. Use a wrench on the flats to hold the slider head,
and tighten the cable nut (25).
or
b. Cable Removal c. Install the bolt (24) securing the control cable.
6036, 6042 - 85 hp (63 kW)
28 27
to
d. Lever Assembly Installation
om
26 1. Secure the lever assembly(s) to the cab with the
28
previously used hardware.
t.c
26
2. Secure the control cable(s) bracket to the main control
en
valve with the previously removed hardware. Torque to

m
7.74 lb-ft (10.5 Nm).

ip
3. Center the control levers and tighten the adjusting

23
qu
nuts (26) as required.

-E
4. Install the previously removed knobs on each lever

24 MZ8510 assembly.
nt
25
ou
6036 (74hp), 6042 (74hp), 8042, 10042, 10054, 12054

sc
6. Test the lever(s) function:

Di
Frame Level Lever:

to
• Move rear lever to right, activating frame level function.

27
28 The machine should move RIGHT.
Go
26
• Move rear lever to left, activating frame level function.
25 The machine should move LEFT.
26 Auxiliary Lever:
23
24 • Move the front leverto the right, the auxiliary

MAE41220 attachment should LOWER/OPEN.
• Move the front lever to the left, the auxiliary attachment
1. Disconnect control cable (23) at the lever control: should RAISE/CLOSE.
a. Remove the bolt (24) securing the control cable.
7. Install console panel in the cab.
b. Push the control lever to expose the cable nut. Use a
wrench on the flats to loosen the cable nut (25). 8. Remove Do Not Operate Tag from ignition key switch
and steering wheel.
c. Remove the cable.
4-8 31211388 6036, 6042, 8042, 10042, 10054, 12054

Cab
4.3.7 Windshield Wiper Assembly 10. Loosen and remove the five bolts (31) securing the
heater hood (32). Remove the heater hood.
Refer to Section 9.10, “Window Wiper/Washer Windshield
Wiper Motor”, for removal and installation information.
34
4.3.8 Heater System (if equipped)
Note: If machine is equipped with air conditioning, DO NOT
loosen or disconnect any air conditioning hoses until the air
conditioning system has been properly drained by the local JLG
dealer or certified air conditioning service center. 35
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a. Cab Heater Assembly Removal
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33
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MAQ1810
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2. Place a Do Not Operate Tag on both ignition key switch 11. Disconnect the wiring harness connection (33) from the
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and steering wheel. roof heater assembly (34).
12. Remove the two clamps (35) securing the heater hoses
or
system fluids to cool. to the side of the cab.
to
13. Label, disconnect and cap the heater hoses. Pull the
hoses away from the heater tubes.
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5. Place a suitable container beneath the radiator drain 36
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plug or petcock. Slowly turn the radiator cap to the first 37

37
stop, and allow any pressure to escape. Remove the
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radiator cap.
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6. Place a funnel at the base of the radiator to channel the

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drained coolant into the container. Loosen the drain

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plug or petcock and allow the coolant to drain.

36
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7. Transfer the coolant to a container with a cover, and

label as “Used Antifreeze”. Dispose of the used coolant
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MZ8530
at an approved recycling facility. 38
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39
8. Close the radiator drain plug or petcock.
14. Remove the left and right front air vents (36) to access
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and remove the duct mounting nuts.

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31 31
31 15. Remove heater ducts (37) from heater assembly.
to
32
16. Remove brackets (38 & 39) securing heater assembly to
29 cab.
Go
29
29
30
MAQ1800
29
9. Loosen and remove the four bolts (29) securing the
heater cover (30). Remove the heater cover.
6036, 6042, 8042, 10042, 10054, 12054 31211388 4-9

Cab
9. Install heater cover (30) to heater assembly and secure

with four bolts (29).
10. Fill the cooling system completely with coolant,
allowing time for the coolant to fill the engine block.
The cooling system capacity is listed in Section 2.3, “Fluid
& Lubricant Capacities”.
and steering wheel.
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13. Start engine, run it briefly at low idle and check machine
for any visual sign of fluid leakage.
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Note: STOP engine immediately if any leakage is noted, and
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make any necessary repairs before continuing.
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14. Wait for the engine to cool and check the coolant level.
Add coolant as required to bring the coolant to the
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proper level.
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15. Check the operation of cab heater.
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16. Shut the engine OFF.
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41 c. Under Seat Heater Assembly Removal
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40
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MAE41790
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17. Label and disconnect floor heater (40) electrical and shut the engine OFF.
connections.
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18. Label and remove hoses (41) connected to heater. and steering wheel.
19. Remove the roof heater assembly (34). 3. Open the engine rear and side engine doors. Allow the
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b. Cab Heater Assembly Installation 4. Properly disconnect the battery. Refer Section 9.8,
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1. Install heater assembly (34) and secure with previously “Battery”, for procedure.
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removed brackets (38 & 39). 5. Place a suitable container beneath the radiator drain
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2. Install heater ducts (37) to heater assembly. plug or petcock. Slowly turn the radiator cap to the first
stop, and allow any pressure to escape. Remove the
3. Install previously removed left and right front air vent
to
radiator cap.
(36).
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6. Place a funnel at the base of the radiator to channel the

4. Uncap and connect the previously labeled heater hoses
to the heater tubes.
plug or petcock and allow the coolant to drain.
5. Install the two clamps (35) securing the heater hoses to
the side of the cab.
label as “Used Antifreeze”. Dispose of the used coolant
6. Connect the wiring harness connection (33) to the at an approved recycling facility.
blower.
7. Install the heater access panel and secure with the
9. Remove the heater access panel.
8. Install brackets (38 & 39) securing heater assembly to
cab.
4-10 31211388 6036, 6042, 8042, 10042, 10054, 12054

Cab
10. Disconnect the wiring harness connections from the 4.3.9 Heater and A/C System (if equipped)
blower.
a. Removal
1. Park machine on a firm, level surface, level machine,
fully retract boom, lower boom, place transmission in
(N) NEUTRAL, engage park brake and shut engine OFF.
42 and steering wheel.
3. Open engine covers. Allow system fluids to cool.
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43 4. Properly disconnect the battery. Refer Section 9.8,
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5. Place a suitable container beneath radiator. Slowly turn
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surge tank cap and allow any pressure to escape.
Remove surge tank cap.
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MZ8520
6. Place a funnel at base of radiator to channel drained
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11. Label, disconnect and cap the seat heater hoses (43). coolant into container. Remove drain plug and allow
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Pull the hoses away from the heater tubes. coolant to drain.
or
12. Remove the four capscrews, nuts and lockwashers (44). 7. Transfer coolant to a container with a cover, and label as
“Used Coolant”. Dispose of used coolant at an approved
to
13. Remove the seat heater assembly (42).
recycling facility.
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d. Under Seat Heater Assembly Installation 8. Tighten radiator drain plug.
9. Drain the refrigerant from the air conditioning system.
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1. Slide the seat heater assembly (42) into the seat riser,
and secure with the four capscrews, lockwashers and Note: The local JLG dealer or certified air conditioning service
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nuts (44). center or personnel to perform the refrigerant removal from the
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2. Connect the wiring harness connections to the seat system.

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heater assembly (42).

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3. Uncap and connect the previously labeled hoses (43) to

the heater tubes.
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4. Install the heater access panel and secure with the

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5. Fill the cooling system completely with coolant, 46

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allowing time for the coolant to fill the engine block.

45
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The cooling system capacity is listed in Section 2.3, “Fluid

& Lubricant Capacities”. 47
to

and steering wheel.
Go
7. Start engine, run it briefly at low idle and check machine

for any visual sign of fluid leakage.
make any necessary repairs before continuing.
41 48
Add coolant as required to bring the coolant to the
MAE4600
proper level.
9. Check the operation of cab heater. 10. Label and disconnect hoses (45) attached to the
10. Shut the engine OFF. condenser assembly (46).
11. Label and disconnect all electrical connections attached
to the condenser assembly (46).
6036, 6042, 8042, 10042, 10054, 12054 31211388 4-11
Cab
12. Remove bolts securing the condenser assembly (46) to Note: Ensure that the petcock is closed for vehicle equipped
cab roof. Remove condenser assembly from rear of the with a cab heater, when one liter of coolant is drained from
cab roof. system and all air is purged.
13. Label and disconnect all electrical connections attached Note: The local JLG dealer or certified air conditioning service
to the heater and air conditioning assembly (48). center or personnel to perform the refrigerant installation to
14. Label and remove hoses (41) connected to the heater the system.
and air conditioning assembly (48). 12. Properly connect the battery. Refer Section 9.8,
15. Label and disconnect air conditioning hoses attached to “Battery”, for procedure.
heater assembly. 13. Start engine, run it briefly at low idle and check machine
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16. Remove bolts securing heater assembly to cab. Remove for any visual sign of fluid leakage.
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heater assembly.
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17. Label and disconnect air conditioning hoses attached to make any necessary repairs before continuing.
compressor (47).
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14. Wait for engine to cool and check coolant level. Add
18. Remove hardware securing compressor to engine. coolant as required to bring coolant to proper level.
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Remove compressor (47).
15. Wait for engine to cool and check coolant level. Add
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b. Installation coolant as required to bring coolant to proper level.
16. Check the operation of cab heater and A/C.
or
1. Install cab condenser assembly (46) to cab roof. Secure
with previously removed hardware. 17. Shut the engine OFF.
2. Connect previously labeled electrical connections to to
18. Close and secure the engine cover.
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the condenser assembly (46). 19. Remove Do Not Operate Tag from ignition key switch
3. Connect previously labeled hoses (41) to condenser and steering wheel.
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assembly (46).
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4. Position heater and air conditioning assembly (48) to

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original orientation to cab. Secure with previously

removed hardware.
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5. Connect previously labeled electrical connections to

heater and air conditioning assembly.
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6. Connect previously labeled heater hoses to appropriate

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locations.
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7. Connect previously labeled air conditioning hoses to

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appropriate locations.
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8. Connect previously labeled air conditioning hoses

attached to compressor (47).
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9. Install compressor (47) to engine.

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10. Fill cooling system completely with coolant, allowing

time for the coolant to fill the engine block. The cooling
system capacity is listed in Section 2.3, “Fluid and
Lubricant Capacities”.
11. Fill air conditioning system completely with refrigerant.
Refer Section 2.3, “Fluid and Lubricant Capacities”, for
refrigerant type and capacity.
4-12 31211388 6036, 6042, 8042, 10042, 10054, 12054

Cab
4.4 CAB REMOVAL 10. Remove the heater access panel. If equipped, Label,
disconnect and cap the cab heater hoses. Refer to
Section 4.3.8, “Heater System (if equipped)”.
WARNING 11. Remove the console panel in the cab.
The protection offered by this ROPS/FOPS will be 12. Label and disconnect the electrical connections. Push
impaired if subjected to any modification or structural the connectors through the opening at the bottom of
damage, at which time replacement is necessary. the cab.
ROPS/FOPS must be properly installed using fasteners of 13. Remove the frame level and auxiliary lever assemblies
correct size and grade, and torqued to their specified from the main control valve. Refer to Section 4.3.6,
value. “Auxiliary/Frame Level Lever Assemblies”.
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Note: To help ensure safety and optimum performance, 14. Label, disconnect and cap all hydraulic hoses. Refer to
Section 4.3.5, “Joystick Assembly”. Cap all fittings to
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replace the cab if it is damaged. Refer to the appropriate parts
manual for ordering information. keep dirt and debris from entering the hydraulic system.
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Push the hoses through the opening at the bottom of
Inspect the cab, its welds and mounts. If modification, the cab.
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damage, a cracked weld and/or fatigued metal is discovered,
15. If necessary, remove mirrors and other cab components
replace the cab. Contact the local JLG dealer with any
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that may become damaged during cab removal.
questions about the suitability or condition of a cab.
1
or
Note: Remove and label cab components as needed before
removing the cab from the machine. Label, disconnect and cap
hydraulic hoses. Transfer cab parts to the replacement cab after to
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the replacement cab is securely mounted on the machine.
1. Park the machine on a firm, level surface. Allow 2
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sufficient overhead and side clearance for cab removal.

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Level the machine, fully retract the boom, lower the

boom, place the transmission in (N) NEUTRAL, engage
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the park brake and shut the engine OFF.

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2. Block all four wheels to help prevent the machine from

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moving. Assure that there is sufficient overhead and 2

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side clearance for cab removal.

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MZ8550
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16. Attach a clevis to each of the cab lifting brackets (1).

5. Place a suitable container beneath the radiator drain Route a sling with a minimum lifting capacity of
to
plug or petcock. Slowly turn the radiator cap to the first 1000 lb (453 kg) to a hoist or overhead crane. Center the
stop and allow any pressure to escape. Remove the sling to ensure even lifting.
Go
radiator cap.
17. Remove the two upper cab-to-frame capscrews and
6. Place a funnel at the base of the radiator to channel the two flat washers (2).
plug or petcock and allow the coolant to drain. 18. Remove the two lower cab-to-frame capscrews and two
flat washers (2).
label as “Used Antifreeze”. Dispose of the used coolant 19. Carefully begin to lift the cab. Stop and check that all
at an approved recycling facility. wiring, hydraulic hoses and fasteners are disconnected
and removed.
9. Remove the transmission covers.
6036, 6042, 8042, 10042, 10054, 12054 31211388 4-13

Cab
20. When all wiring, hydraulic hoses and fasteners are 11. Install the console panel.
disconnected or removed, carefully and slowly lift the 12. Install the transmission covers.
cab and remove it from the frame. Readjust the position
of the sling as needed to help balance the cab during 13. Fill the cooling system completely with coolant, allowing
removal. time for the coolant to fill the engine block. The cooling
system capacity is listed in Section 2.3, “Fluid
21. When the cab is completely clear of the machine, Specifications”.
carefully lower it to the ground. Block up or support the
cab so that it does not move or fall. Assure that no 14. Properly connect the battery. ReferSection 9.8,
personnel enter the cab while it is being removed from “Battery”, for procedure.
the machine. 15. Carefully examine all cab components, fasteners, etc.,
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22. Inspect the condition of the fittings, clamps, hydraulic one last time before engine start-up. Rectify any faulty
hoses, etc. Replace parts as indicated by their condition. conditions.
pa
23. Inspect and replace other machine parts that are 16. Start the engine and check the operation of all controls.
Check for hydraulic fluid leaks. Check the hydraulic fluid
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exposed with the cab removed. Repair or replace as
required. level in the tank and add fluid as required.
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Note: When the engine is initially started, run it briefly at low
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4.5 CAB INSTALLATION idle and check the machine for any visual sign of fluid leakage.
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STOP the engine immediately if any leakage is noted, and make
or
1. Block all four wheels to help prevent the machine from any necessary repairs before continuing.
moving. Assure that there is sufficient overhead and
side clearance for cab installation.
2. Attach a clevis to each of the cab lifting brackets. Route
to
Add coolant to the overflow bottle as required to bring
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the coolant to the proper level.
a sling with a minimum lifting capacity of
18. Install the mirrors and all other cab components as
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1000 lb (453 kg) to carry the weight of the cab through

the clevis’ to a hoist or over head crane. Make sure the needed, if removed.
en
sling is centered between the clevis’ to ensure even 19. Unblock the wheels.
lifting.
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3. Carefully begin to align the cab with the mounting

holes in the frame. Stop and check that wiring, hydraulic
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hoses, cables, etc. will not be pinched or damaged as

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the cab is positioned. Readjust the position of the sling

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as needed to help balance the cab during installation.

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4. Install the two upper cab-to-frame capscrews and

washers. Torque to 480 lb-ft (651 Nm).
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5. Install the two lower cab-to-frame capscrews and

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washers. Torque to 480 lb-ft (651 Nm).

to
6. Push the hoses through the opening at the bottom of

the cab. Uncap and connect the previously labeled
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hydraulic hoses. Refer to Section 4.3.5, “Joystick

Assembly”.
7. Install the frame level and auxiliary lever assemblies
from the main control valve. Refer to Section 4.3.6,
“Auxiliary/Frame Level Lever Assemblies”.
8. Route the wiring harness connectors through the
opening at the bottom of the cab. Connect the
previously labeled connectors.
9. If equipped, install the cab heater hoses. Refer to
Section 4.3.8, “Heater System (if equipped)”.
10. Install the heater access panel.
4-14 31211388 6036, 6042, 8042, 10042, 10054, 12054

Need parts?
Section 5
Axles, Drive Shafts, Wheels and Tires
Contents
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5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
pa
5.1.1 6036 & 6042 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.1.2 8042. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
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5.1.3 10042 & 10054 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
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5.1.4 12054 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
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5.2 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
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5.3 Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
or
5.3.1 Axle Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.3.2 Axle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.3.3
5.3.4
to
Axle Internal Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6
5-7
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5.3.5 Axle Replacement (6036 & 6042) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
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5.3.6 Axle Replacement (8042, 10042, 10054 & 12054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.4 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
en
5.5 Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

m
5.5.1 Drive Shaft Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

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5.5.2 Drive Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

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5.5.3 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5.6 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
-E
5.6.1 Removing Wheel and Tire Assembly from Machine. . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

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5.6.2 Installing Wheel and Tire Assembly onto Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

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5.7 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

5.7.1 Brake Disc Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
sc
5.8 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Di
5.8.1 Manually Releasing the Park Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

to
5.8.2 Manually Resetting the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

Go
6036, 6042, 8042, 10042, 10054, 12054 31211388 5-1

5.1 AXLE, DRIVE SHAFT AND WHEEL

COMPONENT TERMINOLOGY
of the major assemblies of the axles, drive shafts, wheels and
tires. The following illustration identifies the components
that are referred to throughout this section.
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5.1.1 6036 & 6042
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ENGINE-TO-TRANSMISSION
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DRIVE SHAFT
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REAR AXLE
ASSEMBLY
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REAR STEERING
CYLINDER
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FRONT STEERING
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CYLINDER
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REAR DRIVE SHAFT

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REAR AXLE
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WHEEL HUBS
sc
Di
FRONT DRIVE SHAFT

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Go
FRONT AXLE
ASSEMBLY
MAQ1780
FRONT AXLE
WHEEL HUBS
5-2 31211388 6036, 6042, 8042, 10042, 10054, 12054

5.1.2 8042
DRIVE SHAFT
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REAR AXLE
ASSEMBLY
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or
REAR STEERING
CYLINDER
to
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FRONT STEERING
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CYLINDER REAR DRIVE SHAFT

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REAR AXLE
WHEEL HUBS
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FRONT DRIVE SHAFT

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FRONT AXLE
ASSEMBLY
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MAE39470
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FRONT AXLE
Go
WHEEL HUBS
6036, 6042, 8042, 10042, 10054, 12054 31211388 5-3

5.1.3 10042 & 10054
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DRIVE SHAFT
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REAR AXLE
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ASSEMBLY
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REAR STEERING
CYLINDER
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FRONT STEERING
CYLINDER REAR DRIVE SHAFT
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REAR AXLE
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WHEEL HUBS
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FRONT DRIVE SHAFT

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FRONT AXLE
ASSEMBLY
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to
MAE39460
FRONT AXLE
Go
WHEEL HUBS
5-4 31211388 6036, 6042, 8042, 10042, 10054, 12054

5.1.4 12054
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DRIVE SHAFT
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REAR AXLE
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ASSEMBLY
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REAR STEERING
CYLINDER
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FRONT STEERING
CYLINDER
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REAR DRIVE SHAFT

REAR AXLE
m
WHEEL HUBS
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FRONT DRIVE SHAFT

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Di
FRONT AXLE
ASSEMBLY
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MAE40480
Go
FRONT AXLE
WHEEL HUBS
6036, 6042, 8042, 10042, 10054, 12054 31211388 5-5

5.2 GENERAL INFORMATION 5.3 AXLE ASSEMBLIES
5.3.1 Axle Serial Number Plate

WARNING The front axle serial number plate is located on a mounting
DO NOT service the machine without following all safety pad on the inboard portion of the right beam trumpet. The
precautions as outlined in Section 1, “Safety Practices”, of rear axle serial number plate is located on a mounting pad on
this manual. the inboard portion of the left trumpet. Information on the
serial number plate is required in correspondence regarding
Note: To help ensure optimum performance, the drive shaft the axle.
assemblies are specially balanced as a unit at the factory. When
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servicing any flange yoke, slip yoke or drive shaft tube, order a Supply information from the axle serial number plate when
complete assembly if components are bent or damaged. Refer communicating about an axle assembly or axle components.
pa
to the appropriate parts manual for ordering information.
5.3.2 Axle Specifications
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Before performing any inspection, maintenance or service
General axle specifications are found in Section 2.3, “Fluid &
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operation, thoroughly clean the unit. The axles and drive
shafts should be checked and repaired only by experienced
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service technicians who are aware of all safety instructions
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and particular component features.
5.3.3 Axle Internal Service
or
Use suitable products to thoroughly clean all disassembled Detailed axle service instructions (covering the axle,
mechanical parts to help prevent personal injury to the differential, brakes and wheel-end safety, repair,
worker and prevent damage to the parts. Carefully inspect
to
disassembly, reassembly, adjustment and troubleshooting
information) are provided in the appropriate Axle Repair
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the integrity of all moving parts (bearings, yokes, tubes,
gears, shafts, etc.) and fasteners (nuts, bolts, washers, etc.) as Manual.
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they are subject to major stress and wear. Always replace any
damaged, worn, cracked, seized or otherwise improper parts Manufacturer
Machine Axle PN
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that could affect the safe and proper functioning of the Model
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machine, axles and drive shafts. 212/A02 Front

6036, 6042
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212/A03 Rear
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8042 - If Equipped 212HY/B03 Front

31200162
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with 100 hp (82 kW) 212HY/B04 Rear

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8042 - If Equipped 212HY/10057980 Front

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with 74 hp (55 kW) 212HY/10057981 Rear

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10042, 223/145 Front 31200239

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10054 - If Equipped
with 100 hp (82 kW) 212HY/B07 Rear 31200162
to
10042, 223/10057982 Front 31200239

Go
10054 - If Equipped
with 74 hp (55 kW) 212HY/10057983 Rear 31200162
223/10057982 Front
12054 31200239
223/10102783 Rear
5-6 31211388 6036, 6042, 8042, 10042, 10054, 12054

5.3.4 Axle Maintenance Note: Clear the work area of all debris, unnecessary personnel,
etc. Allow sufficient space to raise the machine and to remove
CLEANING: Clean parts with machined or ground surfaces
the axle.
(such as gears, bearings and shafts) with emulsion cleaners
or petroleum-based cleaners. DO NOT steam clean internal 1. Park the machine on a firm, level surface, level the
components and the interior of the planetary hub and axle machine, fully retract the boom, lower the boom, place
housing. Water can cause corrosion of critical parts. Rust the transmission in (N) NEUTRAL, engage the parking
contamination in the lubricant can cause gear and bearing brake, straighten all wheels and shut the engine OFF.
failure. Remove old gasket material from all surfaces. 2. Place a Do Not Operate Tag on both ignition key switch
DRYING: Use clean, lintless towels to dry components after and steering wheel.
cleaning. DO NOT dry bearings by spinning them with 3. Open the engine rear and side engine doors. Allow the
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compressed air; this can damage mating surfaces due to lack system fluids to cool.
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of lubrication. After drying, lightly coat components with oil
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or a rust-preventive chemical to help protect them from
corrosion. If storing components for a prolonged period, wrap “Battery”, for procedure.
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them in wax paper.
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PERIODIC OPERATION REQUIREMENT: Every two weeks,
drive the machine far enough to cause the drive-train
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components to make several complete revolutions. This will
or
help ensure that internal components receive lubrication to
minimize deterioration caused by environmental factors
such as high humidity.
to
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SUBMERSION: If the machine has been exposed to water
deep enough to cover the hubs, disassemble the wheel ends
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and inspect for water damage and contamination. If the

carrier housing was submerged in water, especially if the
en
water level was above the vent tube (breather), drain the axle
MAQ0950
and inspect internal parts for water damage and
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contamination. Before assembling and refilling the unit with

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1
the specified lubricant(s), clean, examine and replace
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5. If the axle will be disassembled after removal, place a

damaged parts as necessary. suitable receptacle under the axle drain plug (1).
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Note: Use a suitable puller for bearing removal. Clean, inspect Remove the drain plug and allow the axle oil to drain
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and lubricate all bearings just prior to reassembly. If into the receptacle. Transfer the used axle oil into a
suitable covered container, and label the container as
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replacement of a damaged bearing cup or cone is necessary,

replace the cup and cone as a set. “Used Oil”. Dispose of used oil at an approved recycling
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facility.
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5.3.5 Axle Replacement (6036 & 6042)

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a. Axle Removal
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The front and rear axle assemblies differ in that the front axle
assembly is equipped with a parking brake mechanism and a
limited-slip feature; the rear axle has neither. The following
steps outline a typical axle removal procedure, suitable for
either the front or the rear axle assembly.
Cleanliness is extremely important. Before attempting to 2
remove the axle, thoroughly clean the machine. Avoid
spraying water or cleaning solution on the stabilizer
solenoids and other electrical components. If using a steam MA9091
cleaner, seal all openings before steam cleaning.
6036, 6042, 8042, 10042, 10054, 12054 31211388 5-7

6. Front Axle: Remove the front access panel (2) to gain b. Axle Installation
access to top of the front axle.
1. Before proceeding, ensure that the machine will remain
in place during axle installation. Block the front and rear
Rear Axle: Open the right and left side engine
of both tires on the axle that is already installed on the
compartment doors to gain access to the rear hose
machine.
connections and mounting bolts.
2. If applicable, raise the machine using a suitable jack or
7. Label, disconnect and cap the steering and brake lines
hoist. Place suitable supports beneath the frame and
at the axle. Cap all fittings to prevent dirt and debris
lower the machine onto the supports, allowing enough
from entering the hydraulic system. Wipe up any spilled
room for axle installation. Ensure that the machine will
oil.
remain in place during axle installation.
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8. Block the front and rear of both tires on the axle that is
3. Using a suitable jack, hoist or overhead crane and sling,
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not being removed. Ensure that the machine will remain
remove the axle from its support or holding stand.
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in place during axle removal before proceeding.
Balance the axle and prevent it from tipping, turning or
9. Raise the machine using a suitable jack or hoist. Place falling while positioning it beneath the machine.
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suitable supports under both sides of the frame and DO NOT raise or otherwise disturb the machine while
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lower the machine onto the supports. Ensure that the installing the axle. Keep the axle supported and
machine will remain in place during axle removal. balanced on the jack, hoist or overhead crane and sling
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10. Support the axle that is being removed with a suitable throughout the installation procedure.
or
jack, hoist or overhead crane and sling. DO NOT raise 4. Install the capscrews securing the axle to the frame.
the axle or the machine. Torque to 500 - 560 lb-ft (678 - 759 Nm).
11. Remove both wheel and tire assemblies from the axle to 11
12
1
om
that is being removed. Refer to Section 5.6.1, “Removing
Wheel and Tire Assembly from Machine”. 3 10 2
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Note: The wheel and tire assemblies must be re-installed later 9 3

en
with the directional tread pattern “arrows” facing in the 4

8
direction of forward travel.
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7 5
6 MT0822
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12. Remove the drive shaft assembly. Refer to Section 5.5.2,

“Drive Shaft Removal”.
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Note: If new frame level (front) or stabilizer (rear) cylinder

13. Remove the capscrew and locknut securing the lower bearings (3) have been installed in the axles or machine frame,
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position cylinder-mount pin to the cylinder. Tap the the fracture in the bearing race must be positioned at the
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cylinder mount pin out, and move the cylinder to 9 o’clock position as shown above.
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prevent it from interfering with axle removal.

5. Move the cylinder into position on the axle cylinder
14. Remove the capscrews securing the axle supports to
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anchor. Insert a cylinder-mount pin through the

the machine frame. cylinder and cylinder anchor. Secure the cylinder-
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15. Remove the axles from the machine using the jack, hoist mount pin with one capscrew and new locknut.
to
or overhead crane and sling supporting the axle. 6. Apply multi-purpose grease through the self-tapping
DO NOT raise or otherwise disturb the machine while lube fitting to lubricate the self-align bearing and the
Go
removing the axle. Balance the axle and prevent it from cylinder-mount pin.
tipping, turning or falling while removing it from
beneath the machine. Place the axle on a suitable 7. Install the drive shaft assemblies. Refer to Section 5.5.3,
support or holding stand. “Drive Shaft Installation”.
8. If reinstalling an axle previously removed from the
machine, position the driveshaft yoke on the axle
according to the alignment marks made earlier. If
installing a new axle, note the position of the driveshaft
yoke at the transmission. Align the driveshaft yoke on
the axle in the same plane as the yoke on the
transmission.
5-8 31211388 6036, 6042, 8042, 10042, 10054, 12054

9. Install the wheel and tire assemblies. Refer to

Section 5.6.2, “Installing Wheel and Tire Assembly onto
Machine”.
10. Carefully remove the jack, hoist or overhead crane and
sling supporting the axle.
11. Carefully raise the machine using a suitable jack or hoist.
Remove the supports from beneath the frame and
lower the machine to the ground.
12. Remove the blocks from the front and rear of both tires
on the other axle.
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ar
4
5
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13. Install new o-rings into the fittings. Lubricate the
o-rings with clean hydraulic oil.
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14. Uncap and connect the steering and brake lines at their
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axle fittings.
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15. Check the hydraulic reservoir oil level.
or
MAE41960

Note: Steps 5 thru 7 apply to 10054 & 12054 Only.
and steering wheel. to
5. Label and disconnect the wiring harness connectors at
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both outrigger cylinder pressure switches (4). Remove
18. Start the engine. Turn the steering wheel several times
the wire ties securing the wiring harness to the
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lock to lock, operate the frame tilt function several times

outrigger cylinders.
in both directions and check the function of the brakes.
en
Check for hydraulic leaks, and tighten or repair as 6. Tie a length of string to each pressure switch wiring
connector, and pull harness out through openings (5) at
m
necessary.
rear of outrigger housing.
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19. Front Axle: Install the front access panel.

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7. Untie strings from wiring connectors and tape, or

otherwise secure ends of strings to outrigger housing.
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Note: The service brake circuit will need to be bled after axle These strings will be used to pull harness through
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installation. Refer to Section 8.8.4, “Brake Bleeding”. housing during installation.

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5.3.6 Axle Replacement

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(8042, 10042, 10054 & 12054)

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a. Outrigger Removal (10042, 10054 & 12054 only)

to
On Models 10042, 10054 & 12054 equipped with outriggers,

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it is necessary to remove the outrigger assembly before

removing the front axle.
brake, straighten all wheels and shut the engine OFF.
and steering wheel.
6036, 6042, 8042, 10042, 10054, 12054 31211388 5-9

b. Outrigger Installation
7 remove the outrigger assembly from its supports.
Balance the assembly and prevent it from tipping,
turning or falling while positioning it on the machine.
DO NOT raise or otherwise disturb the machine while
6 installing the outrigger assembly. Keep the assembly
7 supported and balanced during the installation
procedure.
8 2. Place the same number and thickness of shims (8) on
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6
the pivot pin, as recorded during removal.
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9
3. Position the outrigger assembly onto the machine,
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aligning the hole in the assembly on the axle pivot pin
and the mounting plate under the axle flanges.
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4. Install the two mount plates (7) onto the top of the axle
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and secure with the previously used hardware.
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or
5. Install new o-rings into the fittings. Lubricate the o-rings
with clean hydraulic oil.
to
6. Uncap and connect the previously labeled hydraulic
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hoses (6) to their appropriate locations.
MAE40490
Note: Steps 7 thru 8 apply to 10054 & 12054 Only.
t.c
8. Label, disconnect and cap the outrigger hydraulic 7. Tie the strings left in the outrigger housing during
en
hoses (6). Cap all fittings to keep dirt and debris from removal to each pressure switch wiring connector, and
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entering the hydraulic system. pull the harness through the outrigger housing.
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9. Support the outrigger assembly using a suitable jack, 8. Connect the wiring connectors to the outrigger cylinder
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hoist or overhead crane. pressure switches. Secure the harnesses to the cylinders
10. Remove the capscrews, hex nuts, flat washers and with wire ties.
-E
mount plates (7). 9. Check the hydraulic reservoir oil level.

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Note: Record the number and thickness of shims to ensure 10. Properly connect the battery. Refer Section 9.8,
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correct installation. “Battery”, for procedure.

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11. Remove the outrigger assembly using a suitable jack, 11. Remove Do Not Operate Tag from ignition key switch
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hoist or overhead crane. Remove the shims (8) from the and steering wheel.
pivot pin.
to
12. Move the outrigger assembly away from the machine lock to lock, operate the frame tilt function several times
Go
and carefully lower it to the ground. Block up or support in both directions and check the function of the brakes.
the assembly so that it does not move or fall. Check for hydraulic leaks, and tighten or repair as
13. Inspect the pivot bearing (9). Replace the bearing if necessary.
worn or damaged.
5-10 31211388 6036, 6042, 8042, 10042, 10054, 12054

c. Axle Removal 12054

The front and rear axle assemblies differ in that the front axle
assembly is equipped with a parking brake mechanism and a
limited-slip feature; the rear axle has neither. The following
steps outline a typical axle removal procedure, suitable for
either the front or the rear axle assembly.
Cleanliness is extremely important. Before attempting to
remove the axle, thoroughly clean the machine. Avoid
spraying water or cleaning solution on the stabilizer
solenoids and other electrical components. If using a steam
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cleaner, seal all openings before steam cleaning.
pa
Note: Clear the work area of all debris, unnecessary personnel,
etc. Allow sufficient space to raise the machine and to remove MAE40500
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the axle. 1
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machine, fully retract the boom, lower the boom, place 7. If axle will be disassembled after removal, place a
r
suitable receptacle under axle drain plugs (1). Remove
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brake, straighten all wheels and shut the engine OFF. drain plugs and allow axle oil to drain into receptacle.
or
Transfer used axle oil into a suitable covered container,
2. Place a Do Not Operate Tag on both ignition key switch and label container as “Used Oil”. Dispose of used oil at
and steering wheel.
to
an approved recycling facility.
om
t.c

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5. Remove the fender assembly (if equipped).

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6. Models 10042, 10054 and 12054 Front Axle Only:

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Remove outrigger assembly. Refer to Section 5.3.6, a.

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“Outrigger Removal (10042, 10054 & 12054 only)”

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8042, 10042, 10054

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2
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MAE40510
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to
8. Front Axle: Remove the front access panel (2) to gain

access to top of the front axle.
Go
9. Label, disconnect and cap the steering and brake lines

at the axle. Cap all fittings to prevent dirt and debris
from entering the hydraulic system. Wipe up any spilled
oil.
MAQ0960
10. Block the front and rear of both tires on the axle that is
1
not being removed. Ensure that the machine will remain
in place during axle removal before proceeding.
11. Raise the machine using a suitable jack or hoist. Place
suitable supports under both sides of the frame and
lower the machine onto the supports. Ensure that the
machine will remain in place during axle removal.
6036, 6042, 8042, 10042, 10054, 12054 31211388 5-11

12. Support the axle that is being removed with a suitable 12054
jack, hoist or overhead crane and sling. DO NOT raise
the axle or the machine.
13. Remove both wheel and tire assemblies from the axle
that is being removed. Refer to Section 5.6.1, “Removing
Wheel and Tire Assembly from Machine”.
Note: The wheel and tire assemblies must be re-installed later
with the directional tread pattern “arrows” facing in the
direction of forward travel.
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14. Remove the drive shaft assembly. Refer to Section 5.5.2,
“Drive Shaft Removal”. 10
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10
ur
8042, 10042, 10054 11
yo
11 12
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or
to
12
MAE40520
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15. Remove the capscrew and locknut securing the lower
position cylinder-mount pin (10) to the cylinder. Tap the
t.c
cylinder mount pin out, and move the cylinder to

10 prevent it from interfering with axle removal.
en
16. Remove the capscrew and locknut securing the axle

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pivot pin (11) to the frame.

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12
10 Note: Record the number and location of shims (12) to ensure
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correct installation.
-E
11 11
17. Remove the pivot pin and shims.
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18. Remove the axles from the machine using the jack, hoist
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or overhead crane and sling supporting the axle.

DO NOT raise or otherwise disturb the machine while
sc
removing the axle. Balance the axle and prevent it from

Di
tipping, turning or falling while removing it from

12 MAE40230
beneath the machine. Place the axle on a suitable
to
support or holding stand.

Go
5-12 31211388 6036, 6042, 8042, 10042, 10054, 12054

d. Axle Installation 10. If reinstalling an axle previously removed from the

machine, position the driveshaft yoke on the axle
1. Before proceeding, ensure that the machine will remain
according to the alignment marks made earlier. If
in place during axle installation. Block the front and rear
installing a new axle, note the position of the driveshaft
of both tires on the axle that is already installed on the
yoke at the transmission. Align the driveshaft yoke on
machine.
the axle in the same plane as the yoke on the
2. If applicable, raise the machine using a suitable jack or transmission.
hoist. Place suitable supports beneath the frame and
11. Install the wheel and tire assemblies. Refer to
lower the machine onto the supports, allowing enough
Section 5.6.2, “Installing Wheel and Tire Assembly onto
room for axle installation. Ensure that the machine will
Machine”.
remain in place during axle installation.
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12. Carefully remove the jack, hoist or overhead crane and
ar
sling supporting the axle.
remove the axle from its support or holding stand.
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Balance the axle and prevent it from tipping, turning or 13. Carefully raise the machine using a suitable jack or hoist.
falling while positioning it beneath the machine. Remove the supports from beneath the frame and
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DO NOT raise or otherwise disturb the machine while lower the machine to the ground.
ry
installing the axle. Keep the axle supported and 14. Remove the blocks from the front and rear of both tires
balanced on the jack, hoist or overhead crane and sling on the other axle.
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throughout the installation procedure.
or
4. Position the axle under the frame, and align the pivot
pin bearings with the holes in the frame. 15. Install new o-rings into the fittings. Lubricate the
5. Coat the axle pivot pin (11) with a light film of clean to
o-rings with clean hydraulic oil.
om
engine or hydraulic oil; DO NOT use an anti-seize 16. Uncap and connect the steering and brake lines at their
compound. axle fittings.
t.c
6. Install the axle pivot pin (11) and shims (12). Add or 17. Models 10042, 10054 and 12054 Front Axle Only: Install
en
remove shims until a maximum gap of 0.6 in (1.5 mm) is outrigger assembly. Refer to Section 5.3.6, b. “Outrigger
obtained. Balance the number and thickness of shims Installation”.
m
equally of both sides. Secure the pivot pin with one 18. Check the hydraulic reservoir oil level.
ip
capscrew and a new locknut.

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11 1
-E
3 20. Remove Do Not Operate Tag from ignition key switch

10 2
nt
and steering wheel.

9 3
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8 4 lock to lock, operate the frame tilt function several times
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7 5 in both directions and check the function of the brakes.

Di
6 MT0822 Check for hydraulic leaks, and tighten or repair as

necessary.
to
Note: If new frame level (front) or stabilizer (rear) cylinder

bearings (13) have been installed in the axles or machine 22. Install the fender assembly (if equipped).
Go
frame, the fracture in the bearing race must be positioned at 23. Close and secure the engine rear and side engine doors.
the 9 o’clock position as shown below.
Note: The service brake circuit will need to be bled after axle
7. Move the cylinder into position on the axle cylinder installation. Refer to Section 8.8.4, “Brake Bleeding”.
anchor. Insert a cylinder-mount pin (10) through the
cylinder and cylinder anchor. Secure the
cylinder-mount pin with one capscrew and new
locknut.
8. Apply multi-purpose grease through the self-tapping
lube fitting to lubricate the self-align bearing and the
cylinder-mount pin.
9. Install the drive shaft assemblies. Refer to Section 5.5.3,
“Drive Shaft Installation”.
6036, 6042, 8042, 10042, 10054, 12054 31211388 5-13
5.4 AXLE ASSEMBLY AND DRIVE SHAFT TROUBLESHOOTING
1. Excessive axle noise while 1. Oil level too low. 1. Fill oil to correct level. Refer to
driving. Section 2.3, “Fluid & Lubricant
Capacities”.
2. Axle and/or wheel end housings 2. Drain axle and/or wheel end
filled with incorrect oil or oil level housings and fill to correct level.
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low. Refer to Section 2.3, “Fluid &
ar
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3. Incorrect alignment of ring and 3. Correct alignment by adding or
pinion gears. removing shims as needed.
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4. Incorrect pinion (input) shaft 4. Correct bearing preload by
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bearing preload. adding or removing shims as
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needed.
or
5. Worn or damaged bearings. 5. Replace bearings as needed.
to
6. Worn or broken gear teeth. 6. Replace gears as needed.
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7. Contamination in the axle. 7. Drain axle and/or wheel end
housings and fill to correct level.
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Refer to Section 2.3, “Fluid &

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8. Axle housing damaged. 8. Replace damaged parts.

m
ip
2. Intermittent noise when 1. Universal joint(s) worn or 1. Repair or replace universal joints
qu
traveling. damaged. as needed.

-E
2. Differential ring and/or pinion 2. Determine cause and repair as

gears damaged. needed.
nt
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3. Vibration or intermittent noise 1. Drive shaft universal joint 1. Tighten capscrews to correct
when traveling. assembly(ies) incorrectly torque.
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tightened.
Di
2. Drive shaft universal joint(s) worn 2. Repair or replace universal joints

to
or damaged. as needed.
Go
3. Drive shaft(s) damaged/ 3. Replace drive shaft(s) as needed.

unbalanced.
5-14 31211388 6036, 6042, 8042, 10042, 10054, 12054

4. Oil leaking from axle 1. Drain and/or inspection plugs 1. Replace o-rings as needed and
(differential housing and/or loose and/or o-rings damaged or tighten plugs to
axle housings). missing. 96 lb-ft (130 Nm).
2. Hose fittings loose. 2. Tighten fittings.
3. Axle shaft seal damaged or 3. Replace seal and/or joint coupling

missing and/or worn or damaged fork shaft (axle shaft).
shaft sealing surfaces.
ts
4. Input shaft multi-seal ring 4. Replace multi-seal ring and/or
ar
damaged or missing and/or worn input shaft. Adjust ring and pinion
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or damaged pinion (input) shaft alignment and bearing preload as
sealing surfaces. described in the Dana Repair
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Manuals.
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5. Axle casing to brake housing and/ 5. Replace o-rings and seals.
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or brake housing to differential
assembly o-rings and/or seals
or
worn or damaged.
to
6. Axle housing mounting nuts and 6. Tighten housing nuts and
om
capscrews loose. capscrews to 288 lb-ft (390 Nm).
7. Differential and/or axle housing(s) 7. Replace housing(s) as needed.

t.c
damaged.
en
5. Oil leaking from wheel end 1. Oil level plugs loose and/or 1. Replace o-rings as needed and
m
housing (planet carrier). o-rings damaged or missing. tighten plugs to 96 lb-ft (130 Nm).
ip
2. O-ring between hub and housing 2. Replace o-ring.

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(planet carrier) damaged or

-E
missing.
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3. Shaft seal damaged or missing 3. Replace seal and/or fork joint

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and/or worn or damaged shaft shaft.

sealing surfaces.
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Di
4. Housing capscrews loose. 4. Tighten housing capscrews to

41 lb-ft (55 Nm).
to
5. Housing (planet carrier) damaged. 5. Replace housing (planet carrier).

Go
6. Oil leaking from steering 1. Hose fittings loose. 1. Tighten fittings.

cylinder.
2. Steering cylinder o-rings and/or 2. Replace o-rings and seals.
seals worn or damaged.
3. Piston rod seal worn or damaged. 3. Replace piston rod seal.
4. Cylinder tube damaged. 4. Replace cylinder tube.
6036, 6042, 8042, 10042, 10054, 12054 31211388 5-15

7. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level. Refer to
Section 2.3, “Fluid & Lubricant
Capacities”.
2. Axle and/or wheel end housings 2. Drain axle and fill to correct level.
filled with incorrect oil or oil Refer toSection 2.3, “Fluid &
contaminated or oil level low. Lubricant Capacities”.
3. Dragging park brake. 3. Adjust park brake cable as
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needed.
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8. High steering effort required. 1. Steering (hydraulic) system not 1. Refer to Section 8.5.2, “Pressure
ur
2. Excessive joint housing swivel 2. Correct bearing preload by
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bearing preload. adding or removing shims as
needed.
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3. Worn or damaged swivel 3. Replace swivel bearings as
or
bearings. needed.
9. Slow steering response.

operating properly. to
1. Steering (hydraulic) system not 1. Refer to Section 8.5.2, “Pressure
Specifications”.
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2. Steering cylinder leaking 2. Repair or replace steering cylinder

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internally. as needed.
en
10. Excessive noise when brakes are 1. Brake discs worn. 1. Check brake discs for wear. Refer
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engaged. to Section 5.7.1, “Brake Disc

Inspection”.
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2. Brake discs damaged. 2. Replace brake discs.

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11. Brakes will not engage. 1. Brake (hydraulic) system not 1. Refer to Section 8.5.2, “Pressure
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2. Brake piston o-rings and seals 2. Replace o-rings and seals.

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damaged (leaking).
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12. Brakes will not hold the 1. Brake discs worn. 1. Check brake discs for wear. Refer
machine or braking power to Section 5.7.1, “Brake Disc
to
reduced. Inspection”.
Go
2. Brake (hydraulic) system not 2. Refer to Section 8.5.2, “Pressure

3. Brake piston o-rings and seals 3. Replace o-rings and seals.

damaged (leaking).
5-16 31211388 6036, 6042, 8042, 10042, 10054, 12054

5.5 DRIVE SHAFTS 6036, 6042, 8042, 10042, 10054

TO ENGINE
7
5.5.1 Drive Shaft Inspection and Maintenance 1
2
8
Inspect areas where the drive shaft flange yokes and slip
yokes mount to the drive shafts. Verify all straps and bolts are
tight by attempting to turn each drive shaft in both
TO AXLE
directions. Look for excessive looseness, missing parts, cracks TO
TO TRANSMISSION
or other damage. Worn or damaged drive shafts and bearing TRANSMISSION
cross assemblies may cause an excessive amount of vibration
or noise. 3
ts
2
ar
Verify the mating surfaces between the driveshaft yoke, 5
4
bearing cross and are clean and smooth. 1 6
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Refer to Section 2.5, “Lubrication Schedules”, for information TO
1
2
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TRANSMISSION
regarding the lubrication of the grease fittings on the drive
shafts. 4
ry
MAQ4600
TO AXLE 5
Note: To ensure optimum performance, the driveshaft
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assemblies are specially balanced as a unit at the factory. When 12054
or
servicing any flange yoke, slip yoke or driveshaft tube, order a
TO ENGINE
complete assembly if components are bent or damaged. Refer
to the appropriate parts manual for ordering information.
to 1
7
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Note: Any bolt removed from the drive shaft assembly MUST 2
8
be replaced. DO NOT re-torque.
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TO
Note: Refer to Section 2.6, “Threadlocking Compound”, for all TRANSMISSION
TO AXLE
en

TO 1
2
m
TRANSMISSION
5.5.2 Drive Shaft Removal
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6
1. Park the machine on a firm, level surface, level the 3
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machine, fully retract the boom, lower the boom, place 4 5

5
-E
the transmission in (N) NEUTRAL, engage the park brake TO 4

TRANSMISSION
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and steering wheel.
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TO AXLE MAE40530
Di
system fluids to cool. 7. Remove the four bolts (1) and two straps (2) securing
to
4. Properly disconnect the battery. Refer Section 9.8, the bearing cross of front drive shaft assembly (3) to the
“Battery”, for procedure. transmission output shaft flange. Discard bolts.
Go
5. Block the wheels. 8. Remove the four bolts (4) and two straps (5) securing
6. The drive shaft assemblies are a balanced assembly. the bearing cross of front drive shaft assembly (3) to the
Mark the yoke and axle, transmission and the shaft and front axle. Discard bolts.
slip yoke so that these components can be returned to 9. Remove the front drive shaft assembly (3).
their original positions when reinstalled. Yokes at both 10. Repeat the above procedure for the rear drive shaft
ends of the drive shaft must be in the same plane to assembly (6).
help prevent excessive vibration.
11. Remove the four bolts (1) and two straps (2) securing
the bearing cross of engine/transmission drive shaft
assembly (7) to the transmission output shaft flange.
Discard bolts.
12. Remove the four bolts (8) securing the engine output flange to the engine. Discard bolts.
6036, 6042, 8042, 10042, 10054, 12054 31211388 5-17

13. Remove the engine/transmission drive shaft 5.6 WHEELS AND TIRES
assembly (7).
and steering wheel. WARNING
5.5.3 Drive Shaft Installation Mismatched tire sizes, ply ratings or mixing of tire types
1. Raise the drive shaft assembly into position. The (radial tires with bias-ply tires) may compromise machine
slip-yoke end of the drive shaft mounts toward the axle. stability and may cause machine to tip over.
If reinstalling a drive shaft previously removed, align the It is recommended that a replacement tire to be the same
flange yokes according to the alignment marks made size, ply and brand as originally installed. Refer to the
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during removal. appropriate parts manual for ordering information. If not
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Note: The yokes at both ends of the drive shaft must be in the using an approved replacement tire, It is recommended that
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same plane to help prevent excessive vibration. replacement tires have the following characteristics:
• Equal or greater ply/load rating and size of original.
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2. Install the two straps (2) and four new bolts (1) securing
the bearing cross of front drive shaft assembly (3) to the • Tire tread contact width equal or greater than original.
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transmission. Torque bolts to 60 lb-ft (81 Nm).
• Wheel diameter, width and offset dimensions equal to
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3. Install the two straps (5) and four new bolts (4) securing the original.
the bearing cross of front drive shaft assembly (3) to the
or
axle. Torque bolts to 60 lb-ft (81 Nm). • Approved for the application by the tire manufacturer
(including inflation pressure and maximum tire load).
4. Install front drive shaft assembly (3).
5. Repeat the above procedure for the rear drive shaft to
The rims installed have been designed for stability
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requirements which consist of track width, tire pressure and
assembly (6). load capacity. Size changes such as rim width, center piece
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6. Install the two straps (2) and four new bolts (1) securing location, larger or smaller diameter, etc., without written
the bearing cross of engine/transmission drive shaft factory recommendations, may result in unsafe condition
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assembly (7) to the transmission output shaft flange. regarding stability.

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Torque bolts to 35 lb-ft (47,5 Nm). Foam filled tires have a positive effect on the weight, stability
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7. Install four new bolts (8) securing the engine output and handling characteristics of the machine, especially
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flange to the engine. Torque as required. under load. The use of hydrofill as a tire-fill substance is not
recommended because of possible environmental impact.
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8. Install engine/transmission drive shaft assembly (7).

Large-bore valve stems are used to help expedite tire
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inflation and deflation. An inner tube may be used if a tire

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does not provide an airtight seal. Check tire inflation

pressures when the tires are cold. When mounting a tire on
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the wheel, the tire must be mounted on the wheel respective

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of the directional tread pattern of the tire; this produces a left

or right tire and wheel assembly.
to
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5-18 31211388 6036, 6042, 8042, 10042, 10054, 12054

1 5.6.2 Installing Wheel and Tire Assembly onto

Machine
Note: The wheel and tire assemblies must be installed with the
directional tread pattern “arrows” facing in the direction of
forward travel.
TREAD “ARROWS” MUST

POINT FORWARD
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MY4190
The wheel and tire assemblies must be installed with the
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directional tread pattern “arrows” (1) facing in the direction
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of forward travel.
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5.6.1 Removing Wheel and Tire Assembly from
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Machine
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1. Park the machine on a firm, level surface, fully retract
the boom, lower the boom, place the transmission in (N)
NEUTRAL, engage the park brake and shut the engine to
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OFF. INSTALL TIRES ONTO
WHEELS TO ROTATE IN
2. Place a Do Not Operate Tag on both ignition key switch PROPER DIRECTION
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and steering wheel.

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3. Loosen but DO NOT remove the lug nuts on the wheel

and tire assembly to be removed.
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MAQ0990
4. Place a suitable jack under the axle pad closest to the

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wheel being removed. Raise the machine and position a 1. Position wheel onto studs on wheel end of axle.
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suitable support beneath the axle. Allow sufficient room 2. Start all nuts by hand to prevent cross threading.
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to lower the machine onto the support and to remove DO NOT use a lubricant on threads or nuts.
the wheel and tire assembly.
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5. Lower the machine onto the support.

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6. Remove lug nuts and lug washers in an alternating 3 5

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pattern.
1 7
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7. Remove the wheel and tire assembly from the machine.

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10 9
Go
8 2
6 4
OY1220
3. Tighten lug nuts in an alternating pattern as indicated in

figure. Refer to Section 2.2.5, “Tires”, for proper torque
value.
4. Remove machine from supports.
6036, 6042, 8042, 10042, 10054, 12054 31211388 5-19

5.7 BRAKES 12054
5.7.1 Brake Disc Inspection

A brake lining wear measurement on service brake
(multi-disc brake) gives just limited information about the
overall condition of the multi-disk package–without
disassembly of the output.
Check the brake discs for wear every 1,000 hours of operation
or yearly. Additionally, check brake discs if braking behavior
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has changed in any of following ways:
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• Brake noises
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• Reduced braking power MAE40500
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• Changed deceleration 1
• Changed brake oil level 2. Place a suitable receptacle under axle drain plugs (1).
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Remove drain plugs and allow axle oil to drain into
• Changed braking pressure
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receptacle. Transfer used axle oil into a suitable covered
Wear measurement must be carried out on both output container, and label container as “Used Oil”. Dispose of
or
sides of axle!. used oil at an approved recycling facility.
For more information on brake disc inspection, refer to the
appropriate axle repair manual. to
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1. Block all four wheels to help prevent the machine from
moving.
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6036, 6042, 8042, 10042, 10054

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MAQ0960 2 MAQ1000
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1
3. Using a feeler gauge, check thickness of lined/inner
disc (2). If thickness is less than 5.2 mm, replace the
lined/inner discs.
Note: If discs are worn beyond their tolerance, discs must be
replaced on both sides of axle at the same time.
4. Repeat step 3 for other side of axle.
5. Fill the axle through the axle fill hole until the oil level is
even with both axle level holes. Fill the axle slowly, allow
time for the oil to run across the differential.
6. Reassemble the level plugs using new o-rings.
7. Install the axle fill plug into axle housing.
5-20 31211388 6036, 6042, 8042, 10042, 10054, 12054

5.8 TOWING A DISABLED MACHINE 9. Repeat steps 6 thru 8 for other side of differential.
Note: After machine has been towed to a secure location,
5.8.1 Manually Releasing the Park Brake reactivate park brake. Carefully follow procedures from start to
finish. Contact local JLG dealer if you are unsure about any part
1. Remove load from machine.
of the procedure, or for specific instructions concerning your
2. Fully retract the boom. Position attachment particular situation.
approximately 24 in (610 mm) above the ground.
WARNING
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DO NOT attempt to tow a machine that is loaded or the
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boom/attachment is raised more than approximately
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24 in (610 mm).
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3. Place transmission in (N) NEUTRAL, engage park brake
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4. Block all four wheels.
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or
WARNING
Block all four wheels when preparing the machine for to
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towing to prevent any unexpected movement.
5. Remove front and rear drive shafts. Refer to Section 5.5,

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“Drive Shafts”.
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2
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MAE39750
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1 1 10. Secure machine to a suitable towing vehicle.

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a. For towing or retrieval from front of machine, attach

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towing equipment to lifting points on each side of

the frame directly behind the outrigger weldments.
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b. For towing or retrieval from rear of machine, attach

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towing equipment to the retrieval hitch (2).

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WARNING
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MAE39440
1 1 Use a vehicle of sufficient capacity to tow the machine.
Go
6. Loosen the nuts of the screws (1) for the manual release Tow vehicle must be capable of providing braking for
of the braking units. Draw the nuts back approximately both vehicle and machine.
8 mm. 11. Clear area of any unnecessary personnel.
7. Tighten the screws until they are gently seated on the 12. Have an operator seated in machine operator cab.
driving plate.
13. Remove blocks from all four wheels.
8. Carefully tighten each release screw a 1/4 turn at a time
in sequence until all have been turned one full 14. Disengage machine park brake.
turn 360°. 15. Tow machine to a secure location.
Note: Tow machine at a very slow speed.
16. After towing is complete, engage park brake.
17. Block all four wheels.
6036, 6042, 8042, 10042, 10054, 12054 31211388 5-21

18. Reinstall front and rear drive shafts. Refer to Section 5.5,
“Drive Shafts”.
19. Repair machine as necessary.
Note: Block the wheels of the machine BEFORE attempting to
release the park brake. Once the park brake is released the
machine’s park brake AND service brakes are inoperable.
5.8.2 Manually Resetting the Park Brake

Note: Block the wheels of the machine BEFORE attempting to
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reset the machine’s park brake. Once the park brake is released
the machine’s park brake AND service brakes are inoperable.
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1 1
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MAE39440
1 1
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1. Loosen each release screw (1), only 1/4 turn at a time, in

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sequence, until each screw has lost contact with the

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guide pin.
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2. Remove screws along with nuts and seals. Replace seals,

lubricate screws with a silicone-based grease and
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re-install screws along with nuts.

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3. Adjust the nut of the screw heads in relation to the arm

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by 1.18 in (30 mm).

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4. Repeat steps 1 thru 3 for other side of differential.

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5. After repairs to machine have been made, start machine

and check park brake and service brakes for proper
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function. Refer to Section 8.8.4, “Brake Bleeding” and

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Section 8.8.6, “Steering Orbital Valve”.
5-22 31211388 6036, 6042, 8042, 10042, 10054, 12054

Need parts?
Section 6
Transmission
Contents
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6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
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6.1.1 6036 & 6042 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.1.2 8042, 10042, 10054 & 12054. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
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6.2 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
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6.3 Transmission Specifications and Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . 6-4
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6.4 Transmission Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
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6.4.1 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
or
6.4.2 Transmission Inspection and Internal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.4.3 Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.5
6.4.4
to
After Transmission Service or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7
6-8
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6036, 6042, 8042, 10042, 10054, 12054 31211388 6-1

Transmission
6.1 TRANSMISSION ASSEMBLY

COMPONENT TERMINOLOGY
of the major assemblies of the transmission. The following
6.1.1 6036 & 6042
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OIL FILL TUBE AND
DIPSTICK
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VALVE BLOCK
(CONTROL CIRCUIT 1)
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OIL FILTER
or
VALVE BLOCK
(CONTROL CIRCUIT 2) to
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OUTPUT SHAFT
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to
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MAQ0741
6-2 31211388 6036, 6042, 8042, 10042, 10054, 12054

Transmission
6.1.2 8042, 10042, 10054 & 12054
OIL FILL TUBE AND

DIPSTICK
VALVE BLOCK
(CONTROL CIRCUIT 1)
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OIL FILTER
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VALVE BLOCK
(CONTROL CIRCUIT 2)
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OUTPUT SHAFT
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or
to
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MAE41340
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to
Go
6036, 6042, 8042, 10042, 10054, 12054 31211388 6-3

Transmission
6.4 TRANSMISSION REPLACEMENT

WARNING Note: Contact your local JLG Service Department if internal
DO NOT service the machine without following all safety transmission repair is required during the warranty period.
Note: Cleanliness is of extreme importance. Before attempting
this manual.
to remove transmission, thoroughly clean exterior of
transmission to help prevent dirt from entering during
6.2 TRANSMISSION SERIAL NUMBER replacement process. Avoid spraying water or cleaning solution
onto or near transmission shift solenoids and other electrical
components.
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6.4.1 Transmission Removal
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WARNING
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ry
NEVER lift a transmission alone; enlist the help of at least
one assistant or use a suitable hoist or overhead crane
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and sling with the minimum lifting capacity of
or
1000 lb (454 kg).
1
to
machine, fully retract the boom, raise the boom, place
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OH2381
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Transmission serial number plate (1) is located on pump side 2. Place a Do Not Operate Tag on both ignition key switch
en
(front) of transmission at bottom right toward machine and steering wheel.

frame. Information on serial number plate is required in
3. Temporarily block up or support the boom.
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correspondence regarding transmission.

ip
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6.3 TRANSMISSION SPECIFICATIONS AND system fluids to cool.

MAINTENANCE INFORMATION 5. Drain the hydraulic oil reservoir. Refer to Section 8.6.1,
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“Hydraulic Oil Reservoir Draining”.

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Refer to Section 2, “General Information and Specifications”, 6. Properly disconnect the battery. Refer Section 9.8,
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for transmission, oil specifications and maintenance “Battery”, for procedure.

information.
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Detailed transmission service instructions are provided in the
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following publications: 8. Thoroughly clean the transmission and surrounding

area, including all hoses and fittings.
to
Model Publication Type Publication #

Go
6036, 6042,
8042,
Service Manual 8990455
10042,10054,
12054
6036, 6042, 31211016
8042, 10042,
Parts Manual 31211017
10054
12054 31211463
6-4 31211388 6036, 6042, 8042, 10042, 10054, 12054

Transmission
14. Remove the capscrew securing the black wire (4) to the
transmission housing, and disconnect the wire. DO NOT
reinstall the capscrew at this time.
15. Remove the capscrew securing the clamp (5) and wiring
harness to the transmission housing and move the
wiring harness safely out of the way. DO NOT reinstall
the capscrew at this time.
8
7
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1
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OH2381
9. Place a suitable receptacle under transmission drain
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plug (1). Remove transmission drain plug, and allow
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transmission oil to drain into receptacle.
or
10. Transfer the used transmission oil into a suitable,
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covered container, and label the container as “Used Oil”. 6 MH3401
Dispose of used oil at an approved recycling facility.
16. Remove the capscrew (6) securing the lifting ring (7) to
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Clean and reinstall the transmission drain plug.
the transmission housing. Once the lifting ring has been
11. Remove the engine-to- transmission and transmission- removed, reinstall the capscrew into the hole.
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to-axle drive shafts. Refer to Section 5.5.2, “Drive Shaft

17. Move the lifting ring to the holes (8) used to secure the
en
Removal”.
black wire and clamp. Secure the lifting ring using the
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12. Remove the hydraulic pump. Refer to Section 8.7.1, capscrews and tighten securely.
“Pump Replacement”.
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18. Label, disconnect and cap the transmission oil cooler

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2 5 inlet and outlet hoses on the transmission.

4
19. Connect a lifting strap or chain to the lifting eye at the
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top of the transmission and to a suitable hoist or

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overhead crane. Operate the hoist or crane to remove

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3 slack from the chain, but DO NOT raise the transmission

at this time.
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20. Place blocks under the transmission to help support it

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during removal.
to
Go
3
MH3391
13. Label and disconnect the transmission temperature

switch connector (2) and shift solenoid wiring harness
connectors (3).
6036, 6042, 8042, 10042, 10054, 12054 31211388 6-5

Transmission
6.4.2 Transmission Inspection and Internal

10 Repair
If replacing the entire transmission, transfer the transmission
temperature switch to the replacement transmission. The
gear shift solenoids are included with a new transmission.
6.4.3 Transmission Installation
WARNING
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NEVER lift a transmission alone; enlist the help of at least
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one assistant or use a suitable hoist or overhead crane
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and sling with the minimum lifting capacity of
9 1000 lb (454 kg).
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1. Install two rubber mounts and the rear transmission
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mount (10) in the machine frame. Secure the mount
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MH6290 with the previously used hardware. Torque to
180-320 lb-ft (244-433,8 Nm)
or
21. Remove the four capscrews and lockwashers securing
2. Use a hoist or overhead crane and sling attached to the
the front transmission mount (9) to the transmission.
22. Remove the two capscrews, hex locknuts and rebound to
lifting eye at the top of the transmission. Raise and
position the transmission within the chassis.
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washers. Remove the front transmission mount.
3. Attach the transmission to the rear mounting bracket
23. Remove the four capscrews and lockwashers securing with the previously used hardware. Torque to
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the rear transmission mount (10) to the transmission. 107-191.7 lb-ft (145-260 Nm).
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24. Remove the two capscrews, hex locknuts and rebound 4. Install the two front rubber mounts and the front
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washers. Remove the rear transmission mount. transmission mounting bracket (9) on the transmission
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25. Inspect the rubber mounts. Replace the mounts if with the previously used hardware. Torque to
107-191.7 lb-ft (145-260 Nm).
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damaged.
26. Carefully remove the transmission from the machine. 5. Attach the front mounting bracket to the frame with the
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Avoid causing damage to the transmission or previously used hardware. torque to 180-320 lb-ft
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surrounding parts. (244-433,8 Nm).

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27. Lift the transmission clear of the machine and lower it 6. Remove the hoist or overhead crane and sling.
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onto suitable supports or secure it to a stand built

especially for the transmission or engine service. Secure
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the transmission so that it will not move or fall.

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28. Remove any external transmission components as 11

12
required, including the transmission temperature
Go
switch, and inlet and outlet cooler hose fittings. Cover

all transmission openings.
29. Remove the transmission oil filter and dispose of
properly. Clean the filter mounting surface. Cover or cap
the oil filter mount.
MH3411
Note: The lifting ring (11) must be repositioned to allow the

covers to be installed.
6-6 31211388 6036, 6042, 8042, 10042, 10054, 12054

Transmission
7. Remove the two capscrews securing the lifting ring to 20. Remove Do Not Operate Tags from ignition key switch
the transmission housing. Save the capscrews for later and steering wheel.
use. 21. Close and secure the engine rear and side engine doors.
8. Remove the capscrew and secure the lifting ring in the
storage position (12) on the transmission housing as 6.4.4 After Transmission Service or
shown. Replacement
2 In general:
4
1. Check the transmission oil level and add oil as required.
2. Install a new transmission filter.
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3. Check the torque on the drive shaft yoke cap screws.
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4. When an overhauled or repaired transmission is
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3 installed, thoroughly clean the oil cooler lines to and
from the transmission.
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5. Drain and flush the entire system.
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6. Disconnect and clean all transmission cooler hoses.
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When possible, remove transmission lines from the
machine for cleaning.
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7. Thoroughly clean transmission filter screens and cases,
3 to
and replace transmission filter elements.
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MH3391
9. Connect the transmission temperature switch

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connector (2) and shift solenoid wiring harness 13

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connectors (3).
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10. Attach the black wire (4) to the transmission housing

with a capscrew removed in step 7.
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11. Secure the wiring harness to the transmission housing

using the clip and a capscrew removed in step 7.
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12. Uncap and connect the previously labeled transmission

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oil cooler inlet and out hoses at the transmission.

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13. Install the hydraulic pump. Refer to Section 8.7.1, “Pump

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MH6300
Replacement”.
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14. Install the engine-to-transmission and transmission-to- 8. Reassemble all components and fill the transmission
axle drive shafts. Refer to Section 5.5.3, “Drive Shaft through the dipstick tube opening (13). Check the level
to
Installation”. by taking intermittent dipstick readings as outlined in

the appropriate Operation & Safety Manual. DO NOT
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15. Clean the transmission oil filter mounting surface.

overfill. Reinstall the dipstick when finished.
16. Apply a thin film of clean oil to the new transmission
filter gasket. Install the new filter and torque to 9. Run the engine for two minutes at idle to help prime the
20-25 lb-ft (27-34 Nm). torque converter and the transmission oil lines.
17. Transmission oil may be added through the dipstick 10. Recheck the level of the fluid in the transmission with
tube. Remove the dipstick and add oil. Check the oil the engine running at idle and at the normal operating
level by taking intermittent dipstick readings as temperature 180 - 200° F (83 - 94° C).
outlined in the appropriate Operation & Safety Manual. 11. Add oil as necessary to bring the fluid level to within the
DO NOT overfill. Reinstall the dipstick when finished. “HOT” zone mark on the dipstick.
18. Install the transmission covers. 12. Recheck all drain plugs, lines, connections, etc., for leaks,
19. Properly connect the battery. Refer Section 9.8, and tighten where necessary.
6036, 6042, 8042, 10042, 10054, 12054 31211388 6-7

Transmission
6.5 TRANSMISSION TROUBLESHOOTING

This section provides an easy reference guide covering the
most common problems that may occur during operation of
the transmission.
Note: Contact the JLG Service Department if internal
transmission repair is required during the warranty period.
The transmission should be checked, serviced and repaired
only by experienced service technicians who are aware of all
safety instructions and particular component features.
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1. Transmission will not engage or 1. Oil level too high or low. 1. Fill transmission to correct level.
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will not shift properly. Refer to Section 2.3, “Fluid &
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2. Transmission control lever not 2. Refer to Section 9.5, “Electrical
functioning properly and/or a System Schematics”.
or
fault in the wiring harness.
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Transmission control lever not
functioning properly and/or a
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fault in the wiring harness.
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3. Transmission valve body 3. Refer to Section 9.5, “Electrical

solenoids not functioning System Schematics”.
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properly.
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4. Pilot-operated shift valves not 4. Clean the valve spool and

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operating properly. housing. Replace return spring as

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needed.
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5. Pump output pressure low. 5. Refer to Section 6.5, “Transmission

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Troubleshooting”, Problem 2 “.
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6. Clutch piston o-rings damaged. 6. Replace o-rings.

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7. Clutch discs worn or damaged. 7. Replace clutch discs.

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8. Coupling shafts or gear teeth 8. Replace couplings.

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damaged.
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2. Low or no pump flow or 1. Low oil level. 1. Fill transmission to correct level.
pressure. Refer to Section 2.3, “Fluid &
2. Transmission filled with incorrect 2. Drain transmission and fill to

oil, or oil contaminated. correct level. Refer Section 2.3,
“Fluid & Lubricant Capacities”.
3. Pump suction pipe screen 3. Clean, repair and/or replace

clogged. suction pipe.
4. Central shaft damaged. 4. Replace central shaft.
5. Pump worn or damaged. 5. Repair or replace pump assembly.
6-8 31211388 6036, 6042, 8042, 10042, 10054, 12054

Transmission

3. Low clutch pressure. 1. Incorrect oil level. 1. Fill transmission to correct level.
Refer to Section 2.3, “Fluid &
2. Main pressure valve stuck open. 2. Clean the valve spool and
housing.
3. Broken or worn coupling shaft or 3. Replace coupling and/or o-rings.

piston o-rings.
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4. Pressure reducing valve stuck 4. Clean the valve spool and
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open. housing.
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4. Lack of power. 1. Park or service brake dragging. 1. Refer to Section 8.5.2, “Pressure
Specifications”.
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2. Low engine rpm causes converter 2. Adjust the engine rpm to
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stall. specifications. Refer to
Transmission Service Manual.
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3. Pump output pressure is low. 3. Refer to Section 6.5, “Transmission
to Troubleshooting”, Problem 2 “.
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4. Clutch discs worn or damaged. 4. Replace clutch discs.
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5. Transmission overheating. 5. Refer to Section 6.5, “Transmission

Troubleshooting”, Problem 5 “.
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5. Transmission overheating 1. Low oil level. 1. Fill transmission to correct level.

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(oil above 120° C (248° F)). Refer to Section 2.3, “Fluid &
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2. Clogged radiator. 2. Remove debris from the radiator.

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oil, or oil contaminated. correct level. Refer to Section 2.3,
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4. Excessive “roading.” 4. Stop and idle the engine.

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5. Restriction in oil cooler hoses. 5. Replace cooler hoses.

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6. Pump worn or damaged. 6. Repair or replace pump assembly.

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7. Engine thermostat stuck. 7. Replace engine thermostat.
6036, 6042, 8042, 10042, 10054, 12054 31211388 6-9

Transmission

6. Grinding or “clunking” noise 1. Oil level too low. 1. Fill oil to correct level. Refer to
from transmission. Section 2.3, “Fluid & Lubricant
Capacities”.

oil. correct level. Refer to Section 2.3,
3. Incorrect clutch engagement. 3. Refer to Section 9.12.2,
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“Transmission Solenoid Valves”.
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4. Internal damage. 4. Repair or replace parts as needed.
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5. Broken diaphragm (flex plate). 5. Replace diaphragm (flex plate).
Refer to Section 6.4.1,
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“Transmission Removal”.
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6. Loose diaphragm (flex plate) 6. Tighten capscrews.
mounting capscrews.
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7. Oil leaking from transmission. 1. Oil leaking from vent (high oil 1. Remove drain plug and drain oil
level).
to as needed, until oil is at correct
level. Refer to Section 2.3, “Fluid &
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Lubricant Capacities”. Replace o-
rings as needed and tighten plugs
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to 96 lb-ft (130 Nm).

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2. Drain plug loose and/or o-rings 2. Replace o-rings as needed and

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damaged or missing. tighten plug to 26 lb-ft (35 Nm).

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3. Hose fittings loose. 3. Tighten fittings.

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4. Oil leaking at valve bodies 4. Replace gaskets and/or tighten

(possible valve body gaskets capscrews to 7 lb-ft (9,5 Nm).
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damaged or missing and/or

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mounting capscrews not tight).

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5. Housing capscrews loose. 5. Tighten capscrews to

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34 lb-ft (46 Nm).

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6. Oil leaking at pump (possible 6. Replace o-rings and/or tighten

pump-to-housing o-rings missing capscrews to 85 lb-ft (115 Nm).
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or damaged, and/or pump

mounting capscrews not tight).
7. Oil leaking at converter bell 7. Replace converter and/or input

(possible converter leak and/or shaft seal.
input shaft seal damage).
8. Oil leaking at output shaft (output 8. Replace output shaft seal.

shaft seal damaged).
9. Housing damaged. 9. Replace housing as needed.
6-10 31211388 6036, 6042, 8042, 10042, 10054, 12054

Need parts?
Section 7
Engine
Contents
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7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
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7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
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7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
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7.3.1 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
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7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
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7.4.1 Coolant System Pressure Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
or
7.4.2 Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.4.3 Radiator/Oil Cooler and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.5
7.6
to
Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-6
7-7
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7.6.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
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7.6.2 Fuel/Hydraulic Oil Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7.6.3 After Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
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7.6.4 Diesel Exhaust Fluid (DEF) Pump Filter – 85 hp or 110 hp (63 kW or 82 kW)
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if equipped for ULS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

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7.6.5 Cummins Diesel Exhaust Fluid (DEF) Tank - 110 hp (82 kW)
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7.6.6 Cummins Diesel Exhaust Fluid (DEF) Header – 110 hp (82 kW)
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7.6.7 Diesel Exhaust Fluid (DEF) Pump Filter – 85 hp or 110 hp (63 kW or 82 kW)
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7.6.8 Cummins Diesel Exhaust Fluid (DEF) System Cleaning – 110 hp (82 kW)
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7.6.9 Diesel Exhaust Fluid (DEF) System – Engine Coolant Strainer Cleaning . . . . . . . 7-12
7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
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7.7.1 Exhaust System - 85 hp or 110 hp (63 kW or 82 kW) if equipped for ULS . . . . . . 7-14
7.7.2 Exhaust System - 74 hp (55 kw) if equipped for ULS . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Go
7.7.3 Exhaust System - 85 hp (63 kW) if equipped for LS . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

7.8 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7.8.1 Air Cleaner Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7.8.2 Air Cleaner Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7.9 Engine Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
7.9.1 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
7.9.2 Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
7.10 Isolation Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7.10.1 Isolation Coupler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7.10.2 Isolation Coupler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
6036, 6042, 8042, 10042, 10054, 12054 31211388 7-1

Engine
7.1 INTRODUCTION 7.2 ENGINE SERIAL NUMBER

The engine serial number is located on the turbocharger
WARNING side of the valve cover. Information contained in the serial
number is required in correspondence with the engine
DO NOT service the machine without following all safety manufacturer.
this manual. 7.3 SPECIFICATIONS AND MAINTENANCE
INFORMATION
WARNING
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For engine, coolant and oil specifications, and maintenance
Engine fuel lines are pressurized. DO NOT attempt information, refer to Section 2, “General Information and
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repairs unless specific training has been completed. Specifications”.
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Note: Detailed Cummins engine service instructions (covering
7.1.1 Disclaimer and Scope disassembly, inspection, internal repair, assembly, adjustment
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and troubleshooting) are provided in appropriate Cummins
These instructions are written for worldwide use. In
engine service manual.
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territories where legal requirements govern engine smoke
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emission, noise, safety factors, etc., apply all instructions, Note: Refer to Section 9.20, “Engine Fault Codes”, for error
or
data and dimensions provided herein in such a way that after codes and troubleshooting.
maintenance, service and repair of the engine, engine
operation does not violate local regulations.
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Note: These instructions cover only the routine maintenance,
removal, installation and troubleshooting of engine. Refer to
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local Cummins Engine Distributor and the applicable Cummins

Engine Service Manual for assistance with comprehensive
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engine diagnosis, repair and component replacement. A

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gradual running-in (break-in) of a new engine is not necessary.

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Full load can be applied to a new engine as soon as engine is

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put into service and the coolant temperature is at least

140° F (60° C). Extended light-load operation during early life of
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the engine is not recommended. DO NOT run the engine at

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high, no-load speeds. DO NOT apply an overload to the engine.

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to
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7-2 31211388 6036, 6042, 8042, 10042, 10054, 12054

Engine
7.3.1 Component Terminology

of the engine components. The following illustration
identities the components that are referred to throughout
this section.
IF EQUIPPED FOR ULS

TURBOCHARGER
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STARTER
ALTERNATOR
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IF EQUIPPED WITH AIR SHUTOFF VALVE

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THERMOSTAT
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to
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FUEL INJECTOR AIR SHUTOFF

WATER PUMP VALVE
PUMP
FUEL FILTER
MAE41320
OIL FILTER
6036, 6042, 8042, 10042, 10054, 12054 31211388 7-3

Engine
IF EQUIPPED FOR LS
TURBOCHARGER
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STARTER
ALTERNATOR
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THERMOSTAT
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to
Go
FUEL INJECTOR
PUMP
MAQ1820
WATER PUMP FUEL FILTER
OIL FILTER
7-4 31211388 6036, 6042, 8042, 10042, 10054, 12054

Engine
7.4 ENGINE COOLING SYSTEM

1
7.4.1 Coolant System Pressure Cap

A 17 psi (120 kPa) cap is used on the surge tank. An incorrect
or malfunctioning cap can result in the loss of coolant and a
hot-running engine.
7.4.2 Thermostat Replacement

Before considering thermostat replacement, check the
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coolant level, fan belt tension and instrument cluster
temperature indicator.
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• If engine seems to take a long time to warm, thermostat
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may be stuck in the open position and requires
replacement.
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MAQ1590
• If engine runs hot, check the temperature of the upper
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radiator hose.
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8. Remove capscrews securing thermostat housing (1) to
• If hose is not hot, thermostat may be stuck in the closed the engine.
or
position.
9. Remove thermostat housing, old gasket and
to
• If engine has overheated, performance may thermostat. Clean all gasket surfaces. DO NOT allow dirt
suffer, indicating other damage including a leaking or debris into the thermostat opening.
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cylinder head gasket, cracked cylinder head or block,
and/or other internal engine damage. Note: ALWAYS use correct thermostat and new gasket. NEVER
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operate engine without a thermostat.

a. Thermostat Removal
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1. Park machine on a firm, level surface, level machine, fully b. Thermostat Installation
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retract the boom, lower boom, place transmission in (N)

1. Install engine thermostat, gasket and housing. Secure
NEUTRAL, engage parking brake, and shut engine OFF.
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with previously removed bolts. Torque as required.

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and steering wheel.
-E

3. Open the engine cover. Allow the system fluids to cool.
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3. Open the surge tank cap and fill the radiator completely
4. Properly disconnect the battery(s). Refer Section 9.8, with a 50/50 mixture of ethylene glycol and water. Add
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“Battery”, for procedure. coolant solution at a maximum rate of 1.3 gallons per
sc
5. Slowly turn the surge tank cap to the first stop and allow minute (5 liters per minute). Replace and tighten surge
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any pressure to escape. Remove surge tank cap. tank cap. Add coolant to surge tank until 1/4 to 1/2 full.
This overfilling will compensate for any air trapped in
6. Place a funnel at base of radiator to channel drained
to
the cooling system.

coolant into a container. Loosen drain petcock and
4. Run engine to operating temperature. Visually check for
Go
slowly allow coolant to drain. Transfer coolant into a

properly labeled container. Dispose of properly if leaks with engine running. Check coolant level in surge
coolant needs to be replaced. Tighten the radiator drain tank and fill, or drain, as necessary.
petcock. 5. Close and secure the engine cover.
7. Loosen upper radiator hose clamp and remove the 6. Remove Do Not Operate Tags from both ignition key
radiator hose from the thermostat housing. switch and steering wheel.
6036, 6042, 8042, 10042, 10054, 12054 31211388 7-5

Engine
7.4.3 Radiator/Oil Cooler and Replacement 7. Place a funnel at base of radiator to channel drained
coolant into a container. Loosen drain petcock and
Before considering radiator or oil cooler replacement
slowly allow coolant to drain. Transfer coolant into a
for other than obvious damage, conduct a cooling
properly labeled container. Dispose it properly if coolant
system pressure test, check coolant specific gravity, coolant
needs to be replaced. Tighten the radiator drain
level, fan belt tension and dash panel temperature indicator.
petcock.
• If engine runs hot, check temperature of upper radi-
8. Label and disconnect all hoses and tubes attached to
ator hose.
radiator (3), charge air cooler (4), oil cooler (5), and fuel
• If hose is not hot, thermostat may be stuck in closed cooler (6). Remove surge tank (7).
position.
9. Working at rear of machine, remove capscrews and lock
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• If engine has overheated, performance may washers securing radiator assembly.
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suffer, indicating other damage including a leaking
10. Remove radiator assembly through rear of machine.
cylinder head gasket, cracked cylinder head or
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block, and/or other internal engine damage.
b. Radiator/Oil Cooler Installation
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7 1. Secure radiator (3), charge air cooler (4), oil cooler (5),
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2 and fuel cooler (6) to machine frame with previously
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used hardware. Reinstall surge tank (7).
3
2. Uncap and connect the all the previously labeled hoses
or
and tubes to their appropriate locations.
4
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3. Install the battery or batteries. Connect the battery
positive (+) and negative (-) cables to the appropriate
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battery terminals.
6
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4. Fill the radiator completely with coolant and secure cap.

Refer to Section 2.3, “Fluid & Lubricant Capacities”, for
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proper capacities.
5
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5. Run engine to operating temperature. Visually check for

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leaks with engine running. Check coolant level in

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overflow bottle and fill, or drain, as necessary.

6. Close and secure side and rear engine cover.
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MAQ1200
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a. Radiator/Oil Cooler Removal

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1. Park machine on a firm, level surface, level machine, fully 7.5 ENGINE ELECTRICAL SYSTEM
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retract the boom, lower boom, place transmission in (N)

The engine electrical system, including the starter, alternator
NEUTRAL, engage parking brake, and shut engine OFF.
to
and primary wiring, is described in Section 9, “Electrical

2. Place a Do Not Operate Tag on both ignition key switch System”.
Go
and steering wheel.

4. Properly disconnect the battery(s). Refer Section 9.8,
5. Slowly turn surge tank cap (2) to first stop and allow any
pressure to escape. Remove surge tank cap.
6. Place a suitable container beneath radiator drain.
7-6 31211388 6036, 6042, 8042, 10042, 10054, 12054

Engine
7.6 FUEL SYSTEM

6 1
2 3
7.6.1 Diesel Fuel
Fuel represents a major portion of machine operating costs
and therefore must be used efficiently. ALWAYS use a
premium brand of high-quality, clean diesel fuel. Low cost,
inferior fuel can lead to poor performance and expensive
engine repair.
Refer to Section 2.3, “Fluid & Lubricant Capacities”, for
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approved fuel specification.
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7.6.2 Fuel/Hydraulic Oil Tank
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Note: The fuel/hydraulic oil tank is part of a one piece unit
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divided into a two compartment (tank) unit. It is located on the
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right side of the machine, across from the operator cab. If it is MAQ1210
determined that either the fuel of hydraulic oil tank must be
5
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removed, both the fuel and hydraulic oil must be drained before 4
tank removal. Always dispose of hydraulic oil or fuel properly.
or
5. Remove the hydraulic oil tank top cover (1).
a. Fuel/Hydraulic OIl Tank Removal
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Note: If equipped, the removal of the DEF tank is required to
1. Park the machine on a firm, level surface, level the access the fuel/hydraulic oil tank mounting bolts.
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6. Remove the DEF tank (3). Refer to Section 7.6.5, “Diesel
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Exhaust Fluid (DEF) Tank - 110 hp (82 kW) if equipped

brake, and shut the engine OFF.
for ULS”, for detailed removal instructions.
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7. Drain the fuel tank (4). Remove the fuel tank drain plug
and steering wheel.
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and drain fuel into an approved and suitable container.

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Dispose of fuel properly.

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4. Properly disconnect the battery. Refer Section 9.8, 8. Drain the hydraulic oil tank (5). Refer to Section 8.6.1,
“Battery”, for procedure. “Hydraulic Oil Reservoir Draining”.
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Note: If replacing the tank, remove all internal and external 9. Label, disconnect and cap the fuel and hydraulic lines
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components from the old tank, and retain for use on the from the tank.
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replacement tank. 10. Label and disconnect the electrical components from
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Note: Have a dry chemical (Class B) fire extinguisher near the the fuel/hydraulic oil tank.
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work area. 11. Temporarily install two 1/2-13 lifting eye bolts in the top
of the fuel/hydraulic tank (6).
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WARNING 12. Position and connect a suitable chain support to tank

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lifting point (6) and take up slack in the chain.

NEVER drain or store fuel in an open container due to the 13. While supporting the tank, remove nuts and lock
possibility of explosion or fire. Discard the fuel in an washers securing the tank to the machine frame.
approved manner.
14. Pull tank away from the tank carriage bolts and remove
tank.
6036, 6042, 8042, 10042, 10054, 12054 31211388 7-7

Engine
b. Disassembly 2. With tank removed from machine, plug all openings

except one elbow fitting. Install elbow fitting, and apply
The fuel/hydraulic oil tank is a one-piece unit and cannot be
approximately 1 - 1.5 psi (7 - 10 kPa) of air pressure
disassembled. The fuel level indicator and hydraulic filters can
through elbow. Check reservoir for leaks by applying a
be removed and reused on the new replacement tank. Dispose
soap solution to the exterior and look for bubbles to
of the old tank according to local regulations concerning
appear at cracked or damaged area.
hazardous materials disposal.
f. Fuel/Hydraulic Oil Tank Installation
c. Cleaning and Drying
1. Attach tank to a suitable lifting device at lift point.
If contaminated fuel or foreign material is in the tank, the
tank can usually be cleaned. 2. Place tank carriage bolts into slotted holes in frame.
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Note: If a leak is suspected in the fuel tank, contact your local 3. Position the tank and insert carriage bolts through tank
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authorized Service Department. attachment holes. Install lock washers and finger
tighten nuts onto carriage bolts. Slide the tank and
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To clean the fuel tank: carriage bolts toward the front of machine, until
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1. Have a dry chemical (Class B) fire extinguisher near the carriage bolts are bottomed out into the slotted frame
work area. holes. Tighten and torque as required.
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2. Depending on which side of the tank is contaminated 4. Connect the previously labeled electrical components
(fuel or hydraulic oil), remove the fuel or oil tank drain to the tank.
or
plug, and safely drain any fuel or hydraulic oil into a 5. Uncap and connect the previously labeled hydraulic
suitable container. Dispose of fuel or hydraulic oil
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hoses to their appropriate locations.
properly.
6. Install the previously removed DEF tank. Refer to
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3. Clean the fuel/hydraulic oil tank with a high pressure Section 7.6.5, “Diesel Exhaust Fluid (DEF) Tank - 110 hp
washer, or flush the tank with hot water for five minutes (82 kW) if equipped for ULS”, for detailed installation
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and drain the water. Dispose of contaminated water instructions.

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properly.
7. Fill the hydraulic tank, fuel tank and DEF tank according
4. For the fuel tank side, add a diesel fuel emulsifying
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to specifications. Refer to Section 2.3, “Fluid & Lubricant

agent to the tank. Refer to manufacturer’s instructions Capacities”.
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for the correct emulsifying agent-to-water mixture ratio.

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8. Fill the fuel tank.

Refill the tank with water, and agitate mixture for 10
9. Check tank for leaks.
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minutes. Drain the tank completely. Dispose of

contaminated water properly. 10. Install the hydraulic oil tank cover.
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5. Refill the fuel tank with water until it overflows. 11. Properly connect the battery. Refer Section 9.8,
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Completely flush the tank with water. Empty the fuel “Battery”, for procedure.
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tank, and allow it to dry completely.

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d. Assembly 13. Remove Do Not Operate Tags from both ignition key
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The fuel/hydraulic oil tank is a one piece-unit and cannot be
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disassembled. The fuel level indicator and hydraulic filters 7.6.3 After Fuel System Service
can be removed and reused on the new replacement tank.
Dispose of the old tank according to local regulations 1. Drain and flush the fuel tank if it was contaminated.
concerning hazardous materials disposal regulations. 2. Vent air from the fuel system in accordance with the
instructions found in the appropriate Operation &
e. Inspection Safety Manual.
Note: If a leak is suspected in the fuel tank, contact your local 3. Fill the fuel tank with fresh, clean diesel fuel as required.
authorized Service Department.
1. Inspect the tank thoroughly for any cracks, slices, leaks
or other damage.
7-8 31211388 6036, 6042, 8042, 10042, 10054, 12054

Engine
7.6.4 Diesel Exhaust Fluid (DEF) Pump Filter – c. DEF Pump Filter Installation
85 hp or 110 hp (63 kW or 82 kW) if
equipped for ULS
The pump filter of the DEF System is only required to be
replaced when system maintenance is required or exposed
to contamination.
a. DEF Pump Filter Removal

1. Park the machine on a firm level surface, level machine,
fully retract the boom, lower boom, place transmission
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in (N) NEUTRAL, engage park brake and shut engine
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OFF.
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2. Place a Do Not Operate Tag on both ignition key switch 9
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and steering wheel.
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4. Properly disconnect the battery(s). Refer to Section 9.8,
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5. Thoroughly clean the DEF pump and surrounding area. 7
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MAE16550
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1. Install new DEF pump filter (9) DEF seal assembly (8)
and DEF pump filter cap (7). Tighten as required.
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2. Properly connect the battery(s). Refer to Section 9.8,

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3. Close and secure engine cover.

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4. Remove Do Not Operate Tag from both ignition key

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9 switch and steering wheel.

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7.6.5 Diesel Exhaust Fluid (DEF) Tank - 110 hp

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8 (82 kW) if equipped for ULS

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Note: Contact Cummins at 1-800-CUMMINS for all service if

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the DEF tank assembly is still within warranty. Warranty may be

7
voided if service is conducted by anyone other than Cummins
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service personnel.
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MAE16550 Note: The following procedures are only to be performed when

warranty is expired.
6. Remove the DEF pump filter cap (7), DEF seal assembly
(8) and DEF pump filter (9). Discard the DEF pump filter The DEF tank is located in the front of the fuel/hydraulic oil
(9). reservoir.
a. DEF Tank Removal
b. DEF Pump Cleaning
1. Park machine on a firm, level surface, level machine, fully
1. Wipe out the inside area around the DEF pump filter retract boom, lower boom, place transmission in (N)
housing with a mild dish washing soap and distilled NEUTRAL, engage parking brake, and shut engine OFF.
water.
2. Thoroughly rinse the DEF pump filter housing with and steering wheel.
distilled water. 3. Open the engine cover. Allow the system fluids to cool.
6036, 6042, 8042, 10042, 10054, 12054 31211388 7-9
Engine
4. Properly disconnect battery. Refer Section 9.8, “Battery”, b. DEF Tank Inspection
for procedure.
1. If cleaning DEF tank, Refer to Section 7.6.8, “Diesel
Exhaust Fluid (DEF) System Cleaning – 110 hp (82 kW) if
equipped for ULS” for procedure.
2. If replacing DEF tank, remove all components and retain
for use on replacement tank. Refer to Section 7.6.6,
“Diesel Exhaust Fluid (DEF) Header – 110 hp (82 kW) if
equipped for ULS”.
3. Dispose of damaged DEF tank according to local
regulations concerning hazardous material disposal.
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c. DEF Tank Installation
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1. Install all previously removed components. Refer to
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12 Section 7.6.5, “Diesel Exhaust Fluid (DEF) Tank - 110 hp
(82 kW) if equipped for ULS”, for detailed header
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installation procedure.
13
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MAE23120 2. Install DEF tank and secure to frame with the previously
removed straps (13).
or
5. Open DEF tank filler access cover (10).
3. Remove plugs and/or caps from the previously labeled
to
6. Remove DEF tank access cover at the front of the DEF tank DEF hoses (15) and connect to their
hydraulic oil/fuel reservoir (11). appropriate locations.
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7. Thoroughly clean the DEF tank and surrounding area. 4. Remove plugs and/or caps from the previously labeled
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8. Disconnect electrical connection on top of DEF tank DEF tank coolant hoses (14) and connect to their
(12). appropriate locations. Tighten clamps.
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5. Connect electrical connection on top of DEF tank (12).

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6. Fill DEF tank according to specifications. Refer to

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15 15 Section 2.4, “Fluid and Lubricant Capacities”.

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7. Verify all DEF system hose connections are tight and

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14 secure from any sharp edges, moving parts and/or

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excessive heat.
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14 8. Install DEF tank access cover at the front of the hydraulic

oil/fuel reservoir (11).
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9. Close DEF tank filler access cover (10).

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10. Properly connect the battery(s). Refer to Section 9.8,

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16 11. Close and secure engine cover.
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MAE23130
9. Loosen clamps, label, disconnect and plug and/or cap and steering wheel.
DEF tank coolant hoses (14).
10. Label, disconnect and plug and/or cap DEF tank DEF
hoses (15).
11. Remove DEF tank drain plug (16) and transfer fluid into
a suitable container. Dispose fluid at an approved
recycling facility. Reinstall drain plug (16).
12. Remove straps (13) securing DEF tank to frame and
remove DEF tank.
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Engine
7.6.6 Diesel Exhaust Fluid (DEF) Header – 110 b. DEF Header Filter Replacement
hp (82 kW) if equipped for ULS
Note: Contact Cummins at 1-800-CUMMINS for all service if
the DEF tank assembly is still within warranty. Warranty may be
voided if service is conducted by anyone other than Cummins
service personnel.
18
Note: The following procedures are only to be performed when
20
warranty is expired.
The DEF header should be removed only when system
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maintenance is required.
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a. DEF Header Removal
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1. Refer to Section 7.6.5, “Diesel Exhaust Fluid (DEF) Tank -
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110 hp (82 kW) if equipped for ULS”, for DEF tank
removal.
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19
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17
or
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18
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1. Remove old filter and discard.
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2. Install new filter (20) to the header assembly (18).
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c. DEF Header Installation

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1. Orient and install the header assembly into the DEF tank
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(19).
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19 Note: Verify the indent on the bottom of the header is located

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on the centering nub on the bottom of the DEF tank.

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2. Install and secure the header (18) with the previously

removed hardware (17).
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MAE23140
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2. Loosen and remove six screws (17) securing header (18) 3. Refer to Section 7.6.5, “Diesel Exhaust Fluid (DEF) Tank -
to DEF tank (19). 110 hp (82 kW) if equipped for ULS”, for DEF tank
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installation.
3. Remove header (18) from DEF tank.
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Note: Verify the orientation of the header for reassembly. 7.6.7 Diesel Exhaust Fluid (DEF) Pump Filter –
to
Note: In the event of DEF system contamination, the DEF 85 hp or 110 hp (63 kW or 82 kW)
if equipped for ULS
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system itself can be cleaned, but the DEF header must be

discarded and replaced. Refer to Section 7.6.8, “Diesel Exhaust 1. Refer to Section 7.6.4, “Diesel Exhaust Fluid (DEF) Pump
Fluid (DEF) System Cleaning – 110 hp (82 kW) if equipped for Filter – 85 hp or 110 hp (63 kW or 82 kW) if equipped for
ULS”for DEF system cleaning. ULS” for DEF pump filter information.
6036, 6042, 8042, 10042, 10054, 12054 31211388 7-11

Engine
7.6.8 Diesel Exhaust Fluid (DEF) System 8. Refer to Section 7.6.6, “Diesel Exhaust Fluid (DEF)
Cleaning – 110 hp (82 kW) if equipped for Header – 110 hp (82 kW) if equipped for ULS”, for new
ULS filter and header installation.
Note: Contact Cummins at 1-800-CUMMINS for all service if 9. Refer to Section 7.6.5, “Diesel Exhaust Fluid (DEF) Tank -
the DEF tank assembly is still within warranty. Warranty may be 110 hp (82 kW) if equipped for ULS”, for DEF tank
voided if service is conducted by anyone other than Cummins installation.
service personnel. b. DEF Pump Cleaning
Note: The following procedures are only to be performed when 1. Refer to Section 7.6.4, “Diesel Exhaust Fluid (DEF) Pump
warranty is expired. Filter – 85 hp or 110 hp (63 kW or 82 kW) if equipped for
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Cleaning of the DEF System is only required when the ULS”, for DEF pump filter cleaning procedure.
system is exposed to contamination. If DEF quality is in
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question, obtain a sample from the DEF tank and place in a 7.6.9 Diesel Exhaust Fluid (DEF) System –
clear container. DEF should be crystal clear with a light Engine Coolant Strainer Cleaning
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ammonia smell. If the DEF appears cloudy, has a colored tint The engine coolant strainer is installed on the DEF engine
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or has a strong ammonia smell, it is NOT likely to be within coolant supply hose and should be cleaned every 2000
specifications. hours.
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Ensure the DEF solution is the correct specification. 1. Park machine on a firm level surface, level machine, fully
Cummins recommends using only DEF solutions that
or
retract boom, level boom, place transmission in (N)
maintain 32.5% (+/- 1.5%) of urea content by weight. The NEUTRAL, engage park brake and shut the engine OFF.
urea content can be easily checked with a Refractometer
(PN 70011925). The DEF solution must meet the to
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requirements International Standard ISO 22241-1 for diesel and steering wheel.
engines. There is no acceptable substitute. For engines using 3. Open the engine rear and side doors. Allow the system
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Selective Catalytic Reduction (SCR) Systems, operating in fluids to cool.

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the United States and Canada, DEF certified by the American 4. Properly disconnect the battery.
Petroleum Institute (API) is recommended for use.
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21
DEF should be stored in sealed containers and at 23° to 77° F
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(-5° to 25°C). Avoid storing containers in direct sunlight to

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assure better shelf life.

21
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Note: The DEF header cannot be cleaned if contaminated. It

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must be replaced. Ensure a replacement header has been

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obtained before beginning DEF system cleaning procedures.

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a. DEF Tank Cleaning

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1. Refer to Section 7.6.5, “Diesel Exhaust Fluid (DEF) Tank -

110 hp (82 kW) if equipped for ULS” for DEF tank
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removal.
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2. Refer to Section 7.6.6, “Diesel Exhaust Fluid (DEF)

Header – 110 hp (82 kW) if equipped for ULS”, for
header removal.
3. Discard the contaminated header.
MAG3050
4. Remove the drain plug.
5. Thoroughly clean the DEF tank with a mild dish washing 5. Remove and retain hardware and covers (21) from top
soap and distilled water. of machine frame.
6. Thoroughly flush the DEF tank with distilled water. Note: Thoroughly clean DEF engine coolant supply hose,
7. Install and tighten drain plug. fittings, and surrounding area.
7-12 31211388 6036, 6042, 8042, 10042, 10054, 12054

Engine
9. Brush any debris from the screen and upstream side of

the housing.
Note: If the screen is damaged, replace engine coolant strainer.
10. Install the screen in its original location. To reassemble,
connect strainer housings and torque from 35 - 45 ft.lbs
(47 - 61 Nm).
11. Install strainer, oriented as shown, with the longer end
pointing towards the DEF coolant valve (25). Secure
with the two previously removed clamps. Orient clamps
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as shown.
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12. Tighten and torque clamps to 40 in-lb (4,5 Nm).
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13. Remove hose pliers from the DEF coolant supply hose.
22
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14. Clean up debris, coolant, etc., in, on, near, and around
the machine.
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24
15. Properly connect the battery.
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23 16. Start the engine and check strainer for leaks. Check the
coolant level in the tank and add coolant as required.
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17. Shut the engine OFF.
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24
18. Reinstall covers to top of machine frame with previously
22
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removed hardware.
25
19. Close and secure the engine rear and side doors.
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MAE19780
20. Remove Do Not Operate Tag from both ignition key
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6. Clamp the DEF engine coolant supply hose (22) with switch and steering wheel.
hose pliers at each end of engine coolant strainer (23).
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21. Return machine to service.

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Note: Use a suitable container to catch coolant drainage

beneath the engine compartment.
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7. Loosen and remove two clamps (24) from DEF coolant

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supply hose (22). Remove engine coolant strainer (23).

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Note: Prevent dirt, debris, and/or hose particles from entering

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exposed hose ends.

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8. Loosen and separate the strainer housings. Remove the

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filter screen from inside strainer.

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6036, 6042, 8042, 10042, 10054, 12054 31211388 7-13

Engine
7.7 ENGINE EXHAUST SYSTEM 6. Label and disconnect all coolant lines and electrical
connections (3). Note the exact routing of all coolant
Rattles and noise vibrations in the exhaust system are usually and electrical lines.
caused by misalignment or parts. When aligning the system, 7. Loosen two bolts (4) securing muffler mounting plate to
leave all capscrews and nuts slightly loose until all parts are machine frame on right side of machine. Do Not
properly aligned, then tighten all fasteners working from the Remove bolts.
front of the system to the rear.
8. Remove two bolts (5) securing muffler mounting plate
Before assembling components, use exhaust system sealer on left side of machine.
at all slip joint connections.
Note: For 12054 model, remove Spacer Block (6) from both the
When installing exhaust system components, allow
side of mounting plate.
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sufficient clearance between the components and other
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pipes, hoses and wiring that could be adversely affected by 9. Be sure to properly support muffler mounting plate and
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excessive heat. muffler for removal.
10. Drop muffler mounting plate down on left side.
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7.7.1 Exhaust System - 85 hp or 110 hp (63 kW
11. Lift right side and slip bolts up and through slots on the
or 82 kW) if equipped for ULS
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right side of frame.
a. Exhaust Removal
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12. Place mounting plate on level surface and replace
1. Park the machine on a firm, level surface, level the muffler, clamps and tailpipe. Note position of muffler for
or
machine, fully retract the boom, lower the boom, place re-installation purposes.
to
brake, and shut the engine OFF. b. Exhaust System Installation
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2. Place a Do Not Operate Tag on both ignition key switch Note: Install muffler in proper direction.
and steering wheel.
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Note: Keep all clamps loosened until entire exhaust system is in

3. Open the engine cover. Allow the system fluids to cool. place.
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4. Properly disconnect the battery. Refer Section 9.8, 1. Install muffler and tailpipe on muffler mounting
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“Battery”, for procedure plate using proper clamps in proper position.

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Note: For 12054 model, Spacer Block (6) should be installed on

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both the side of mounting plate.

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2. Lift muffler mounting plate up and slide mounting plate

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bolts (4) through slot in right side of frame.

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3. Lift left side of muffler mounting plate up and

1
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re-install mounting plate bolts (5).

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2 3 3 4. Tighten all mounting plate bolts and torque to 71.5 lb-ft

(97 Nm).
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4 5. Measure distance (A) 11.77 - 12.95 in. (299 - 329 mm)

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between the center of the locating pins on the flex pipe

section of the exhaust pipe (2). Adjust if required.
6
5
6
5
6 MAE42140
5. Loosen three clamps (1) securing exhaust pipe to

muffler and engine. Remove exhaust pipe (2).
7-14 31211388 6036, 6042, 8042, 10042, 10054, 12054

Engine
7.7.2 Exhaust System - 74 hp (55 kw) if

equipped for ULS
a. Exhaust Removal
2 1. Park the machine on a firm, level surface, level the
the travel select lever in the (N) NEUTRAL position,
engage the parking brake, and shut the engine OFF.
A
and steering wheel.
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3. Open the rear door. Allow the system fluids to cool.
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7
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2
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B
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8
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12
4
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11
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MAE42150
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6. Adjust the muffler intake tube to approximately (B) 10

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74.0°.
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7. Install exhaust pipe (2) to muffler and engine.

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8. Verify NoX sensor (7) is mounted in the vertical position 9

(‡ 10°). 5 11
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9. Adjust the muffler intake tube to approximately (B)

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MAQ2120
74.0°.
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10. Tighten all clamps (1). muffler and engine.

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11. Install all previously removed coolant lines and 6. Loosen two bolts (8) securing exhaust pipe to frame.
reconnect electrical connections. Verify proper routing
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of all coolant and electrical lines. 7. Remove exhaust pipe (2).

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12. Properly connect the battery. Refer Section 9.8, 8. Loosen two bolts (4) securing muffler mounting
“Battery”, for procedure. plate (9) to machine frame on right side of machine.
Do Not Remove bolts.
13. Start engine and check for exhaust leaks at all exhaust
connections. Adjust or repair as needed. 9. Remove two bolts (5) securing muffler mounting plate
on left side of machine.
10. Be sure to properly support muffler mounting plate and
15. Remove Do Not Operate Tags from both ignition key muffler for removal.
11. Drop muffler mounting plate down on left side.
12. Lift right side and slip bolts up and through slots on the
right side of frame.
6036, 6042, 8042, 10042, 10054, 12054 31211388 7-15

Engine
13. Place mounting plate (9) on level surface and replace 8. Measure distance (A) 11.77-12.95 in. (299-329 mm)
muffler (10), clamps (11) and tailpipe (12). Note position between locating pins on the flex pipe section of the
of muffler for re-installation purposes. exhaust pipe (2).
The following steps may be required to achieve distance (A)
b. Exhaust System Installation (Expanded web).
Note: Install muffler in proper direction. • Loosen the turbocharger clamp to allow rotation of the
Note: Keep all clamps loosened until entire exhaust system is in top exhaust pipe (2). Do Not remove clamp.
place. • Pull up and out on exhaust pipe (2) to allow for a
straight line and expansion of the flex pipe.
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• Tighten the turbocharger clamp while holding the
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exhaust pipe (2) in place.
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• If the flex pipe is in a “S” shape, loosen the band clamp
(1) securing the muffler.
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• Rotate the muffler inlet tube forward until the flex pipe
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becomes straight.
A
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• It may be necessary to pull the muffler closer to the
frame until the flex pipe becomes straight.
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9. Tighten the muffler band clamp and all remaining
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clamps.
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8
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2 11. Start engine and check for exhaust leaks at all exhaust
connections. Adjust or repair as needed.
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12. Close and secure the rear door.

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10 1 switch and steering wheel.

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4
9
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5
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MAQ2130
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1. Install muffler (10) and tailpipe on muffler mounting

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plate (9) using proper clamps (1) in proper position.

DO NOT tighten.
re-install mounting plate bolts (5).
4. Tighten all mounting plate bolts.
5. Tighten band clamp (10) enough to hold the muffler in
place.
6. Install exhaust pipe (2) to muffler and engine.
7. Install exhaust pipe mounting bolts (8) to frame.
7-16 31211388 6036, 6042, 8042, 10042, 10054, 12054

Engine
7.7.3 Exhaust System - 85 hp (63 kW) if b. Exhaust System Installation

equipped for LS Note: Install muffler in proper direction.
a. Exhaust Removal
Note: Keep all clamps loosened until entire exhaust system is in
1. Park the machine on a firm, level surface, level the place.
machine, fully retract the boom, lower the boom, place 1. Install muffler and tailpipe on muffler mounting
the transmission in (N) NEUTRAL, engage the parking plate (9) using proper clamps in proper position.
and steering wheel.
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3. Open the engine cover. Allow the system fluids to cool. re-install mounting plate bolts (5).
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4. Properly disconnect the battery. Refer Section 9.8, 4. Tighten all mounting plate bolts.
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2
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1
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A
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2 4
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1
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9
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1
5
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MAQ1830
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muffler and engine. Remove exhaust pipe (2).
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MAQ184
6. Loosen two bolts (4) securing muffler mounting plate to
5. Measure distance (A) 11.95-12.75 in. (304-324 mm) of
Go
machine frame on right side of machine. Do Not

Remove bolts. the flex pipe section of the exhaust pipe (2). Adjust if
required.
7. Remove two bolts (5) securing muffler mounting plate
on left side of machine. 6. Install exhaust pipe (2) to muffler and engine.
8. Be sure to properly support muffler mounting plate and 7. Tighten all clamps (1).
muffler for removal. 8. Properly connect the battery. Refer Section 9.8,
9. Drop muffler mounting plate down on left side. “Battery”, for procedure.
10. Lift right side and slip bolts up and through slots on the 9. Start engine and check for exhaust leaks at all exhaust
right side of frame. connections. Adjust or repair as needed.
11. Place mounting plate on level surface and replace 10. Close and secure the engine cover.
muffler, clamps and tailpipe. Note position of muffler for 11. Remove Do Not Operate Tags from both ignition key
re-installation purposes. switch and steering wheel.
6036, 6042, 8042, 10042, 10054, 12054 31211388 7-17
Engine
7.8 AIR CLEANER ASSEMBLY 7.8.2 Air Cleaner Assembly Installation

Note: Refer to Section 2.6, “Threadlocking Compound” for all
CAUTION 1. Secure air cleaner assembly to air cleaner bracket with
NEVER run the engine with only the inner safety element previously used hardware (3).
installed. 2. Install the air cleaner assembly.
Note: Refer to the appropriate Operation & Safety Manual for 3. Install air cleaner hose (2) to the air cleaner assembly
the correct element change procedure. and secure with clamps.
4. Install air intake tube (1) and secure with clamp.
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7.8.1 Air Cleaner Assembly Removal
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5. Tighten all clamps.
1. Park machine on a firm, level surface, level machine, fully
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retract boom, lower boom, place the transmission in (N)
NEUTRAL, engage the parking brake, and shut the
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engine OFF. 7. Close and secure engine cover.
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2. Place a Do Not Operate Tag on both ignition key switch 8. Remove Do Not Operate Tags from both ignition key
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and steering wheel.
3. Open engine cover. Allow system fluids to cool.
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to
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3
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1
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2
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MAQ1240
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5. Loosen clamp securing air intake tube (1) and remove

tube.
6. Loosen clamps securing air cleaner hose (2) to air
cleaner assembly and remove elbow/hose from air
cleaner assembly.
7. Remove capscrews and lock washers (3) securing
mounting band to air cleaner bracket. Remove air
cleaner assembly.
7-18 31211388 6036, 6042, 8042, 10042, 10054, 12054

Engine
7.9 ENGINE REPLACEMENT 14. Remove the exhaust pipe and muffler system. Refer to
Section 7.7.1, “Exhaust System - 85 hp or 110 hp (63 kW
or 82 kW) if equipped for ULS”.
7.9.1 Engine Removal
Note: Engine Lift Bracket Kit PN 1001177168 is required for
proper engine removal.
Note: The radiator and oil cooler must be removed from the
machine before engine removal. Refer to Section 7.4, “Engine
Cooling System” Several additional components must be
removed before engine removal. They will be addressed in the
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following procedures.
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and steering wheel.
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3. Open the engine cover. Allow the system fluids to cool. 3
or
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“Battery”, for procedure. 2
MAE41330
5. Remove the engine cover. 3 1
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6. Drain and remove radiator assembly. Refer to 15. At the front right engine mount (1), remove the
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Section 7.4.3, “Radiator/Oil Cooler and Replacement”. hardware securing the mount to the frame.
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7. Label, disconnect and cap the heater hoses attached to 16. Remove hardware securing rear engine mounts (2).
the engine (if equipped). 17. Remove the exhaust pipe bracket.
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Note: The engine harness is routed and attached to the engine

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18. Install left and right engine lift brackets (3).

using hold-down clamps and plastic wire ties at various places
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19. Position a fork truck behind the machine, and drive

on the engine. Before removing engine, ensure that the harness
forward, placing the forks underneath the rear engine
-E
has been completely separated (disconnected) from the engine.

mount and front engine lift brackets. Slightly lift the
Move the harness clear of the engine, and with the help of an
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engine, and slowly back engine out of the machine.

observer, ensure that the engine clears the harness during
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Have an assistant ensure that the engine clears all frame

removal.
components during removal.
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8. Label and disconnect all electrical wire connections on 20. Place engine on a flat, level surface.
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the engine.
21. If replacing engine, attach a lifting chain to the front and
9. Label, disconnect and cap the fuel inlet line at the fuel
to
rear engine lift brackets, and lift engine clear of the

lift pump. ground.
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10. Label, disconnect and cap the fuel return line from the 22. Remove the two engine lift brackets (3).
injector pump.
23. Remove the three engine mounting brackets.
11. Remove the engine-to-transmission drive shaft. Refer to
Section 5.5.2, “Drive Shaft Removal”. 24. Remove air intake assembly.
12. Loosen the clamps on the sleeve reducer at the engine

and on the air suction pipe.
13. Remove air intake hoses and pre-cleaner. It is not
necessary to remove air cleaner assembly before engine
is removed from frame.
6036, 6042, 8042, 10042, 10054, 12054 31211388 7-19

Engine
7.9.2 Engine Installation 19. Check that all hydraulic system, electrical system,
cooling system, fuel system and exhaust system
Note: The engine harness is routed and attached at various
connections are correct and connected tightly.
places on the engine using hold-down clamps and plastic wire
ties. Before installing engine and with the help of an assistant, Note: Have an assistant stand by with a Class B fire
ensure that the engine clears the harness during installation. extinguisher.
1. If replacing the engine, attach a lifting strap or chain to 20. Start the engine and run to normal operating
the front and rear engine lift brackets, and lift the temperature then shut off the engine. While the engine
engine clear of the ground. is cooling, check for leaks.
2. Install the engine mounting brackets. Torque to 21. Allow the engine to cool. Check the radiator coolant
ts
93-100 lb-ft (125-135 Nm). level, and add coolant if needed. Replace the radiator
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3. Install left and right engine lift brackets (3). cap.
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4. Place the engine on a flat, level surface. 22. Check for leaks from the engine, main hydraulic pump
and lines, transmission, hydraulic reservoir and fuel
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5. Position a fork truck behind the engine, and drive tank. Check the levels of all fluids and lubricants. Fill as
forward, placing the forks underneath the rear engine required.
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mount and front right and left engine lift brackets. Lift
the engine and slowly drive it into the back of the Note: During the full throttle check:
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machine. Have an assistant ensure that the engine • DO NOT operate any hydraulic function.
or
clears all frame, hose and harness components during
installation. Position the engine brackets over rear and • DO NOT steer or apply any pressure to the steering
front frame mounts.
to
wheel.
• Place the transmission in (N) NEUTRAL.
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6. Secure the rear engine mounts (2) to the frame using
the previously used hardware. Torque to 135 lb-ft 23. Obtain and connect an appropriate engine analyzer or
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(100 Nm). tachometer. Check the engine rpm at full throttle.

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7. Secure front (1) engine mount to frame using previously 24. Purge the hydraulic system of air by operating all boom
used hardware. Torque to 135 lb-ft (100 Nm). functions through their entire range of motion several
m
8. Remove the two engine lift brackets (3). times. Check the hydraulic oil level.
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9. Install exhaust pipe mount bracket. 25. Check for proper operation of all components.
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10. Install the radiator overflow tube, overflow tank and 26. Turn the engine OFF.
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hose support. 27. Install the side and rear engine covers.
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11. Install the engine-to-transmission drive shaft. Refer to

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Section 5.5.3, “Drive Shaft Installation”.

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12. Uncap and connect the previously labeled fuel return

line to the injector pump.
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13. Uncap and connect the previously labeled fuel inlet line
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to the fuel lift pump.

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14. Connect the previously labeled electrical wire

connections on the engine.
15. Uncap and connect the previously labeled heater hoses
to the engine (if equipped).
16. Install the complete radiator assembly. Refer to
Section 7.4.3, “Radiator/Oil Cooler and Replacement”.
7-20 31211388 6036, 6042, 8042, 10042, 10054, 12054

Engine
7.10 ISOLATION COUPLER 10. At this time, use a suitable cleaner/solvent and
thoroughly clean the mounting lip of the flywheel. Wipe
any debris from the inside of the bell housing. Use the
7.10.1 Isolation Coupler Removal cleaner to clean the threaded holes around the flange of
1. Park the machine on a firm, level surface, level the the bell housing.
the transmission in (N) NEUTRAL, engage the park brake, 7.10.2 Isolation Coupler Installation
1. Use cleaner to clean the backside of the coupler, where
2. Place a Do Not Operate Tag on both ignition key switch it comes in contact with the flywheel.
and steering wheel.
Note: Refer to Section 2.6, “Threadlocking Compound” for all
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3. Open the engine cover. Allow the system fluids to cool. thread locking requirements.
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Note: The new coupler is heavy and requires two people, one
on each side, to install.
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Note: Rotating the fan belt by hand gives greater access to
2. Place the new coupler into the indentation of the
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removing the drive shaft mounting capscrews.
flywheel and use new hardware to secure the coupler to
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5. Remove the capscrews and straps that secure the drive the flywheel. DO NOT fully tighten until all capscrews
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shaft to the transmission yoke. are in place.
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6. Remove the capscrews and lock washers securing the 3. After all capscrews are in place, check to be sure the
drive shaft to the coupling flange. coupler is resting squarely in the indentation of the
Note: It may be necessary to loosen/remove the motor mounts to
flywheel. Torque all the capscrews to 40.5 lb-ft (55 Nm).
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on either side of the engine to gain access to the bottom Note: Before assembling the drive shaft to the coupling; be
capscrews on the outer half of the coupler. Place a jack under sure the access cover plate is placed on the engine-side of the
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the bell housing (use a wood block to support the engine) and frame member that mounts the rear axle to the frame.
carefully lift the engine until the bottom edge of the bell
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4. Install the access cover plate over the drive shaft and
housing is at the top edge of the frame member that mounts
assemble the drive shaft flange to the coupler using
m
the rear axle to the frame. Watch the fan-to-radiator clearance

new hardware. Torque to 48 lb-ft (65 Nm).
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as your are lifting the engine. If necessary, turn the fan slightly
5. If engine mounts were previously removed or loosened,
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by hand to gain additional clearance.

carefully lower the engine down onto the front engine
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mounts. Reassemble the rebound washer and secure in

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place with a new locknut. Torque to 60 lb-ft (81 Nm).

Repeat this procedure for the engine mount on the
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other side.
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6. Thoroughly clean the transmission yoke and secure in

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place with new straps and hardware. Torque to

55 – 60 lb-ft (75 – 81 Nm).
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2
7. After the drive shaft is in place, grease both u-joints and
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the slip joint using multi-purpose grease.

1 MH6361 8. Properly connect the battery. Refer Section 9.8,
7. Remove the capscrews and lock washers securing the
access cover plate (1). 9. Close and secure the engine cover.
8. Remove the capscrews securing the coupler (2) to the 10. Remove Do Not Operate Tags from both ignition key
flywheel. switch and steering wheel.
Note: The coupler is heavy and requires two people, one on

each side, to remove.
9. Remove the coupler assembly.
6036, 6042, 8042, 10042, 10054, 12054 31211388 7-21

Need parts?
Section 8
Hydraulic Section
Contents
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8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
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8.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
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8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
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8.5 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
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8.5.1 Pressure Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
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8.5.2 Pressure Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
or
8.5.3 Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
8.6 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
8.6.1
8.6.2
to
Hydraulic Oil Reservoir Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Oil Reservoir Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-37
8-37
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8.6.3 Hydraulic Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
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8.6.4 Hydraulic Oil Reservoir Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38

8.7 Hydraulic System Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38
en
8.7.1 Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38

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8.8 Valves and Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39

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8.8.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39

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8.8.2 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42

8.8.3 Service Brake Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43
-E
8.8.4 Brake Bleeding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43

nt
8.8.5 Brake System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44

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8.8.6 Steering Orbital Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45

8.8.7 Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-45
sc
8.8.8 Secondary Function Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46

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8.8.9 Outrigger Valve (10042, 10054 & 12054 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47

to
8.8.10 Extend Lockout Valve (10054 & 12054 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49

8.9 Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50
Go
8.9.1 General Cylinder Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50

8.9.2 Cylinder Pressure Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
8.9.3 Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
8.9.4 Cylinder Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-53
6036, 6042, 8042, 10042, 10054,12054 31211388 8-1

Hydraulic Section
8.1 HYDRAULIC COMPONENT

TERMINOLOGY
To understand the safety, operation and service information
presented in this section, it is necessary that the operator/
mechanic be familiar with the name and location of the
hydraulic components of the machine. The following
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6036 & 6042
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LIFT/LOWER
CYLINDER(S)
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COMPENSATION
CYLINDER(S)
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ATTACHMENT
TILT CYLINDER
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or
EXTEND/RETRACT
CYLINDER
MAIN PISTON PUMP

(FOR 74 HP) to
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HYDRAULIC FLUID
RESERVOIR
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MAIN GEAR
STEER SELECT
PUMP (FOR LS)
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VALVE
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MAIN CONTROL
VALVE (FOR LS)
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STABILIZER
CYLINDER
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FRAME LEVEL
(6042 ONLY)
CYLINDER
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to
MAIN CONTROL
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STEERING
VALVE (FOR 74 HP)
SECONDARY CYLINDER
JOYSTICK
FUNCTION (REAR)
VALVE
STEERING
ORBITROL
SERVICE VALVE
BRAKE VALVE
STEERING
CYLINDER MAE42160
(FRONT)
8-2 31211388 6036, 6042, 8042, 10042, 10054,12054

Hydraulic Section
8042, 10042 & 10054

EXTEND/RETRACT
CYLINDER COMPENSATION
CYLINDER(S)
LIFT/LOWER
CYLINDER(S)
ATTACHMENT
TILT CYLINDER
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rp
MAIN PISTON
PUMP
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HYDRAULIC FLUID
RESERVOIR
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STEER SELECT
VALVE
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MAIN CONTROL
VALVE
or
to
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EXTEND LOCKOUT
VALVE (10054) ONLY)
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STABILIZER
en
CYLINDER
FRAME LEVEL
CYLINDER
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JOYSTICK
STEERING
-E
CYLINDER
STEERING (REAR)
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ORBITROL
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VALVE
SERVICE
SECONDARY BRAKE VALVE
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FUNCTION
VALVE
Di
to
OUTRIGGER VALVE
(10042 & 10054 ONLY)
Go
OUTRIGGER STEERING
CYLINDERS CYLINDER
(10042 & 10054 ONLY) (FRONT)
MAQ1271
6036, 6042, 8042, 10042, 10054,12054 31211388 8-3

Hydraulic Section
12054 EXTEND/RETRACT
CYLINDER
COMPENSATION
CYLINDER(S)
ATTACHMENT
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TILT CYLINDER
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LIFT/LOWER
rp
CYLINDER(S)
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MAIN PISTON
HYDRAULIC PUMP
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FLUID RESERVOIR
STEER SELECT
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VALVE
or
MAIN CONTROL
VALVE
to
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EXTEND LOCKOUT
VALVE
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STABILIZER
FRAME LEVEL CYLINDER
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CYLINDER
m
STEERING CYLINDER
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(REAR)
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JOYSTICK
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SECONDARY
STEERING
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FUNCTION SERVICE
ORBITROL
VALVE BRAKE VALVE
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VALVE
OUTRIGGER VALVE
to
Go
STEERING
CYLINDER
OUTRIGGER CYLINDERS (FRONT)
MAE41510
8-4 31211388 6036, 6042, 8042, 10042, 10054,12054

Hydraulic Section
8.2 SAFETY INFORMATION Reference Section 2.4, “Service and Maintenance Schedules”,
for the appropriate maintenance intervals based on hours of
operation, but if your equipment is exposed to extremely
WARNING dirty or hostile conditions service may be required more
frequently. Always use OEM filters to assure the necessary
DO NOT service the machine without following all safety filtration requirements are met.
precautions as outlined in Section 1, “Safety Practices”, of Some hydraulic functions are actuated by interfacing with
this manual. electrical system components (switches, solenoids and
Petroleum-based hydraulic fluids are used in this machine. sensors). When the hydraulic system is not functioning
Temperature of hydraulic fluid increases properly, check the electrical aspect of the malfunctioning
ts
during operation of various hydraulic functions. A heated circuit also. Refer to Section 9.5, “Electrical System
petroleum-based hydraulic fluid presents a fire hazard,
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Schematics”.
especially when an ignition source is present. Hydraulic fluid
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has a flash point that ranges from 300 - 600° F (150 - 318° C)
and an auto-ignition temperature of 500 - 750° F (262 - 402° C). 8.3 SPECIFICATIONS
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Accordingly, periodically inspect all hydraulic system Refer to Section 2.2, “Specifications”, for hydraulic system
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components, hoses, tubes, lines, fittings, etc. Carefully specifications.
examine any deterioration and determine whether any
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further use of the component would constitute a hazard. If in
doubt, replace the component.
or
Operate the hydraulic controls after the engine has stopped
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to relieve trapped pressure.
Whenever you disconnect a hydraulic line, coupler, fitting or
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other component, slowly and cautiously loosen the part
involved. A hissing sound or slow seepage of hydraulic fluid
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may occur in most cases. After the hissing sound has ceased,
continue removing the part. Any escaping oil should be
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directed into an appropriate container. Cap or otherwise

block off the part to prevent further fluid seepage.
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Hydraulic system maintenance will, at times, require that the

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engine be operated. Always follow safety precautions.

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A major cause of hydraulic component failure is

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contamination. Keeping the hydraulic fluid as clean as

possible will help avoid downtime and repairs. Dirty or
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contaminated hydraulic oil can damage internal

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components and void the manufacturer’s warranty. When

servicing the system, cap or plug hydraulic fittings, hoses and
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tube assemblies. Plug all cylinder ports, valves and the

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hydraulic reservoir, and pump openings until installation

occurs. Protect threads from contamination and damage.
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Manufacture’s recommended hydraulic oil cleanliness levels

are based on the three digit ISO code for 6 micron/ 14 micron
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particle sizes found in one ml of fluid (reference ISO 4406:

199(E). The acceptable level is 17/14 or below; anything
higher requires system cleaning and filter replacement.
Note: The human eye can only distinguish particles down to 40
microns.
6036, 6042, 8042, 10042, 10054,12054 31211388 8-5

Hydraulic Section
8.4 HYDRAULIC CIRCUITS 8.5 HYDRAULIC PRESSURE DIAGNOSIS

This section covers the hydraulic circuits and includes listings
for all hydraulic function pressures, where and how to check 8.5.1 Pressure Checks and Adjustments
those pressures and a hydraulic schematic. When diagnosing trouble in the hydraulic system, use the
Electrical and hydraulic functions are often related. Verify hydraulic testing information in Section 8.5.2, “Pressure
that electrical components of the circuit are functioning Specifications”.
properly whenever troubleshooting the hydraulic circuit. In general, follow the steps below whenever conducting
Always check the following before beginning to pressure checks and performing adjustments:
troubleshoot a circuit that is not functioning correctly. 1. Park the machine on a firm, level surface, engage the
1. Check hydraulic oil level in reservoir. Level should be in park brake, place the transmission in (N) NEUTRAL, level
rts
middle of sight glass with all cylinders retracted. the boom and turn the engine OFF.
2. Install a digital or a 5000 psi (345 bar) at the appropriate
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2. Check hoses, tubes, fittings and other hydraulic
components for leaks, bends, kinks, interference, etc. test port.
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3. Check for air in the hydraulic system. Erratic machine 3. All hydraulic pressures are factory set and/or adjusted at
performance and/or spongy cylinder operation are an ambient temperature between 60-80°F (15,5-26,6°C).
yo
signs of air in the hydraulic system. If air in the hydraulic 4. Start the engine. If necessary, operate machine
system is suspected, you will hear air leakage when functions several times to allow hydraulic oil to reach
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hydraulic fittings are loosened and see air bubbles in
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operating temperature.
the hydraulic fluid.
5. Refer to Section 8.5.2, “Pressure Specifications”, for
or
4. Loose fittings, faulty o-rings or seals, trapped oil, leaks, testing procedures.
system opened for service, etc., can cause air in the
system. Determine what is causing air to enter the
system and correct it. Bleed air from the system. to
6. Fully depress accelerator pedal if required. Place and
hold joystick in position needed to operate the
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particular machine function being checked. Continue
holding the joystick in position until pressure is stable
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and readings are taken.

7. Check pressure gauge reading. It should read as
en
specified in Pressure Readings column of the charts

found in Section 8.5.2, “Pressure Specifications”. If the
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reading is not as specified, turn the engine OFF and

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check other components in the system. Verify that all

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related hydraulic components and electrical switches,

sensors, solenoids, etc. are operating correctly.
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to
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8-6 31211388 6036, 6042, 8042, 10042, 10054,12054

Hydraulic Section
8.5.2 Pressure Specifications
a. 6036 - 85 hp (63 kW)
SECONDARY FUNCTION MANIFOLD

MAIN CONTROL VALVE
C B
(PRH1) (PRH2)
ts
ar
rp
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ry
PBG
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(PARK BRAKE BVG
GAUGE) (BRAKE VALVE
or
GAUGE)
to
MAQ1500
A MAE41250
(LOAD SENSE RELIEF
om
M VALVE)
(MAIN PUMP
PRESSURE)
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SERVICE BRAKE VALVE

en
m
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nt
D
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(AXLE BRAKE
PRESSURE)
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Di
to
MAE14330
Go
Note: Install pressure gauge at test port M on main control valve BEFORE Starting engine.
All pressures must be checked in numerical order.
Note: Only operate the functions that are specified in the particular pressure check. Operating other functions than those specified
may cause false readings.
Note: Boom level unless otherwise noted.
6036, 6042, 8042, 10042, 10054,12054 31211388 8-7

Hydraulic Section
Test Adjustment Range/

Hydraulic Circuit Procedure Notes
Port Location Pressure
Standby Connect gauge to M port, run 325 - 375 psi
1 M NA Park Brake - ON
(low idle) engine at low idle, no function. (22,4 - 25,8 bar)
Standby Connect gauge to M port, run 525 - 575 psi
(high idle) engine at high idle, no function. (36,2 -39,6 bar)
Connect gauge to M port, run
engine at high idle, fully retract
extend/retract cylinder.
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Main Pump/Load NOTE: When bottoming Lift, Tilt, 3050-3100 psi
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3 Sense M Frame Level or Auxiliary at high LS (A) (210,3-213,7 Park Brake - ON
(high idle) idle, the pressure seen at the M bar)
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port should be within
100 psi (6,4 bar) of the noted
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extend/retract cylinder pressure.
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Connect gauge to M port, run 2600-2700 psi Park Brake - ON
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Steering
4 M engine at low idle, in front steer NA (179,3-186,2 Front Steering
(low idle)
or
mode, turn steering lock to lock. bar) Mode Selected
to
Secondary
Connect gauge to BVG port, run
Function Manifold 550-560psi
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5 BVG engine at high idle, fully retract PRH2(B) Park Brake ON
(Service Brake) (37,9-38,6 bar)
(high idle)
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Secondary
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engine at high idle, stall

Function Manifold 580-590psi
6 BVG steering. Pressure should not NA Park Brake - ON
m
(Service Brake) (39,9-40,6 bar)

increase more than 30 psi (2,0
ip
(high idle)
bar) from pressure 5.
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Connect gauge to PBG port, run

-E
Secondary
Function Manifold
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extend/retract cylinder. 0-10 psi

7 (Park Brake PBG NA Park Brake - ON
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NOTE: Range/Pressure should (0-0,7 bar)

Pressure)
repeat in all machine conditions
(high idle)
sc
with park brake ON.

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Secondary
Function Manifold
to
engine at high idle, fully retract 380-390 psi

8 (Park Brake PBG PRH1(C) Park Brake - OFF
extend/retract cylinder, switch (26,2-26,8 bar)
Go
Pressure)
park brake OFF.
(high idle)
engine at high idle, stall
Steering 410-420 psi
9 PBG steering. Pressure should not PRH1(C) Park Brake - OFF
(high idle) (28,2-28,9 bar)
increase more than 30 psi (2,0
bar) from pressure 8.
Block tire, connect gauge to D
Service Brake port. Start engine and run at low
10 D NA 0 psi (0 bar) Park Brake - OFF
(low idle) idle. Do Not apply brake pedal
pressure.
8-8 31211388 6036, 6042, 8042, 10042, 10054,12054

Hydraulic Section
Test Adjustment Range/

Hydraulic Circuit Procedure Notes
Port Location Pressure
Connect gauge to D port, run
Service Brake 650 psi (44,8
11 D engine at low idle, apply NA Park Brake - OFF
(low idle) bar) Minimum
maximum brake pedal effort.
Connect gauge to D port. Verify
machine is parked on flat
ground, Run engine at low idle,
Service Brake 80 psi (5,5 bar)
12 D transmission in (N) Neutral, turn NA Park Brake - OFF
(low idle) Minimum
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engine OFF, wait 3 seconds,
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apply maximum brake pedal
effort.
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or
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m
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6036, 6042, 8042, 10042, 10054,12054 31211388 8-9

Hydraulic Section
b. 6042 - 85 hp (63 kW)

SECONDARY FUNCTION MANIFOLD
MAIN CONTROL VALVE
B
C (PRH2)
(PRH1)
ts
ar
PBG
rp
(PARK BRAKE
GAUGE)
ou
BVG
(BRAKE VALVE
ry
GAUGE)
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MAQ1500
A MAE41250
or
(LOAD SENSE RELIEF
M VALVE)
(MAIN PUMP
to
PRESSURE)
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SERVICE BRAKE VALVE STABIL-TRAK VALVE

en
m
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D
(AXLE BRAKE
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PRESSURE)
Di
to
G1 E
MAE14330
STABIL-TRAK PRV
Go
PRESSURE ADJUSTMENT
SCREW
MAQ1530
8-10 31211388 6036, 6042, 8042, 10042, 10054,12054

Hydraulic Section
Note: Install pressure gauge at test port M on main control valve BEFORE Starting engine.
Hydraulic Test Adjustment

Procedure Range/Pressure Notes
Circuit Port Location
Standby Connect gauge to M port, run 325-375 psi
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(low idle) engine at low idle, no function. (22,4-25,8 bar)
pa
Standby Connect gauge to M port, run 525-575 psi
(high idle) engine at high idle, no function. (36,2-39,6 bar)
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Connect gauge to M port, run
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Main extend/retract cylinder.
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Pump/ NOTE: When bottoming Lift, Tilt,
3050-3100 psi
3 Load M Frame Level or Auxiliary at high idle, LS (A) Park Brake - ON
or
(210,3-213,7 bar)
Sense the pressure seen at the M port
to
(high idle) should be within 100 psi (6,4 bar) of
the noted extend/retract cylinder
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pressure.
Connect gauge to M port, run Park Brake - ON
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4 M engine at low idle, in front steer NA Front Steering
(low idle) (179,3-186,2 bar)
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mode, turn steering lock to lock. Mode Selected

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Secondary
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Function
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Manifold 550-560psi
5 BVG engine at high idle, fully retract PRH2(B) Park Brake ON
(Service (37,9-38,6 bar)
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Brake)
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(high idle)
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Secondary
Function Connect gauge to BVG port, run
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Manifold engine at high idle, stall steering. 580-590psi

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6 BVG NA Park Brake - ON

(Service Pressure should not increase more (39,9-40,6 bar)
Brake) than 30 psi (2,0 bar) from pressure 5.
to
(high idle)
Go
Secondary Connect gauge to PBG port, run

Function engine at high idle, fully retract
Manifold extend/retract cylinder. 0-10 psi
7 PBG NA Park Brake - ON
(Park Brake NOTE: Range/Pressure should (0-0,7 bar)
Pressure) repeat in all machine conditions
(high idle) with park brake ON.
Secondary
Function Connect gauge to PBG port, run
Manifold engine at high idle, fully retract 380-390 psi
8 PBG PRH1(C) Park Brake - OFF
(Park Brake extend/retract cylinder, switch park (26,2-26,8 bar)
Pressure) brake OFF.
(high idle)
6036, 6042, 8042, 10042, 10054,12054 31211388 8-11

Hydraulic Section

Steering engine at high idle, stall steering. 410-420 psi
9 PBG PRH1(C) Park Brake - OFF
(high idle) Pressure should not increase more (28,2-28,9 bar)
than 30 psi (2,0 bar) from pressure 8.
Service Block tire, connect gauge to D port.
10 Brake D Start engine and run at low idle. Do NA 0 psi (0 bar) Park Brake - OFF
(low idle) Not apply brake pedal pressure.
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Service Connect gauge to D port, run engine
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650 psi (44,8 bar)
11 Brake D at low idle, apply maximum brake NA Park Brake - OFF
Minimum
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(low idle) pedal effort.
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Connect gauge to D port. Verify
machine is parked on flat ground,
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Service
Run engine at low idle, transmission 80 psi (5,5 bar)
12 Brake D NA Park Brake - OFF
in (N) Neutral, turn engine OFF, wait Minimum
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(low idle)
3 seconds, apply maximum brake
or
pedal effort.
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Verify Ignition is in the OFF position.
Remove plug G1 and replace with
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Stabil-Trak Test Port Fitting (SAE-4 O-Ring Boss
75-150 psi
13 Valve G1 7/16-20 UNF 2B) and connect PRV (E) Park Brake - ON
t.c
(5,1-10,3 bar)
(low idle) pressure gauge. Start machine with
boom lowered, frame leveled left at
en
low idle.
m
Low idle with boom lowered, frame

ip
level left - 200 psi (13,7 bar)

qu
Stabil-Trak Maximum Pressure

200 psi (13,7 bar)
-E
14 Valve G1 No Adjustment NA Park Brake - ON

Maximum
(low idle) Pressure over
nt
200 psi (13,7 bar) indicates a

ou
Stabil-Trak Valve or cylinder failure

sc
Low idle with boom lowered, frame

Di
Stabil-Trak level right - 50 psi (3,4 bar)

50 psi (3,4 bar)
15 Valve G1 No Adjustment. Pressure under NA Park Brake - ON
Minimum
to
(low idle) 50 psi (3,4 bar) indicates a

Stabil-Trak Valve or cylinder failure
Go
8-12 31211388 6036, 6042, 8042, 10042, 10054,12054

Hydraulic Section

Block tire, connect gauge to D port.
Start engine and run at low idle,
raise boom above 40° (verify boom
angle sensor is OFF), place the
transmission in 4th gear Forward
Stabil-Trak and release the park brake.
Brake 200-300 psi
16 D A. With the service brake released - NA Park Brake - OFF
Switch (13,7-20,6 bar)
ts
the Stabil-Trak light must be OFF.
(low idle)
ar
B. Slowly apply the service brake -
rp
the Stabil-Trak light must be ON with
a service brake pressure of 200 - 300
ou
psi (13,7 - 20,6 bar) Adjust service
brake switch if required.
ry
de
or
to
om
t.c
en
m
ip
qu
-E
nt
ou
sc
Di
to
Go
6036, 6042, 8042, 10042, 10054,12054 31211388 8-13

Hydraulic Section
c. 6036 - 74 hp (55 kW)

MAIN CONTROL VALVE SECONDARY FUNCTION MANIFOLD
C
(LOAD SENSE RELIEF PRH2
VALVE)
PRH1
rts
pa
ur
yo
BVG
PBG (BRAKE VALVE
(PARK BRAKE GAUGE)
GAUGE)
r
de
MAE41270
or
PG
to
(MAIN PUMP
PRESSURE)
MAE41260
om
t.c
SERVICE BRAKE VALVE HYDRAULIC PUMP

en
m
X
PUMP LOAD
ip
SENSE PORT
qu
-E
nt
ou
sc
A
Di
E STANDBY
(AXLE BRAKE PRESSURE
PRESSURE) SCREW
to
B
MAE14330
PUMP MAX
Go
PRESSURE MAQ1540
SCREW 1
8-14 31211388 6036, 6042, 8042, 10042, 10054,12054

Hydraulic Section
Note: Install pressure gauge at test port PG on main control valve BEFORE Starting engine.

Park Brake - ON
ts
Load Connect gauge to X port. All
50-100 psi *Record Load
1 Sense X hydraulic functions and NA
ar
(3,4-6,8 bar) Sense Value for
(low idle) transmission in Neutral.
rp
use in Step 2
Connect gauge to PG port, run
ou
engine at low idle, no function.
ry
*Standby pressure should read
320-350 PSI (22,0-24,1 bar)
de
Standby higher than the Load Sense *400-430 psi
2 PG A Park Brake - ON
or
(low idle) pressure measured in Step 1. (27,5-29,6 bar)
Example - If 80 psi (5,5 bar) is
recorded in Step 1, the Standby
pressure should read 400-430 to
om
PSI (27,5-29,6 bar).
t.c

en
Load
m
NOTE: When bottoming Lift, Tilt,

Sense 3050-3100 psi
ip
3 PG Frame Level or Auxiliary at high LS (C) Park Brake - ON

Relief (210,2-213,7 bar)
idle, the pressure seen at the
qu
(high idle)
port PG should be within 100 psi
-E
(6,4 bar) of the noted extend/

nt
retract cylinder pressure.

ou
Connect gauge to PG port, run Park Brake - ON

4 PG engine at low idle, in front steer NA Front Steering
sc
(low idle) (179,1-193,0 bar)

Di
Temporarily increase the Load

to
Main Sense Relief pressure by turning

Only needed if
Pump High the adjustment screw (PRH1)
Go
3250 -3310 psi step 2, 3 & 4

5 Pressure PG two turns clockwise. Connect B
(224,1-228,2 bar) cannot be
Cutoff gauge to PG port, run engine at
achieved
(high idle) high idle, retract and stall
Secondary
Function
Manifold 550-560 psi
6 BVG engine at high idle, fully retract PRH2 Park Brake - ON
Brake)
(high idle)
6036, 6042, 8042, 10042, 10054,12054 31211388 8-15

Hydraulic Section

Manifold extend/retract cylinder. 0 psi
(Park Brake NOTE: Range/Pressure should (0 bar)
Secondary
ts
ar
8 PBG PRH1 Park Brake - OFF
(Park Brake extend/retract cylinder, switch (25,1-26,2 bar)
rp
Pressure) park brake OFF.
ou
(high idle)
ry
Block tire, connect gauge to E
Service
port. Start engine and run at
9 Brake E NA 0 psi (0 bar) Park Brake - OFF
de
idle. Do Not apply brake pedal
(Idle)
pressure.
or
Service Connect gauge to E port, run
to
650 psi (44,8 bar)
10 Brake E engine at idle, apply maximum NA Park Brake - OFF
Minimum
(Idle) brake pedal effort.
om
Connect gauge to E port. Verify

t.c

Service ground, Run engine at low idle,
en
80 psi (5,5 bar)

11 Brake E transmission in (N) Neutral, turn NA Park Brake - OFF
Minimum
m
(low idle) engine OFF, wait 3 seconds,

ip

qu
effort.
-E
nt
ou
sc
Di
to
Go
8-16 31211388 6036, 6042, 8042, 10042, 10054,12054

Hydraulic Section
d. 6042 - 74 hp (55 kW)

C
(LOAD SENSE RELIEF
PRH2
VALVE)
PRH1
ts
ar
rp
BVG
ou
PBG (BRAKE VALVE
(PARK BRAKE GAUGE)
ry
GAUGE)
MAE41280
de
or
PG STABIL-TRAK VALVE
(MAIN PUMP
PRESSURE)
MAE41260
to
om
HYDRAULIC PUMP
t.c
X
en
PUMP LOAD
SENSE PORT
m
ip
qu
-E
nt
ou
F
G1 PRV
A STABIL-TRAK
sc
STANDBY ADJUSTMENT
PRESSURE SCREW
PRESSURE
Di
SCREW
MAQ1530
B
to
PUMP MAX MAQ1540 SERVICE BRAKE VALVE

PRESSURE
SCREW 1
Go
E
(AXLE BRAKE
PRESSURE)
MAE14330
6036, 6042, 8042, 10042, 10054,12054 31211388 8-17

Hydraulic Section

Park Brake - ON
ts
Load Connect gauge to X port. All 50-100 psi *Record Load
ar
rp
use in Step 2
ou
ry
320-350 psi (22,0-24,1 bar)
de
or
om
psi (27,5-29,6 bar).
t.c

en
Load
m

Sense 3050-3100 psi
ip

Relief (210,2-213,7 bar)
qu
(high idle)
-E

nt

ou

sc
(low idle) (179,1-193,0 bar)

Di

to

Only needed if
Pump High the adjustment screw (C) two
Go
3250 -3310 psi step 2, 3 & 4

5 Pressure PG turns clockwise. Connect gauge B
Cutoff to PG port, run engine at high
achieved
(high idle) idle, retract and stall extend/
retract cylinder.
Secondary
Function
6 BVG engine at high idle, fully retract PRH2 Park Brake ON
Brake)
(high idle)
8-18 31211388 6036, 6042, 8042, 10042, 10054,12054

Hydraulic Section

Secondary
ts
ar
rp
ou
(high idle)
ry
Service
port. Start engine and run at
9 Brake E NA 0 psi (0 bar) Park Brake - OFF
de
idle. Do Not apply brake pedal
(Idle)
pressure.
or
Service Connect gauge to E port, run
to
650 psi (44,8 bar)
10 Brake E engine at idle, apply maximum NA Park Brake - OFF
Minimum
(Idle) brake pedal effort.
om

t.c

en
80 psi (5,5 bar)

Minimum
m

ip

qu
effort.
-E
Verify Ignition is in the OFF

position. Remove plug G1 and
nt
replace with Test Port Fitting

ou
Stabil-Trak
(SAE-4 O-Ring Boss 7/16-20 UNF 75-150 psi
12 Valve G1 PRV (F) Park Brake - ON
2B) and connect pressure gauge. (5,1-10,3 bar)
sc
(Idle)
Start machine with boom
Di
lowered, frame leveled left at

idle.
to
Idle with boom lowered, frame

Go

Maximum Pressure
Stabil-Trak 200 psi (13,7 bar)
No Adjustment
13 Valve G1 NA Park Brake - ON
Pressure over Maximum
(Idle)
Stabil-Trak Valve or cylinder
failure
6036, 6042, 8042, 10042, 10054,12054 31211388 8-19

Hydraulic Section

level right - 50 psi (3,4 bar)
No Adjustment. Pressure under
50 psi (3,4 bar) indicates a Minimum
(Idle)
failure
rts
port. Start engine and run at low
idle, raise boom above 40°
pa
(verify boom angle sensor is
OFF), place the transmission in
ur
4th gear Forward and release
yo
Stabil-Trak the park brake.
Brake A. With the service brake 200-300 psi
r
15 E NA Park Brake - OFF
de
Switch released - the Stabil-Trak light (13,7-20,6 bar)
(low idle) must be OFF.
or
B. Slowly apply the service brake
- the Stabil-Trak light must be
ON with a service brake pressure to
om
of 200 - 300 psi (13,7 - 20,6 bar)
Adjust service brake switch if
t.c
required.
en
m
ip
qu
-E
nt
ou
sc
Di
to
Go
8-20 31211388 6036, 6042, 8042, 10042, 10054,12054

Hydraulic Section
e. 8042, 10042, 10054

C
(LOAD SENSE RELIEF PRH2
VALVE)
PRH1
ts
ar
PBG
rp
(PARK BRAKE BVG
GAUGE) (BRAKE VALVE
ou
GAUGE)
ry
MAE41290
de
STABIL-TRAK VALVE
or
PG
to
(MAIN PUMP
PRESSURE) MAE41260
om
HYDRAULIC PUMP
t.c
en
X
PUMP LOAD
m
SENSE PORT
ip
qu
F
-E
G1 PRV
ADJUSTMENT
nt
STABIL-TRAK
PRESSURE SCREW
ou
MAQ1530
sc
A
STANDBY
Di
PRESSURE
SCREW SERVICE BRAKE VALVE
B
to
PUMP MAX
PRESSURE MAQ1540
Go
SCREW 1
E
(AXLE BRAKE
PRESSURE)
MAE14330
6036, 6042, 8042, 10042, 10054,12054 31211388 8-21

Hydraulic Section

ts
Park Brake - ON
ar
rp
use in Step 2
ou
ry
de
320-350 psi (22,0-24,1 bar)
or
to
om
pressure should read 400-430
psi (27,5-29,6 bar).
t.c

en

m
Load
ip
Sense 3050-3100 psi

Relief (210,2-213,7 bar)
qu

(high idle)
-E

nt

ou

sc

(low idle) (179,1-193,0 bar)
Di

to

Only needed if
Go

3250 -3310 psi step 2, 3 & 4
achieved
retract cylinder.
Secondary
Function
6 BVG engine at high idle, fully retract PRH2 Park Brake ON
Brake)
(high idle)
8-22 31211388 6036, 6042, 8042, 10042, 10054,12054

Hydraulic Section

Secondary
engine at idle, fully retract the
Function
extend/retract cylinder, switch
Manifold 0 psi
7 PBG park brake switch ON. NA Park Brake - ON
Park Brake (0 bar)
NOTE: Range/Pressure should
Pressure
repeat in all machine conditions
(Idle)
with park brake ON.
ts
Secondary
ar
Manifold engine at idle, fully retract 365-380 psi
rp
ou
(Idle)
ry
de
Service port. Start engine and run at idle
9 Brake E and transmission in (N) neutral. NA 0 psi (0 bar) Park Brake - OFF
or
(Idle) Do Not apply brake pedal
to
pressure.
Connect gauge to E port, run
om
Service
engine at idle and transmission 650 psi (44,8 bar)
10 Brake E NA Park Brake - OFF
t.c
in (N) Neutral, apply maximum Minimum

(Idle)
brake pedal pressure.
en

m

ip

80 psi (5,5 bar)
qu
11 Brake E transmission in (N) Neutral, N/A Park Brake - OFF

Minimum
(low idle) release Park Brake, turn engine
-E
OFF, wait 3 seconds, apply

nt
maximum brake pedal pressure.

ou

sc
Stabil-Trak replace with Test Port Fitting

Di
75-150 psi
12 Valve G1 (SAE-4 O-Ring Boss 7/16-20 UNF PRV (F) Park Brake - ON
(5,1-10,3 bar)
(Idle) 2B) and connect pressure gauge.
to

Go
lowered at idle.
Engine at idle with boom
lowered, frame level left - 200
psi (13,7 bar) Maximum Pressure
Stabil-Trak
No Adjustment 200 psi (13,7 bar)
(Idle)
failure
6036, 6042, 8042, 10042, 10054,12054 31211388 8-23

Hydraulic Section

Engine at idle with boom
lowered, frame level right - 50
Stabil-Trak psi (3,4 bar)
50 psi (3,4 bar)
14 Valve G1 No Adjustment. Pressure under NA Park Brake - ON
Minimum
(Idle) 50 psi (3,4 bar) indicates a
failure
ts
ar
rp
ou
ry
de
or
- the Stabil-Trak light must be to
om
ON with a service brake pressure
of 200 - 300 psi (13,7 - 20,6 bar)
t.c

en
required.
m
ip
qu
-E
nt
ou
sc
Di
to
Go
8-24 31211388 6036, 6042, 8042, 10042, 10054,12054

Hydraulic Section
f. 12054

C PRH2
(LOAD SENSE
RELIEF VALVE)
PRH1
ts
ar
rp
PBG BVG
ou
(PARK BRAKE (BRAKE VALVE
GAUGE) GAUGE)
ry
MAE41580
de
STABIL-TRAK VALVE
or
PG
(MAIN PUMP
PRESSURE)
MAE41260
to
om
HYDRAULIC PUMP
t.c
X
PUMP LOAD
F
en
SENSE PORT
PRV
ADJUSTMENT
m
SCREW
ip
qu
-E
nt
G1
ou
STABIL-TRAK
A PRESSURE
MAE41920
sc
STANDBY
PRESSURE
Di
SCREW SERVICE BRAKE VALVE
B
to
PUMP MAX MAQ1540

PRESSURE
Go
SCREW 1
E
(AXLE BRAKE
PRESSURE)
MAE14330
6036, 6042, 8042, 10042, 10054,12054 31211388 8-25

Hydraulic Section

Park Brake - ON
ts
ar
rp
use in Step 2
ou
ry
319-349 psi (21,9-24,0 bar)
de
or
om
psi (27,5-29,6 bar).
t.c

en
m
Load NOTE: When bottoming Lift, Tilt,

3050-3100 psi
ip
3 Sense PG Frame Level or Auxiliary at high LS (C) Park Brake - ON

(210,3-213,7 bar)
(high idle) idle, the pressure seen at the
qu

-E

nt

ou

sc
(low idle) (179,1-193,0 bar)

Di

to

Only needed if
Go
3250 -3300 psi step 2, 3 & 4

achieved
retract cylinder.
Secondary
Function
6 BVG engine at idle, fully retract PRH2 Park Brake ON
Brake)
(Idle)
8-26 31211388 6036, 6042, 8042, 10042, 10054,12054

Hydraulic Section

Function engine at idle, fully retract
Secondary
rts
Manifold engine at idle, fully retract 365-380 psi
pa
ur
(high idle)
yo
Service port. Start engine and run at idle
r
de
9 Brake E and transmission in (N) Neutral. NA 0 psi (0 bar) Park Brake - OFF
(Idle) Do Not apply brake pedal
or
pressure.
Service
Connect gauge to E port, Start
engine and run at idle and
to
om
650 psi (44,8 bar)
10 Brake E transmission in (N) Neutral, NA Park Brake - OFF
Minimum
t.c
(Idle) apply maximum brake pedal

effort.
en

m

ip

80 psi (5,5 bar)
qu

Minimum
-E

nt
effort.
ou

sc
replace with Test Port Fitting

Di
Stabil-Trak
(SAE-4 O-Ring Boss 7/16-20 UNF 75-150 psi
12 Valve G1 PRV (F) Park Brake - ON
2B) and connect pressure gauge. (5,1-10,3 bar)
to
(Idle)
Go
lowered, frame leveled left at

idle.
Maximum Pressure
No Adjustment
(Idle)
failure
6036, 6042, 8042, 10042, 10054,12054 31211388 8-27

Hydraulic Section

level right - 50 psi (3,4 bar)
No Adjustment. Pressure under
50 psi (3,4 bar) indicates a Minimum
(Idle)
failure
ts
ar
rp
ou
ry
de
or
- the Stabil-Trak light must be
ON with a service brake pressure to
om
of 200 - 300 psi (13,7 - 20,6 bar)
t.c
required.
en
m
ip
qu
-E
nt
ou
sc
Di
to
Go
8-28 31211388 6036, 6042, 8042, 10042, 10054,12054

8.5.3
8 7 6 5 4 3 2 1
Slave Cylinders
ø 3.54 Base x ø 1.77 Rod x 4.34 Stroke Hoist Cylinders ø 3.75 Base x ø 1.5 Rod x 11.40 Stroke
ø 4.72 Base x ø 3.35 Rod x 39.65 Stroke
Steering Valve, Front

Pilot Ratio : 8:1
H Displacement- 400 CC/Rev Setting : 2610 psi
H
Frame Tilt Cylinder
Extend Cylinder ø4.5 Base x ø 2.25 Rod x 8.69 Stroke
3335 psi 3335 psi
ø 4.5 Base x ø 3 Rod x 102.5 Stroke
Go
Crab 4 Wheel Pilot Ratio : 3:1
Steer Steer Pilot Ratio : 4:1 Setting : 3500 psi
Setting : 4000 psi
Pilot Ratio : 4:1

Pilot Ratio : 8:1
Setting : 3500 psi
Setting : 2610 psi
to
Rear
ø 0.047
Fork Tilt Cylinder
ø 5 Base x ø 2 Rod x 16.75 Stroke
2465 psi Pilot Ratio : 4:1
Setting : 3500 psi
Pilot Ratio : 4:1
6036, 6042, 8042, 10042, 10054,12054

G Setting : 4000 psi G
Pilot Ratio : 4:1
Di
T LS P Setting : 4000 psi
a. 6036 - 85 hp (63 kW) Engine
ø 0.040
sc
Hydraulic Schematics
ou
Aux. Function
Quick Disconnect
At Boom Gooseneck
nt
F F
5 psi
M LS D b1 B1 A1 b2 B2 A2 B3 A3 B4 A4 B5 A5
-E
DLS
P2
qu
P
ip
280 psi
E E
m
Hoist Extend Aux. Frame Tilt Fork Tilt
Steering Priority
en
2715 psi
3625 psi 3625 psi 3625 psi 3625 psi

HOC Bypass
31211388
65 psi
t.c
T
D D
A1 A2 Pr TPr
om
5 psi
Front Wheel
to
Brake
2 3 4
Cooler 1
P N L R1 B
C C
P T B1
Filter Bypass
or
25 psi
Joystick
Engine ENG
PBG PB JS BV BVG Rear Wheel
VALVE, BRAKE ASSEMBLY Brake
de
. Gear Pump : 3.45 in³/rev 10 µ 5 psi 365 psi 550 psi
. 330 psi, Stand by CP
. Low idle 1000 rpm, 14.9 gpm Return Line Filter

High Idle 2675 rpm, 39.9 gpm
Rated 2500 rpm, 37.3 gpm T P
ry
Secondary Function
Manifold_Dana axle
B configuration B
ou
rp
ar
A A
ts
1001205802-E
8 7 6 5 4 3 2 1
MAE41080E
Hydraulic Section
8-29
8-30
8 7 6 5 4 3 2 1
Slave Cylinders
ø 3.54 Base x ø 1.77 Rod x 4.34 Stroke Hoist Cylinders

ø 4.72 Bore x ø 3.35 Rod x 39.65 Stroke
Front
Steering Valve,
H Displacement- 400 CC/Rev H
Extend Cylinder Frame Tilt Cylinder
3335 psi ø 4.5 Base x ø 3 Rod x 102.5 Stroke ø4.5 Base x ø 2.25 Rod x 8.69 Stroke
Setting : 2610 psi
Pilot Ratio : 3:1
Crab 4 Wheel Setting : 3500 psi
Steer Steer Pilot Ratio : 4:1
Setting : 4000 psi
Pilot Ratio : 4:1

Setting : 3500 psi
Rear
Go
Pilot Ratio : 8:1
Setting : 2610 psi

Setting : 3500 psi Fork Tilt Cylinder
to
G Pilot Ratio : 4:1 ø 5 Base x ø 2 Rod x 16.75 Stroke G
Hydraulic Section
Setting : 4000 psi

T LS P Pilot Ratio : 4:1
Setting : 4000 psi
b. 6036 - 74 hp (55 kW) Engine
Di
sc
Aux. Function
Quick Disconnect
At Boom Gooseneck
1A 1B
ou
F 1b 2b 2A 2B 3A 3B 4A 4B 5A 5B F
HOC Bypass
T2 3480 psi 3480 psi
nt
LS 3625 psi 3625 psi T1 65 psi
-E
2712 psi
S
qu
E E
SLS
ip
PG
m
P2
P1
31211388
en
SS
D STEERING PRIOTITY
EXTEND
D
AUX. FORK TILT
FRAME TILT
HOIST
t.c
PS
1a 2a
X
om
. Piston Pump : 3.85 in³/rev
. Low idle : 1000 rpm, 16.6 gpm
2 3 4
High Idle : 2675 rpm, 44.5 gpm 1
Rated : 2500 rpm, 41.6 gpm Front Wheel
Brake
Cooler
to
C B C
5 psi
P T
Joystick
Filter Bypass PB JS BV BVG P N L R1 B
PBG
25 psi
ENG
B1
or
5 psi 365 psi 550 psi Rear Wheel
10 μ CP
Brake
S L2 L1 L
Return Line Filter VALVE, BRAKE ASSEMBLY
de
Secondary Function T P
r
Manifold_Dana axle
B conguration
B
yo
. Pump Cut-off Pressure : 3280 psi
. Standby Pressure : 400 psi
ur
A A
pa
rts
1001205807-F
8 7 6 5 4 3 2 1
MAE41090F
6036, 6042, 8042, 10042, 10054,12054

8 7 6 5 4 3 2 1
c.
Slave Cylinders

ø 4.92 Bore x ø 3.15 Rod x 44.36 Stroke V FTR G3 G2
Front
H Steering Valve, H
Displacement- 400 CC/Rev
3335 psi 3335 psi

Stabilizer Cylinder
Go
Extend Cylinder ø 0.03 ø 4.50 Base x ø 2.25 Rod x 8.69 Stroke
Crab 4 Wheel ø 4.5 Base x ø 3 Rod x 131.25 Stroke
Setting : 4000 psi Pilot Ratio : 4:1
Setting : 4000 psi
Frame Tilt Cylinder

to
Rear
ø4.5 Base x ø 2.25 Rod x 8.69 Stroke Fork Tilt Cylinder
200 psi ø 5 Base x ø 2 Rod x 16.75 Stroke
ø 0.06 ø 0.06 Pilot Ratio : 4:1
Setting : 4000 psi
2465 psi 100 psi
G G
6036, 6042, 8042, 10042, 10054,12054

ø 0.040
Pilot Ratio : 4:1
Setting : 4000 psi
Di
T LS P T P G1
6042 - 85 hp (63 kW) Engine
sc
ø 0.047
ou
Aux. Function
nt
F F
Quick Disconnect
5 psi
At Boom Gooseneck
M LS D b1 B1 A1 b2 B2 A2 B3 A3 B4 A4 B5 A5
-E
qu
DLS
P2
ip
P
280 psi
E
m E
Hoist Extend Aux. Frame Tilt Fork Tilt

Steering Priority
en
2715 psi
31211388
t.c
3625 psi 3625 psi 3625 psi 3625 psi
HOC Bypass
D T D
65 psi
om
A1 A2 Pr TPr
to
Front Wheel
Brake
5 psi
2 3 4
1
C Cooler C
or
P N L R1 B
Filter Bypass P T
25 psi Joystick
de
Rear Wheel
PBG PB JS BV BVG Brake
B1
Engine
r
5 psi 365 psi 550 psi
ENG 10 μ
CP VALVE, BRAKE ASSEMBLY
Return Line Filter
yo
T P
Secondary Function Manifold_Dana axle

B B
. Gear Pump : 3.45 in³/rev conguration
. 330 psi, Stand by
. Low idle 1000 rpm, 14.9 gpm
ur
High Idle 2675 rpm, 39.9 gpm
Rated 2500 rpm, 37.3 gpm
pa
rts
A A
1001205803-E
Hydraulic Section
8 7 6 5 4 3 2 1
MAE41100E
8-31
8-32
8 7 6 5 4 3 2 1
Slave Cylinders

ø 4.92 Bore x ø 3.15 Rod x 44.36 Stroke V FTR G3 G2
Front
H Steering Valve, H
Displacement- 400 CC/Rev Pilot Ratio : 8:1
Setting : 2610 psi
3335 psi 3335 psi
Stabilizer Cylinder
Extend Cylinder ø 0.03 ø 4.50 Base x ø 2.25 Rod x 8.69 Stroke
Crab 4 Wheel ø 4.5 Base x ø 3 Rod x 131.25 Stroke
Setting : 4000 psi Pilot Ratio : 4:1
Setting : 4000 psi
Frame Tilt Cylinder Pilot Ratio : 8:1

Go
Rear
ø4.5 Base x ø 2.25 Rod x 8.69 Stroke Setting : 2610 psi
200 psi
ø 0.06 ø 0.06
Fork Tilt Cylinder
2465 psi 100 psi
Pilot Ratio : 4:1
to
G Setting : 4000 psi
G
Pilot Ratio : 4:1
Hydraulic Section
Setting : 4000 psi

T LS P T P G1
d. 6042 - 74 hp (55 kW) Engine
Di
sc
Aux. Function
F Quick Disconnect
F
ou
1b 1A 1B 2b 2A 2B 3A 3B At Boom Gooseneck 4A 4B 5A 5B
T2 3480 psi 3480 psi

HOC Bypass
nt
LS 3625 psi 3625 psi
T1
-E
2712 psi 65 psi
S
qu
E E
SLS
ip
PG
m
P1 P2
31211388
en
SS
D D
STEERING PRIOTITY
EXTEND AUX.
FRAME TILT FORK TILT
HOIST
t.c
PS
1a 2a
X
om
2 3 4
. Low idle : 1000 rpm, 16.6 gpm 1
High Idle : 2675 rpm, 44.5 gpm Front Wheel
Cooler
Rated : 2500 rpm, 41.6 gpm Brake
P T
C B C
to
Filter Bypass
PBG PB JS BV BVG 5 psi
25 psi
ENGINE Joystick P N L R1 B
ENG Rear Wheel

B1 Brake
or
10 μ CP
Return Line Filter
S L2 L1 L VALVE, BRAKE ASSEMBLY

de
T P
Secondary Function
B Manifold_Dana axle
B
. Standby Pressure : 400 psi conguration
ry
ou
rp
A A
ar
1001205810-F
ts
8 7 6 5 4 3 2 1
MAE41110F
6036, 6042, 8042, 10042, 10054,12054

8 7 6 5 4 3 2 1
e. 8042
Slave Cylinders
ø 4.25 Base x ø 1.75 Rod x
Hoist Cylinders 13.75 Stroke
ø 5.7 Base x ø 3.5 Rod x 42.41 Stroke V FTR G3 G2
Front
Pilot Ratio : 8:1
Steering Valve, Setting : 2610 psi
H Displacement- 400 CC/Rev Extend Cylinder H
3335 psi 3335 psi Stabilizer Cylinder
ø 0.03 ø 4.50 Base x ø 2.25 Rod x 8.69 Stroke
Go
Crab 4 Wheel
Setting : 3500 psi
Frame Tilt Cylinder
Pilot Ratio : 3:1 ø4.5 Base x ø 2.25 Rod x 8.69 Stroke Pilot Ratio : 8:1
Setting : 3500 psi Setting : 2610 psi
Rear
to
200 psi Fork Tilt Cylinder
0.06 in 0.06 in
ø 6 Base x ø 2.5 Rod x 16.75 Stroke
Pilot Ratio : 4:1
100 psi Setting : 3000 psi
2465 psi
Pilot Ratio : 3:1
6036, 6042, 8042, 10042, 10054,12054

G Setting : 3500 psi
G
T P G1
Di
T LS P
sc
Aux. Function
ou
Quick Disconnect
nt
F HOC Bypass F
T2 3480 psi 3480 psi
LS 3625 psi 3625 psi T1
65 psi
-E
2712 psi
S
qu
ip
SLS m
E E
PG
P1 P2
en
SS
STEERING PRIOTITY
31211388
EXTEND AUX. FORK TILT
t.c
FRAME TILT
HOIST
D PS D
1a 2a
om
to
Front Wheel
Brake
2 3 4
1
C 5 psi C
or
P T
Joystick P N L R1 B
PB
Rear Wheel
PBG JS BV BVG
Brake
de
B1
X Cooler
r
. Low idle : 1000 rpm, 16.6 gpm 5 psi 365 psi 550 psi
High Idle : 2675 rpm, 44.5 gpm VALVE, BRAKE ASSEMBLY
Rated : 2500 rpm, 41.6 gpm CP
yo
Filter Bypass
25 psi T P
B B
B
Secondary Function
Manifold_Dana axle conguration
ur
Engine 10 μ
Return Line Filter

ENG
pa
S L2 L1 L
A . Pump Cut-off Pressure : 3280 psi A

rts
1001224166-D
Hydraulic Section
8 7 6 5 4 3 2 1
MAE41120D
8-33
f.
8-34
8 7 6 5 4 3 2 1
10042
Slave Cylinders
ø 3.93 Base x ø 1.97 Rod x 4.56 Stroke 13.75 Stroke
Hoist Cylinders V FTR G3 G2
Front ø 6 Base x ø 3 Rod x 42.41 Stroke
Steering Valve,
Pilot Ratio : 8:1
H Displacement- 400 CC/Rev Extend Cylinder Setting : 2610 psi H
3335 psi 3335 psi
Stabilizer Cylinder
Crab 4 Wheel ø 0.03 ø 4.50 Base x ø 2.25 Rod x 8.69 Stroke
Steer Steer
Pilot Ratio : 3:1
Setting : 3500 psi Frame Tilt Cylinder
ø4.5 Base x ø 2.25 Rod x 8.69 Stroke
Pilot Ratio : 3:1
Rear Setting : 3500 psi Pilot Ratio : 8:1
Setting : 2610 psi
Go
200 psi
ø 0.06 ø 0.06
Fork Tilt Cylinder
2465 psi 100 psi
Pilot Ratio : 4:1
Setting : 3000 psi
G Pilot Ratio : 3:1 G
to
P Setting : 3500 psi T P G1
T LS
Hydraulic Section
Di
Aux. Function
Quick Disconnect
sc
F T2 3480 psi 3480 psi
HOC Bypass F
ou
LS 3625 psi 3625 psi T1
65 psi
2712 psi
nt
S
-E
SLS
qu
E E
PG
P2
P1
ip
P
ø 0.156"
m
T
SS
STEERING PRIOTITY
EXTEND AUX.
FRAME TILT FORK TILT
31211388
HOIST
en
ø 0.156"
0.071 in LS
PS
D D
B1 A1 B2 A2 1a 2a
B1 A1 B2 A2
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om
Front Wheel
Pilot Ratio : 4:1
Pilot Ratio : 4:1

Brake
Setting : 1000 psi
Setting : 1000 psi

Left Side Right Side 2 3 4
1
Outrigger Cylinders 5 psi
C ø 5 Base x ø 3 Rod x 13.31 Stroke C
to
P T P N L R1 B
Joystick
Cooler Rear Wheel
PBG PB JS BV BVG Brake
B1
or
X
. Piston Pump : 3.85 in³/rev 5 psi 365 psi 550 psi VALVE, BRAKE ASSEMBLY
High Idle : 2675 rpm, 44.5 gpm CP
de
Rated : 2500 rpm, 41.6 gpm
Filter Bypass
25 psi
B T P B
B
Secondary Function
ry
Manifold_Dana axle
configuration
Engine 10 μ
Return Line Filter

ENG
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S L2 L1 L
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A . Standby Pressure : 400 psi A
ar
1001224167-E
ts
8 7 6 5 4 3 2 1
MAE41130E
6036, 6042, 8042, 10042, 10054,12054

8 7 6 5 4 3 2 1
g. 10054
ø 3.93 Base x ø 1.97 Rod x 4.56 Stroke Hoist Cylinders FTR G3 G2 Slave Cylinders
V
ø 6 Base x ø 3.5 Rod x 42.41 Stroke ø 4.25 Base x ø 1.75 Rod x
13.75 Stroke
Front
Steering Valve,
H Displacement- 400 CC/Rev Extend Cylinder H
ø 0.03 ø 4.50 Base x ø 2.25 Rod x 8.69 Stroke
Go
Crab 4 Wheel
Pilot Ratio : 3:1
Steer Steer Setting : 3500 psi
Pilot Ratio : 3:1

Rear ø4.5 Base x ø 2.25 Rod x 8.69 Stroke
to
ø 0.06 ø 0.06 ø 6 Base x ø 2.5 Rod x 16.75 Stroke

2465 psi
Setting : 3000 psi
Pilot Ratio : 3:1
6036, 6042, 8042, 10042, 10054,12054

G G
Setting : 3500 psi T P G1
P
Di
T LS
sc
ou
Aux. Function
Quick Disconnect
nt
F F
T2 3480 psi 3480 psi
HOC Bypass
LS 3625 psi 3625 psi T1
-E
2712 psi
65 psi
S
qu
ip
SLS
E E
m
PG
P2
P1
ø 0.156"
en
T
SS
STEERING PRIOTITY
31211388
EXTEND AUX. FORK TILT
t.c
FRAME TILT
HOIST
ø 0.156"
0.071" LS
D PS D
B1 A1 B2 A2
1a 2a
om
B1 A1 B2 A2
Front Wheel
to
Pilot Ratio : 4:1
Pilot Ratio : 4:1

Setting : 1000 psi
Setting : 1000 psi

Brake
2 3 4
Left Side Right Side 1

C ø 5 Base x ø 3 Rod x 13.31 Stroke C
or
P T P N L R1 B
Joystick
PBG PB JS BV BVG Rear Wheel

B1 Brake
de
X
Cooler
High Idle : 2675 rpm, 44.5 gpm 5 psi 365 psi 550 psi VALVE, BRAKE ASSEMBLY
Rated : 2500 rpm, 41.6 gpm
CP
ry
Filter Bypass
25 psi
B T P
B B
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Secondary Function
Manifold_Dana axle
Engine configuration
10 μ
ENG Return Line Filter
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S L2 L1 L
ar
A . Pump Cut-off Pressure : 3280 psi A
ts
1001224168-E
8 7 6 5 4 3 2 1
Hydraulic Section
MAE41140E
8-35
8-36
8 7 6 5 4 3 2 1

V FTR G3 G2 Comp Cylinders
h. 12054
13.78 Stroke
Front
Steering Valve,
Displacement- 400 CC/Rev Extend Cylinder Pilot Ratio: 9:1
H Setting: 2610 psi
H
ø 0.03 ø 5 Base x ø 3 Rod x 8.69 Stroke
Crab 4 Wheel
Pilot Ratio : 3:1
Steer Steer Setting : 3500 psi
Pilot Ratio: 9:1

Pilot Ratio : 3:1
Setting: 2610 psi
Rear ø 5 Base x ø 3 Rod x 8.69 Stroke
Go
ø 0.06 ø 0.06 ø 6.69 Base x ø 2.76 Rod x 16.75
Stroke
2465 psi
Setting : 3000 psi
G Pilot Ratio : 3:1 G

to
Setting : 3500 psi T P G1
Hydraulic Section
T LS P Di
sc
Aux. Function
Quick Disconnect
F At Boom Gooseneck F
ou
1b 1A 1B 2b 2A 2B 3A 3B 4A 4B 5A 5B
3480 psi 3480 psi
HOC Bypass
T2
3625 psi 3625 psi T1
LS
nt
2712 psi
-E
qu S
E E
SLS 65 psi
ip
PG
P P2
m
T1
P1
SS
31211388
T2
en
2 mm LS STEERING PRIOTITY
D EXTEND AUX. D
B1 A1 B2 A2 FRAME TILT FORK TILT
HOIST
B1 A1 B2 A2 PS
t.c
1a 2a
Boom Lock Out Valve
om
Front Wheel
Pilot Ratio : 4:1
Pilot Ratio : 4:1

Setting : 1000 psi
Setting : 1000 psi

Brake
Left Side Right Side

C ø 5.75 Base x ø 3.50 Rod x 13.31 Stroke C
2 3 4
to
1
P N L R1 B
PBG PB JS BV BVG
Rear Wheel
P T B1 Brake
Joystick
X Cooler
or
High Idle : 2675 rpm, 44.5 gpm VALVE, BRAKE ASSEMBLY
Rated : 2500 rpm, 41.6 gpm CP
de
Filter Bypass
25 psi
B B T P
Secondary Function
r B
Manifold_Dana axle
Configuration
Engine
10 μ
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E NG Return Line Filter
S L2 L1 L
ur
A . Nominal Pump Cut-off Pressure : 3280 psi A
. Nominal Standby Pressure : 410 psi
pa
. Nominal Pump Margin : 320 psi
1001245786-B
rts
8 7 6 5 4 3 2 1
MAE41150B
6036, 6042, 8042, 10042, 10054,12054

Hydraulic Section
8.6 HYDRAULIC RESERVOIR 8. Wipe up any hydraulic fluid spillage in, on, near and
around the machine and the work area.
3
2 8.6.2 Hydraulic Oil Reservoir Filling
1. Be sure the reservoir is clean and free of all debris.
2. Install a new hydraulic oil filter. Refer to Section 8.6.3,
“Hydraulic Filter Replacement”.
3. Fill the hydraulic reservoir. Refer to Section 2.3, “Fluid &
1 Lubricant Capacities”.
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4 MAQ1340 “Battery”, for procedure.
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Hydraulic oil reservoir (1) and fuel tank are one unit located 5. Remove Do Not Operate Tag on both ignition key
ur
on the right side of the frame. The hydraulic fluid filler/ switch and steering wheel.
breather and filter are accessed under filter access cover (2).
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Occasionally, fluid may seep, leak or be more forcefully
r
expelled from the filler/breather cap (3) when system 8.6.3 Hydraulic Filter Replacement
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pressure exceeds the rating of the breather. If the return filter 1. Be sure the hydraulic oil reservoir is clean and free of all
or
becomes plugged, return hydraulic oil will bypass the filter debris.
when pressure reaches 25 psi (1,7 bar) and return to the
reservoir unfiltered.
to 5
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Carefully examine fluid seepage or leaks from the hydraulic
reservoir to determine the exact cause. Clean the reservoir 6
t.c
and note where any seepage occurs. 8

7
en
Leaks from a cracked or damaged reservoir require that the 9

reservoir be removed from the machine, flushed completely
m
with water and repaired by a certified welder using approved

ip
techniques. If these conditions cannot be met, the reservoir

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must be replaced in its entirety.

-E
8.6.1 Hydraulic Oil Reservoir Draining

nt

ou

sc

Di

to
and steering wheel. MAQ1330
3. Open the engine cover. Allow the system fluids to cool. 2. Loosen and remove the six nuts (5) securing the filter
Go
cover (6) to the hydraulic reservoir.

“Battery”, for procedure. 3. Remove the filter (7) and spring (8) from the hydraulic
reservoir allowing any excess hydraulic oil to drain into
5. Remove filter access cover (2).
the reservoir.
6. Remove the filler/breather cap (3) on the hydraulic oil
4. Replace the hydraulic filter head gasket (9) if necessary.
reservoir (1). Remove the drain plug (4) on the bottom
of the hydraulic oil reservoir. 5. Install the new hydraulic filter and spring. Lower the
hydraulic filter assembly into the hydraulic reservoir.
7. Transfer the used hydraulic oil into a suitable covered
container, and label as “Used Oil”. Dispose of used oil at 6. Install the six previously removed nuts securing the
an approved recycling facility. Clean and reinstall the hydraulic filter cover to the hydraulic reservoir. Torque
drain plug (4). the nuts to 75 lb-in (8.5 Nm).
7. Install the previously removed access cover (2).
6036, 6042, 8042, 10042, 10054,12054 31211388 8-37

Hydraulic Section
8. Wipe up any hydraulic fluid spillage in, on, near and 10. Remove the o-ring (4) located between the
around the machine and the work area. transmission and the pump. Wipe up any hydraulic oil
spillage.
8.6.4 Hydraulic Oil Reservoir Replacement 11. Remove the hydraulic fittings from the pump to use for
The hydraulic reservoir and the fuel tank are one unit and are later installation.
removed together. Refer to Section 7.6.2, “Fuel/Hydraulic Oil Note: Before removing any fittings from the pump, note their
Tank”, for information on hydraulic reservoir/fuel tank orientation to ensure correct installation.
replacement.
Note: DO NOT disassemble the operating pump. The pump is
8.7 HYDRAULIC SYSTEM PUMP pre-set from the manufacturer. Any adjustments or repairs
ts
performed by anyone other than an authorized dealer could
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For internal service instructions contact your local void the warranty.
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authorized service distributor.
b. Pump Installation
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8.7.1 Pump Replacement 1. Install the fittings on the pump in the same orientation
as noted during removal.
ry
a. Pump Removal
2. Place the pump and a new, oiled o-ring into position on
de
1. Park the machine on a firm, level surface, level the the transmission. Align the pump shaft with the internal
or
machine, fully retract the boom, raise the boom, place transmission gear, so that the machined teeth mesh
the transmission in (N) NEUTRAL, engage the park brake together.
to
3. Align the bolt holes with the pump mount holes. Secure
om
the pump to the transmission with the previously used
and steering wheel. hardware.
t.c
3. Properly support the boom. 4. Uncap and connect the previously labeled hydraulic hoses
4. Open the engine cover. Allow the system fluids to cool. to their appropriate locations.
en
5. Properly disconnect the battery. Refer Section 9.8, 5. Fill the hydraulic reservoir. Refer to Section 8.6.2,
m
“Battery”, for procedure. “Hydraulic Oil Reservoir Filling”.

ip
6. Drain the hydraulic reservoir. Refer to Section 8.6.1, 6. Prime the pump by filling the case drain port with fresh,
qu
“Hydraulic Oil Reservoir Draining”. filtered hydraulic oil from a clean container before
-E
installing the case drain connector and hose.

3
nt
1 4 7. Check all routing of hoses and tubing for sharp bends or

2 interference with any rotating members. All tube and
ou
hose clamps must be tight.

sc

Di

to
9. Remove boom support.

10. Remove Do Not Operate Tag on both ignition key
Go

12. Start engine and run at approximately one-third to one-
half throttle for about one minute without moving the
MAQ1350
machine or operating any hydraulic functions.
7. Thoroughly clean the pump (1) and surrounding area.
13. Inspect for leaks and check all fluid levels. The hydraulic
8. Label, disconnect and cap the hydraulic hoses attached reservoir oil level must be to the middle of the sight
to the pump. gauge.
9. Remove the bolts (2), lockwashers and washers
securing the pump to the transmission (3).
8-38 31211388 6036, 6042, 8042, 10042, 10054,12054

Hydraulic Section
c. Pump Test 6036, 6042 - 85 hp (63 kW)

1. Refer to Section 8.5.1, “Pressure Checks and
Adjustments”.
8.8 VALVES AND MANIFOLDS
8.8.1 Main Control Valve

The main control valve is mounted on the frame under the
lower transmission cover.
ts
The main control valve assembly consists of individual
ar
working sections with their own valve assemblies, each
rp
providing a specific hydraulic function.
2
3
ou
MAQ1390
a. Main Control Valve Removal
ry
machine, fully retract the boom, raise the boom, place 6036 (74hp), 6042 (74hp), 8042, 10042, 10054, 12054
de
or
and steering wheel. to
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3. Temporarily block up or support the raised boom.
t.c
5. With the engine OFF, operate all the hydraulic functions

en
to relieve trapped pressure.

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6. Remove the transmission covers. Thoroughly clean the

ip
main control valve and surrounding area, including all

qu
hoses and fittings, before proceeding. 2 3

7. Place a suitable container to collect hydraulic fluid
-E
drainage beneath the frame. MAE41370

nt
6036 & 6042

1 Note: Record the location, and label all cables to ensure correct
ou
FRAME SHOWN
(High HP control valve) installation.
sc
10. Disconnect the control cables:

Di
a. Remove the clip and anchor pin (2). Retain the clip
and anchor pin for installation.
to
b. Loosen and remove the two bolts (3), and remove

Go
the control cable mount or bracket/control cable.

c. Route the cable clear of the main control valve.
d. Repeat steps for the remaining control cables.
11. Remove the bolts and nuts securing the main control
MAQ1380 valve to the frame.
12. Remove the main control valve from the frame.
8. Label, disconnect and cap all the hydraulic hoses, tubes
and wires at the main control valve (1).
9. Wipe up any hydraulic fluid spillage in, on, near and
around the machine and the work area.
6036, 6042, 8042, 10042, 10054,12054 31211388 8-39

Hydraulic Section
b. Main Control Valve Disassembly 4. Remove both end caps from each end of the valve
sections then remove each control spool.
6036, 6042 - 85 hp (63 kW)
5. Remove any check valves, compensator valves,
anti-cavitation valves or shock valves from individual
valve section if equipped.
6. Keep all parts being removed from individual valve
sections tagged and kept together.
c. Main Control Valve Parts Cleaning

4
Clean all components with a suitable cleaner, such as
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triclorethylene, before continuing. Blow dry.
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d. Main Control Valve Parts Inspection
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Inspect all parts and internal passageways for wear, damage,
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etc. If inner surfaces of any component DO NOT display an
MAQ1880
4 ultra-smooth, polished finish, or are damaged in any way,
r
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replace the damaged part. Often, dirty hydraulic fluid causes
6036 (74hp), 6042 (74hp), 8042, 10042, 10054, 12054 failure of internal seals, damage to the polished surfaces
or
within the component, and wear of and/or harm to other
parts.
to
om
e. Main Control Valve Assembly
Note: ALWAYS replace seals, o-rings, gaskets, etc., with new
t.c
parts to help ensure proper sealing and operation. Lubricate

en
seals and o-rings with clean hydraulic oil.

m
Assemble each Valve Section

ip
4
1. Reassemble any check valves, compensator valves, anti-
qu
cavitation valves or shock valves from each individual

-E
valve sections if equipped.

nt
MAE41380
2. Install the control spool being careful not to nick or
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4 scratch the valve section bore or the control spool.

1. To disassemble the individual sections of the main 3. Install the end caps on each end of the valve section.
sc
control valve, remove the three nuts from one end of

Di
the tie rods.

2. Disassemble each section assembly as required.
to
Some sections include a pre-adjusted relief valve that

Go
regulates pressure in a specific circuit.

Note: DO NOT adjust any of the relief valve assemblies.
Tampering with a relief valve will irrevocably alter pressure in the
affected circuit, requiring recalibrating or a new relief valve.
Disassemble each Valve Section.
1. Carefully separate the load sense outlet section from the
next section.
2. Remove the o-rings from between the two sections.
3. Carefully separate each remaining sections, being
careful not to lose the load sense shuttle ball.
8-40 31211388 6036, 6042, 8042, 10042, 10054,12054

Hydraulic Section
Assemble the Main Control Valve f. Main Control Valve Installation

6036, 6042 - 85 hp (63 kW) 1. Install the main control valve onto the frame, aligning
the bolts with the holes in the end sections of the main
control valve. Slide the main control valve into position,
and tighten the bolts. Torque as required.
2. Prime the main control valve by filling the inlet
openings with fresh, filtered hydraulic oil from a clean
container, before attaching the hoses.
4 3. Use new oiled o-rings as required. Uncap and connect
all previously labeled hoses, clamps, etc. to the main
rts
control valve.
pa
6036, 6042 - 85 hp (63 kW)
ur
yo
MAQ1880
4
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de
6036 (74hp), 6042 (74hp), 8042, 10042, 10054, 12054
or
to
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t.c
en
2
3
5 MAQ1390
m
ip
6036 (74hp), 6042 (74hp), 8042, 10042, 10054, 12054

qu
-E
nt
MAE41380
4
ou
1. Stand the end main control valve section on end.

sc
2. Install the proper o-rings and load sense shuttle on the

Di
inner face of the end main control valve section. Align

the next valve section over the three tie rods and slide
to
onto the end main control valve section.

Go
3. Using the proper o-rings and load sense shuttle, repeat 5

step two for the remaining valve sections and lastly the
2 3
inlet end valve section.
4. Install the three nuts on the tie rods. Torque the three MAE41370
nuts (4) to 82-90 lb-ft (111 - 122 Nm). 4. Connect the control cables to the main control valve:
5. Replace all fittings in the previously noted locations and a. Install the two bolts (3), and secure the control cable
torque as required. mount/bracket to the main control valve. Torque
the bolt of mount to 7.74 lb-ft (10,5 Nm)
b. Connect the end of the cable to the shaft from the
control valve. Secure with the pin and clip (2).
6036, 6042, 8042, 10042, 10054,12054 31211388 8-41

Hydraulic Section
c. If required, adjust the jam nuts (5) until the distance 8.8.2 Service Brake Valve
from the outer jam nut to the end of the ferrule is
the same as recorded during removal. Tighten the a. Service Brake Valve Removal
jam nuts.
d. Repeat steps for remaining control cables. machine, fully retract the boom, lower the boom, place
5. Check routing of all hoses, wiring and tubing for sharp the transmission in (N) NEUTRAL, engage the park brake
bends or interference with any rotating members, and and shut the engine OFF.
install the tie wraps and/or the protective conduit as 2. Place a Do Not Operate Tag on both ignition key switch
required. Tighten all the tube and hose clamps. and steering wheel.
6. Fill the hydraulic fluid reservoir. Refer to Section 8.6.2, 3. Open the engine cover. Allow the system fluids to cool.
ts
“Hydraulic Oil Reservoir Filling”. 4. Properly disconnect the battery. Refer Section 9.8,
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7. Start engine and run at approximately one-third to one- “Battery”, for procedure.
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half throttle for about one minute without moving the 5. Remove the lower and front dash panels.
machine or operating any hydraulic functions.
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8. Inspect for leaks and check the level of the hydraulic
ry
fluid in the reservoir. Shut the engine OFF.
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Note: Check for leaks and repair as required before continuing.
Add hydraulic fluid to the reservoir as needed.
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to
6
around the machine, work area and tools.
om
10. Install the transmission covers.
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en
and steering wheel.

m
g. Main Control Valve Test

ip
Conduct a pressure check of the hydraulic system in its

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entirety. Adjust pressure(s) as required. Refer to Section 8.5.1,

-E
“Pressure Checks and Adjustments”. MAE4430

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6. Label, disconnect and cap all hose attached to the

Note: DO NOT loosen, disassemble or attempt to adjust any of
service brake valve (6).
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pressure valves unless specifically instructed by manufacturer

to do so. Tampering with a pressure valve will irrevocably alter 7. Remove the four capscrews and four lockwashers
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pressure in the affected circuits. mounting the service brake valve to the steering
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column support.
Note: DO NOT disassemble the service brake valve. The service
to
brake valve is not serviceable and must be replaced in its

entirety, if defective.
Go
8-42 31211388 6036, 6042, 8042, 10042, 10054,12054

Hydraulic Section
8.8.3 Service Brake Valve Installation 6036, 6042

7
1. Install the service brake valve with the four capscrews
and four lockwashers onto the steering column
support.
2. Use new oiled o-rings as required. Uncap and connect
the previously labeled hoses to the service brake valve.
3. Check the routing of all hoses, and tubing for sharp
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bends or interference with any rotating members, and
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install tie wraps and/or protective conduit as required.
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Tighten all tube and hose clamps.
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ry
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MAQ1860
6. Start the engine and run at approximately one-third to
or
one-half throttle for about one minute, without moving 8042, 10042, 10054, 12054
the machine or operating any of the hydraulic functions.
to
FRONT AXLE
7. Inspect the service brake valve and connections for
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leaks, and check the level of the hydraulic fluid in the
reservoir. Shut the engine OFF.
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Note: Check for leaks, and repair as required before

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continuing. Add hydraulic fluid to the reservoir as needed.

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9. Install the lower and front dash panels.

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-E
8.8.4 Brake Bleeding

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Carefully bleed the brake lines as soon as the brake valve is

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installed in the machine. Air in the system will not allow

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the brakes to apply properly. There are four brake bleeder

locations on the axles & one brake bleeder in the machine.
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Work with an assistant to perform this procedure.

7
to
1. Place the transmission in (N) NEUTRAL, engage the park MAE39730

brake, and start the engine.
Go
6036, 6042, 8042, 10042, 10054,12054 31211388 8-43

Hydraulic Section
8042, 10042, 10054 4. Remove the bleed screw (7) with a wrench and allow
REAR AXLE the fluid to escape. As the fluid escapes, maintain the
same pressure on the brake pedal not allowing it to
7 raise. Close the brake bleeder when brake pedal is fully
depressed. Repeat the procedure until oil is not aerated
further. Remove the tubing from the brake bleeder.
5. Repeat steps 2, 3 and 4 for remaining brake bleeders (7)
in this order, the right-rear axle bleed screw, the left-
front axle screw, the right-front axle screw, and the
center bleeder.
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8.8.5 Brake System Check
1. Place the transmission in (N) NEUTRAL, engage the park
pa
brake, and start the engine.
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8
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or
MAE39740
2
12054
to
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REAR AXLE
7
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MAE14330
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2. Attach pressure gauge to brake pressure tap (8).

ip
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3. Apply service brakes with a single pedal press to STOP.

Hold the brake pedal in this position and measure the
-E
gauge pressure. the allowable pressure limit is

725 - 760 psi (50 - 52,4 bar).
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to
MAE41570
Go
Note: Verify brake reservoir oil is at the full mark. DO NOT

allow the brake reservoir oil to go below the minimum level
during the bleeding procedure.
2. Depress the brake pedal 4 - 5 times, then hold at the
bottom of the last stroke.
Note: Work with an assistant to perform this procedure.
3. Attach one end of a length of transparent tubing over
the brake bleeder at left hand side of the rear axle. Place
the other end of this tubing in a suitable transparent MAE13530
container that is partially filled with automatic A
transmission fluid (ATF oil). The end of the tubing must
be below the oil level in the container. 4. Measure the distance from the back of the pedal arm to
cab firewall. This distance should be 2.88 in. (73 mm).
8-44 31211388 6036, 6042, 8042, 10042, 10054,12054

Hydraulic Section
8.8.6 Steering Orbital Valve a. Steer Select Valve Removal

9 machine, fully retract the boom, raise the boom, place
and steering wheel.
MZ0370
ts
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The power steering valve (9) is located at the base of the “Battery”, for procedure.
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steering wheel shaft, concealed by the lower dash cover. The 6. Remove the transmission covers.
valve is not serviceable and must be replaced in its entirety if
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defective. For detailed information refer toSection 4.3.2, 7. Label, disconnect and cap hydraulic hoses and electrical
“Steering Column and Steering Valve”. plugs connected to steering select valve.
ry
8. Remove the bolts holding the steer select valve to the
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8.8.7 Steer Select Valve mounting plate on the frame.
9. Remove steer select valve from machine. Wipe up any
or
hydraulic fluid spillage in, on, near and around the
to
machine.
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b. Steer Select Valve Disassembly, Cleaning, Inspection
10 and Assembly
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1. Place the steer select assembly on a suitable

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work surface.
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2. Separate the steer select valve from the manifold by

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removing the four socket head capscrews. Discard the

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four o-rings.
3. Remove the solenoid valves and spool from the steer
-E
select housing.
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4. Clean all the components with a suitable cleaner before

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MAQ1420
inspection.
The machine can be used in the front-wheel, four-wheel or
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5. Inspect the solenoids for proper operation. Check by

crab steering mode. The steer select valve (10) controls the
Di
shifting the spool to ensure that it is functioning

direction of hydraulic fluid flow to the steering cylinders
properly. Check the spring is intact. Inspect the
mounted on each axle. The steer select valve is attached to a
to
cartridge interior for contamination.

manifold mounted to a mounting plate inside the frame near
6. Inspect internal passageways of the steer select
Go
the fuel tank.

manifold and valve for wear, damage, etc. If inner
Verify the correct operation of the steer select valve
surfaces of the manifold DO NOT display an
solenoids before considering replacement of the valve. The
ultra-smooth, polished finish, or components are
housing of the steer select valve is not serviceable and must
damaged in any way, replace the manifold or
be replaced if defective.
appropriate part. Often, dirty hydraulic fluid causes
failure of internal seals and damage to the polished
surfaces within the valve.
6036, 6042, 8042, 10042, 10054,12054 31211388 8-45

Hydraulic Section
7. Install the solenoid valves in the steer select housing. 8.8.8 Secondary Function Manifold
8. Attach steer select valve to the manifold using four new, The secondary function manifold is a directional control
oiled o-rings and four socket head capscrews. valve. Hydraulic oil from the pump flows into the secondary
function manifold where the pressure is reduced before the
c. Steer Select Valve Installation oil is directed to the park brake.
1. Install the steer select valve to the mounting plate on The secondary function manifold is a machined block with
the frame using two capscrews. the ports for two pressure reducing valves, a pressure relief
2. Connect all the previously labeled hydraulic hoses, valve, two park brake solenoid valves (one normally open
fittings, solenoid wire terminal leads, etc., to the steer and one normally closed), a check valve and diagnostic test
select valve. nipples. The secondary function manifold is secured on the
ts
left side of the frame with two carriage bolts and two hex
ar
3. Check the routing of all hoses, wiring and tubing for flange nuts.
sharp bends or interference with any rotating members,
rp
and install tie wraps and/or protective conduit as Verify the correct operation of the solenoids before
considering replacement of the secondary function
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required. Tighten all hose clamps.
manifold. The manifold itself is not serviceable and must be
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replaced if defective.
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5. Remove Do Not Operate Tag on both ignition key a. Secondary Function Manifold Removal
or
6. Start the engine and run at approximately 1/3-1/2 machine, fully retract the boom, raise the boom, place
throttle for about one minute without moving the
to
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machine or operating any hydraulic functions. and shut the engine OFF.
7. Inspect for leaks and check the level of the hydraulic 2. Place a Do Not Operate Tag on both ignition key switch
t.c
fluid in the reservoir. Shut the engine OFF. and steering wheel.
en
Note: Check for leaks and repair as required before continuing. 3. Temporarily block up or support the raised boom.
Add hydraulic fluid to the reservoir as needed. 4. Open the engine cover. Allow the system fluids to cool.
m
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8. Wipe up any hydraulic fluid spillage in, on, near and 5. Properly disconnect the battery. Refer Section 9.8,
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around the machine, work area and tools. “Battery”, for procedure.
9. Install the transmission covers. 6. Remove the transmission covers.
-E

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d. Steering Test
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Refer to Section 8.5.2, “Pressure Specifications”.

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1. Conduct a pressure check of the steering

hydraulic circuit.
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2. Check each steering mode for proper function.

Go
6036 & 6042

SECONDARY MANIFOLD
SHOWN
MAE41250
7. Label, disconnect and cap hydraulic hoses and electrical

plugs connected to secondary manifold.
8. Remove the bolts holding the secondary manifold to
the mounting plate on the frame.
8-46 31211388 6036, 6042, 8042, 10042, 10054,12054

Hydraulic Section
9. Remove secondary manifold with attached steer select 8. Inspect for leaks and check the level of the hydraulic
valve from machine. Wipe up any hydraulic fluid spillage fluid in the reservoir. Shut the engine OFF.
in, on, near and around the machine.
Note: Check for leaks and repair as required before continuing.
b. Secondary Function Manifold Disassembly, Add hydraulic fluid to reservoir as needed.
Cleaning, Inspection and Assembly 9. Wipe up any hydraulic fluid spillage in, on, near and
1. Secure the secondary function manifold assembly in a around the machine, work area and tools.
suitable bench vise if possible. Label and remove the 10. Install the transmission covers.
solenoid nut, coil, reducing valve(s) and test ports from
the valve.
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2. Clean all components with a suitable cleaner 8.8.9 Outrigger Valve (10042, 10054 & 12054
before inspection. only)
pa
3. Inspect the solenoid cartridge for proper operation. The outrigger valve allows the left and right outriggers to be
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Check by shifting the spool to ensure that it is raised or lowered depending on the position of the outrigger
functioning properly. Check the spring is intact. Inspect
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switches located on the side console in the cab.
the cartridge interior for contamination.
Verify the correct operation of the outrigger valve solenoids
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4. Inspect internal passageways and the secondary
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before considering replacement of the valve.
manifold overall for wear, damage, etc. If inner surfaces
or
of the component DO NOT display an ultra-smooth, a. Outrigger Valve Removal
polished finish, or are damaged in any way, replace the
valve assembly. Often, dirty hydraulic fluid causes
failure of internal seals and damage to the polished to
machine, fully retract the boom, raise the boom, place
om
surfaces within the valve. the transmission in (N) NEUTRAL, engage the park brake
t.c

parts to help ensure proper sealing and operation. Lubricate 2. Place a Do Not Operate Tag on both ignition key switch
en
and steering wheel.

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5. Install the solenoid valve.

ip

6. Install previously removed reducing valve(s) and test
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ports. Torque as required. 5. Properly disconnect the battery. Refer Section 9.8,
-E
c. Secondary Function Manifold Installation 6. Remove the transmission covers.

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7. Label, disconnect and cap the hydraulic hoses and the

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1. Place the secondary function manifold into position on

the mounting plate on the machine frame. electrical plugs connected to the outrigger valve.
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2. Install bolt and nut securing valve to frame. 8. Remove the two flange nuts and two carriage bolts
Di
securing the outrigger valve to the frame. Remove the

3. Connect all the previously labeled hydraulic hoses,
outrigger valve from the machine.
to
fittings, solenoid wire terminal leads, etc., to the

secondary function manifold. 9. Wipe up any hydraulic fluid spillage in, on, near and
Go

4. Check the routing of all hoses and wiring for sharp
Tighten all hose clamps.
7. Start the engine and run at approximately
1/3 - 1/2 throttle for about one minute without moving
the machine or operating any hydraulic functions.
6036, 6042, 8042, 10042, 10054,12054 31211388 8-47

Hydraulic Section
b. Outrigger Valve Disassembly, Cleaning, Inspection 6. Inspect internal passageways of the outrigger
and Assembly valve for wear, damage, etc. If inner surfaces of the valve
DO NOT display an ultra-smooth, polished finish, or
1. Place the outrigger valve assembly on a suitable work
components are damaged in any way, replace the valve
surface.
or appropriate part. Often, dirty hydraulic fluid causes
10042, 10054 surfaces within the valve block.
12
11
ts
7. Install the shuttle cartridges into the outrigger valve.
ar
Torque to 35 lb-ft (48 Nm).
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8. Attach the solenoid assemblies to the outrigger valve
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using four new, oiled o-rings and the previously used
capscrews.
ry
13
c. Outrigger Valve Installation
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1. Insert the previously used bolts through the bottom of
or
MAE41500E
the outrigger valve and loosely attach the flange nuts to
to
the carriage bolts.
12054 2. Position the outrigger valve so that the heads of the
om
12
carriage bolts go through the slots in the frame. Tighten
the flange nuts.
t.c

en
11
fittings, solenoid wire terminal leads, etc., to the
m
outrigger valve.
ip

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-E

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13
5. Properly connect the battery. Refer to Section 9.8,
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MAE41490 6. Remove Do Not Operate Tag on both ignition key

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2. Remove the solenoid valve assemblies (11) from the

outrigger valve by removing the four capscrews (12). 7. Start the engine and run at approximately
to
Discard the four o-rings. 1/3 - 1/2 throttle for about one minute without moving
3. Remove four shuttle cartridges (13) from outrigger the machine or operating any hydraulic functions.
Go
valve. CV3 and CV4 are located on the opposite end of 8. Inspect for leaks and check the level of the hydraulic
the valve body. fluid in the reservoir. Shut the engine OFF.
4. Clean all components with a suitable cleaner Note: Check for leaks and repair as required
before inspection. before continuing. Add hydraulic fluid to the reservoir
5. Inspect the solenoid cartridges for proper operation. as needed.
Check by shifting the spool to ensure that it is 9. Wipe up any hydraulic fluid spillage in, on, near and
functioning properly. Check that the spring is intact. around the machine, work area and tools.
Inspect the cartridge interior for contamination.
8-48 31211388 6036, 6042, 8042, 10042, 10054,12054

Hydraulic Section
8.8.10 Extend Lockout Valve (10054 & 12054 b. Extend Lockout Valve Disassembly, Cleaning,
only) Inspection and Assembly
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ur
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MAE42100
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1. Secure the extend lockout valve assembly in a suitable
or
14 bench vise if possible. Remove the cartridge nut and
MAE42090 adaptors from the valve.
Model 10054 & 12054 has an extend lockout valve (14) which to
2. Clean all components with a suitable cleaner
before inspection.
om
prevents the boom from being extended beyond 42 feet
unless the outriggers are lowered onto firm terrain. Once the 3. Inspect internal passageways and the extend lockout
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outriggers are lowered, pressure switches located on each valve overall for wear, damage, etc. If inner surfaces of
outrigger cylinder close and energize the solenoid on the the component DO NOT display an ultra-smooth,
en
boom extend lockout valve. The boom can then be fully polished finish, or are damaged in any way, replace the
m
extended. extend lockout valve. Often, dirty hydraulic fluid causes

ip

surfaces within the valve.
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a. Extend Lockout Valve Removal

1. Park the machine on a firm, level surface, level the Note: ALWAYS replace seals, o-rings, gaskets, etc., with new
-E
machine, fully retract the boom, raise the boom, place parts to help ensure proper sealing and operation. Lubricate
nt
the transmission in (N) NEUTRAL, engage the park brake seals and o-rings with clean hydraulic oil.
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and shut the engine OFF. 4. Install the cartridge nut and adaptors.
sc
2. Place a Do Not Operate Tag on both ignition key switch 5. Install the pressure sensing valve. Torque to
and steering wheel.
Di
65 lb-ft (88 Nm).

to

Go

7. Label, disconnect and cap hydraulic hoses and electrical
plugs connected to extend lockout valve.
8. Remove nut and bolt securing extend lockout valve to
the frame. Remove the valve from the machine.
6036, 6042, 8042, 10042, 10054,12054 31211388 8-49

Hydraulic Section
c. Extend Lockout Valve Installation 8.9 HYDRAULIC CYLINDERS

1. Place the extend lockout valve into position on the
mounting plate on the machine frame. 8.9.1 General Cylinder Instructions
2. Install bolt and nut securing valve to frame.
a. Cylinder Removal
fittings, solenoid wire terminal leads, etc., to the extend 1. Remove any attachment from the machine. Park the
lockout valve. machine on a firm level surface and fully retract the
boom. Allow sufficient work space around the hydraulic
cylinder being removed. Support the boom if the
lift/lower cylinder is being removed. Place the
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transmission in (N) NEUTRAL, engage the park brake,
pa
shut the engine OFF and chock wheels.
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and steering wheel.
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6. Remove Do Not Operate Tag on both ignition key 3. Open the engine cover. Allow the system fluids to cool.
4. Label, disconnect and cap or plug hydraulic hoses in
r
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7. Start the engine and run at approximately relation to the cylinder.
1/3 - 1/2 throttle for about one minute without moving
or
the machine or operating any hydraulic functions. 5. Attach a suitable sling to an appropriate lifting device
and to the cylinder. Make sure the device used can
to
8. Inspect for leaks and check the level of the hydraulic actually support the cylinder.
fluid in the reservoir. Shut the engine OFF.
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6. Remove the lock bolt and/or any retaining clips
Note: Check for leaks and repair as required before continuing. securing the cylinder pins. Remove the cylinder pins.
Add hydraulic fluid to reservoir as needed.
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7. Remove the cylinder.

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around the machine, work area and tools. around the machine, work area and tools.
m

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11. Close and secure the engine cover. b. Cylinder Disassembly

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1. Clean the cylinder with a suitable cleaner before

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d. Extend Lockout Valve Test disassembly. Remove all dirt, debris and grease from the
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Conduct a test of the extend lockout valve. cylinder.

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1. Park the machine on a firm, level surface.

sc
2. With the boom fully retracted and lowered, lower TYPICAL TILT CYLINDER
the outriggers.
Di
3. Extend the boom to 54 ft (16,5 m). The boom should

to
extend fully and should not stop at 42 ft (12,8 m).

Go
MAE42130
8-50 31211388 6036, 6042, 8042, 10042, 10054,12054

Hydraulic Section
2. Clamp the barrel end of the cylinder in a soft-jawed vise 10. Remove the piston head from the rod and carefully slide
or other acceptable holding equipment if possible. the head gland off the end of the rod.
11. Remove all seals, backup rings and o-rings from piston
head and all seals, backup rings and o-rings from the
WARNING head gland.
Significant pressure may be trapped inside the cylinder. Note: The head gland bearing will need to be inspected to
Exercise caution when removing a counterbalance valve determine if replacement is necessary.
or a pilot-operated check valve from a cylinder. DO NOT attempt to salvage cylinder seals, sealing rings or
o-rings. ALWAYS use a new, complete seal kit when
Note: Avoid using excessive force when clamping the cylinder rebuilding hydraulic components. Consult the parts catalog
in a vise. Apply only enough force to hold the cylinder securely.
rts
for ordering information.
Excessive force can damage the cylinder tube.
pa
3. If applicable, remove the counterbalance valve from the c. Cylinder Cleaning Instructions
side of the cylinder barrel. 1. Discard all seals, backup rings and o-rings. Replace with
ur
Note: DO NOT tamper with or attempt to adjust the new items from seal kit to ensure proper cylinder
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counterbalance valve cartridge. If adjustment or replacement is function.
necessary, replace the counterbalance valve with a new part. 2. Clean all metal parts with an approved cleaning solvent
r
such as trichlorethylene. Carefully clean cavities,
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4. Extend the rod as required to allow access to the base of
the cylinder. grooves, threads, etc.
or
Note: Protect the finish of the rod at all times. Damage to the Note: If a white powdery residue is present on threads or parts,
it can be removed by using a soft brass wire brush. Wipe clean
surface of the rod can cause seal failure.
5. Using a pin spanner wrench, unscrew the head gland to
with Threadlocking Cleaner prior to reassembly.
om
from the tube. A considerable amount of force will be d. Cylinder Inspection
needed to remove the head gland. Carefully slide the
t.c
head gland down along the rod toward the rod eye and 1. Inspect internal surfaces and all parts for wear, damage,
etc. If the inner surface of the cylinder barrel does not
en
piston, away from the cylinder barrel.

display a smooth finish, or is scored or damaged in any
Note: When sliding the rod and piston assembly out of the
m
way, replace the barrel.

barrel, prevent the threaded end of the barrel from damaging
ip
the piston. Keep the rod centered within the barrel to help 2. Remove light scratches on the piston, head gland, rod
with a 400 - 600 grit emery cloth. Use the emery cloth in
qu
prevent binding.
a rotary motion to polish out and blend the scratch(es)
-E
6. Carefully pull the rod assembly along with the head into the surrounding surface.
gland out of the cylinder barrel.
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3. Proper honing is required to smooth the inner surface

7. Fasten the rod eye in a soft-jawed vise, and place a of the cylinder barrel.
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padded support under and near the threaded end of 4. Check the piston rod assembly for run-out. If the rod is
the rod to prevent any damage to the rod.
sc
bent, it must be replaced.

8. Remove the set screw from the piston head.
Di
5. Inspect rod eye bushing and replace if worn or

9. Remove the lock nut from the piston rod. damaged.
to
Note: It may be necessary to apply heat to break the bond of

the sealant between the piston and the rod before the piston e. Cylinder Assembly Instructions
Go
can be removed. 1. Use the proper tools for specific installation tasks. Clean
Some cylinder parts are sealed with a special organic sealant tools are required for installation.
and locking compound. Before attempting to disassemble 2. Install new seals, backup rings and o-rings on the piston
these parts, remove any accessible seals from area of bonded and new seals, backup rings, o-rings and bearing on the
parts. Wipe off any hydraulic oil, then heat part(s) uniformly head gland.
to break bond. A temperature of 300 - 400° F (149 - 204° C)
Note: The extend/retract cylinder has a spacer that MUST be
will destroy bond. Avoid overheating, or parts may become
distorted or damaged. Apply sufficient torque for removal installed over the rod AFTER the head gland and BEFORE the
while parts are still hot. The sealant often leaves a white, piston head.
powdery residue on threads and other parts, which must be 3. Fasten the rod eye in a soft-jawed vise, and place a
removed by brushing with a soft brass wire brush prior to padded support under and near the threaded end of
reassembly. the rod to prevent any damage to the rod.
6036, 6042, 8042, 10042, 10054,12054 31211388 8-51

Hydraulic Section
Note: Protect the finish on the cylinder rod at all times. 8.9.2 Cylinder Pressure Checking
Damage to the surface of the rod can cause seal failure.
Attach a digital or 4000 psi (276 bar) gauge to test port on
4. Lubricate and slide the head gland over the cylinder hydraulic pump to check system pressure. For more
rod. Install the piston head on to the end of the cylinder information, refer Section 8.5.1, “Pressure Checks and
rod. Medium Strength Threadlocking Compound and Adjustments”.
install the set screw in the piston head. Refer to Section
8.9.4, “Cylinder Torque Specifications”, for torque Note: If a hydraulic cylinder pressure is greater than main
specifications for the piston head and the set screw. control valve pressure, increase main control valve pressure by
adjusting the main relief. Generally, one half turn clockwise will
Note: Avoid using excess force when clamping the cylinder be adequate to check an individual circuit. Activate circuit and
barrel in a vise. Apply only enough force to hold the cylinder if pressure is obtained turn main relief counter clockwise one
barrel securely. Excessive force can damage the cylinder barrel. half turn. Re-check main relief setting and adjust if necessary.
rts
5. Place the cylinder barrel in a soft-jawed vise or other
pa
acceptable holding devise. 8.9.3 Steering Cylinders
Note: When sliding the rod and piston assembly into the The steer cylinder is attached to each axle center housing.
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cylinder barrel, prevent the threaded end of the cylinder barrel The steer cylinder assembly can be found in Section 5.3,
“Axle Assemblies”. The steer cylinder is covered in the
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from damaging the piston head. Keep the cylinder rod centered
within the barrel to prevent binding. appropriate manufacturer’s axle literature.
r
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6. Carefully insert the cylinder rod assembly into the
cylinder barrel. STEERING CYLINDER
or
7. Screw the head gland into the cylinder barrel and
to
tighten with a spanner wrench. Refer to Section 8.9.4,
“Cylinder Torque Specifications”, for torque
om
specifications for the head gland.
8. If applicable, install new counter balance valve into
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block on the cylinder barrel.

en
f. Cylinder Installation
m
1. Grease the bushings at the ends of the hydraulic AXLE CENTER SECTION
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cylinder. Using an appropriate sling, lift the cylinder into MAQ2070

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it’s mounting position.

2. Align cylinder bushing and install pin, lock bolt or
-E
retaining clip.
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3. Connect the hydraulic hoses in relation to the labels or

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markings made during removal.

4. Before starting the machine, check fluid level of the
sc
hydraulic fluid reservoir and if necessary fill to full mark.

Di
5. Start the machine and run at low idle for about one
minute. Slowly activate hydraulic cylinder function in
to
both directions allowing the cylinder to fill with

hydraulic oil.
Go
6. Inspect for leaks and check level of hydraulic fluid in

reservoir. Add hydraulic fluid if needed. Shut the engine
OFF.
8-52 31211388 6036, 6042, 8042, 10042, 10054,12054

Hydraulic Section
8.9.4 Cylinder Torque Specifications
a. Lift/Lower Cylinder
Model Head Piston Piston Lock Nut Valve Set Screw

295 lb-ft 966 lb-ft 33 - 37 lb-ft 7.4 lb-ft
6036, 6042 NA
(400 Nm) (1310 Nm) (45 - 50 Nm) (10 Nm)
33 - 37 lb-ft
8042 NA NA NA NA
(45 - 50 Nm)
ts
300 - 400 lb-ft 1750 - 2000 lb-ft 30 - 35 lb-ft 10 - 26 lb-ft
10042, 10054 NA
ar
(407 - 542 Nm) (2372 - 2556 Nm) (41 - 47 Nm) (13 - 35 Nm)
rp
1450 lb-ft
12054 360 lb-ft (488 Nm) NA 33 lb-ft (45 Nm) 21 lb-ft (28 Nm)
(1966 Nm)
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ry
b. Extend/Retract Cylinder
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Model Head Piston Valve Set Screw
or
6036
to
(407 - 542 Nm) (447 - 529 Nm) (54 - 67 Nm) (12 - 15 Nm)
300-400 lb-ft 330-390 lb-ft 40 - 50 lb-ft 9 - 11 lb-ft
om
6042
(407-542 Nm) (447-529 Nm) (54 - 67 Nm) (12 - 15 Nm)
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8042, 10042, 10054, 300 - 400 lb-ft 390 - 460 lb-ft 150 - 160 lb-ft 9 - 11 lb-ft
12054 (407 - 542 Nm) (529 - 624 Nm) (203 - 217 Nm) (12 - 15 Nm)
en
m
c. Tilt Cylinder
ip
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Model Head Piston Piston Locknut Valve Set Screw

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6036, 6042 NA
nt
(407-542 Nm) (325 - 380 Nm) (41 - 47 Nm) (12 - 15 Nm)

ou
8042, 10042, 500 - 600 lb-ft 1850 - 2000 lb-ft 30 - 35 lb-ft

NA N/A
10054 (678-813 Nm) (2508 - 2712 Nm) (41 - 47 Nm)
sc
33 lb-ft (45
Di
12054 360 lb-ft (488 Nm) 1450 lb-ft (1966 Nm) NA 21 lb-ft (28 Nm)
Nm)
to
d. Frame Level Cylinder

Go
Model Head Piston Locknut Valve Plug

6036, 6042, 8042, 300 - 400 lb-ft 1100 - 1250 lb-ft 35 - 40 lb-ft 10 - 12 lb-ft
10042, 10054 (407 - 542 Nm) (1491 - 1695 Nm) (47 - 54 Nm) (13 - 16 Nm)
250 - 350 lb-ft 2200 - 2650 lb-ft 30 - 35 lb-ft
12054 NA
(339 - 475 Nm) (2983 - 3593 Nm) (41 - 47 Nm)
6036, 6042, 8042, 10042, 10054,12054 31211388 8-53

Hydraulic Section
e. Stabil-TRAK Cylinder
Model Pressure
Check
Head Piston Locknut Set Screw Reducing/PO Solenoid Coil
Valve
Check Valve
6042, 8042, 250 - 350 lb-ft 1175 - 1400 lb-ft 20 - 25 lb-ft 3 - 4 lb-ft 35 - 40 lb-ft 25 - 30 lb-ft
10042, 10054 (339 - 475 Nm) (1593 - 1898 Nm) (27 - 34 Nm) (4 - 5 Nm) (47 - 54 Nm) (34 - 41 Nm)
250 - 350 lb-ft 1175 - 1400 lb-ft 20 - 25 lb-ft 3 - 4 lb-ft 35 - 40 lb-ft 25 - 30 lb-ft
12054
(339 - 475 Nm) (1593 - 1898 Nm) (27 - 34 Nm) (4 - 5 Nm) (47 - 54 Nm) (34 - 41 Nm)
rts
f. Compensation Cylinder
pa
Model Head Locknut Valve Set Screw
ur
yo
6036, 6042
(339 - 474 Nm) (881 - 949 Nm) (40 - 47 Nm) (4 - 5 Nm)
r
de
8042, 10042, 300 - 400 lb-ft 900 - 1050 lb-ft
NA
10054 (407 - 542 Nm) (1220 - 1424 Nm)
or
12054 360 lb-ft (488 Nm) 1000 lb-ft (1356 Nm) 33 lb-ft (45 Nm) NA
g. Swing Carriage Cylinder (If Equipped) to

om
t.c
Piston Head Set Screw Valves

en
(576 - 678 Nm) (339 - 474 Nm) (115 - 129 Nm) (41 - 47 Nm)
m
ip
h. Side Tilt Carriage Cylinder (If Equipped)

qu
-E
Head Locknut Valve

nt
300-400 lb-ft 550 - 650 lb-ft 30 - 35 lb-ft

(407-542 Nm) (745 - 881 Nm) (41 - 47 Nm)
ou
sc
i. Outrigger Cylinder
Di
Model Head Locknut Valves

to
250 - 350 lb-ft 1650 - 1800 lb-ft 30 - 35 lb-ft

Go
10042, 10054
(339 - 475 Nm) (2237 - 2440 Nm) (41 - 47 Nm)
250 - 350 lb-ft 2200 - 2650 lb-ft 30 - 35 lb-ft
12054
(339 - 475 Nm) (2983 - 3593 Nm) (41 - 47 Nm)
8-54 31211388 6036, 6042, 8042, 10042, 10054,12054

Need parts?
Section 9
Electrical System
Contents
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9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
pa
9.1.1 General Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
ur
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9.4 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
r
9.4.1 Engine Compartment Fuse and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
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9.4.2 Cab Harness Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
or
9.5 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.5.1 Cab Schematic (85 hp (63 kW), 110 hp (82 kW) if equipped for ULS). . . . . . . . . . 9-7
9.5.2
9.5.3
to
Cab Schematic (85 hp (63 kW), 110 hp (82 kW) if equipped for LS) . . . . . . . . . . .
Cab Schematic (74 hp (55 kW) if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-8
9-9
om
9.5.4 Chassis - Engine Schematic (85 hp (63 kW), 110 hp (82 kW) if equipped for ULS) 9-10
t.c
9.5.5 Chassis - Engine Schematic (85 hp (63 kW), 110 hp (82 kW) if equipped for LS) 9-11
9.5.6 Chassis - Engine Schematic (74 hp (55 kW) if equipped) . . . . . . . . . . . . . . . . . . . . . 9-12
en
9.5.7 Cab O/R Option Schematic (10042 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13

m
9.5.8 Cab O/R Option Schematic (10054 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14

ip
9.5.9 HVAC Option Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15

qu
9.5.10 Roadlights Option/Worklights Option/Roadlights-Worklights Schematic. . . . . 9-16

9.5.11 Beacon Option Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
-E
9.5.12 Beacon/Camera Option Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18

nt
9.5.13 Telematics Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19

ou
9.6 Dielectric Grease Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20

9.6.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
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9.7 Engine Start Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22

Di
9.7.1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22

to
9.8 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23

9.8.1 Battery Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Go
9.8.2 Battery Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24

9.8.3 Battery Disconnect/Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
9.9 Charging Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
9.9.1 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
9.10 Window Wiper/Washer Windshield Wiper Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
9.10.1 Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
9.10.2 Skylight Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
9.10.3 Windshield Washer Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
9.11 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
9.11.1 Cab Heater Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
6036, 6042, 8042, 10042, 10054, 12054 31211388 9-1

Electrical System
9.12 Solenoids, Sensors and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30

9.12.1 Coolant Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
9.12.2 Transmission Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
9.12.3 Transmission Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
9.12.4 Service Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
9.12.5 Boom Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
9.12.6 Boom Extend Interlock Sensor (10054 & 12054 only). . . . . . . . . . . . . . . . . . . . . . . . . 9-34
9.12.7 Outrigger Pressure Switches (10054 & 12054 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
9.12.8 Reverse Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35
9.13 Display Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35
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9.14 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
pa
9.14.1 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
9.14.2 Dash Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
ur
9.15 Machine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
yo
9.15.1 Machine Data Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
9.15.2 Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
r
9.15.3 Mobile Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
de
9.15.4 Analyzer Software Version P2.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
or
9.16 Analyzer Software Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41
9.16.1 Access Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41
9.16.2 to
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41
om
9.16.3 Machine Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
9.16.4 Personalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43
t.c
9.16.5 Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44

en
9.17 Telematics Gateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-45

9.17.1 Telematics-Ready (TCU) Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46
m
9.17.2 Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46

ip
9.17.3 Telematics Gateway Harness Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-47

qu
9.18 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-51

-E
9.18.1 Fault Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-51

9.18.2 Offboard Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-51
nt
9.19 Machine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-52

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9.19.1 Help Comment (00X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-52

sc
9.19.2 Power-Up (21x). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-52

Di
9.19.3 Platform Inputs (22x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-52

9.19.4 Cabin Controls (23x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-52
to
9.19.5 Function Prevented (25x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-53

9.19.6 Output Drivers (33x). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-53
Go
9.19.7 Engine (43x). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-54

9.19.8 Battery Supply (44x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-54
9.19.9 Communications (66x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-55
9.19.10 Hardware (99x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-55
9.20 Engine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-56
9-2 31211388 6036, 6042, 8042, 10042, 10054, 12054

Electrical System
9.1 ELECTRICAL COMPONENT

TERMINOLOGY
To understand the safety, operation, and service information
presented in this section, it is necessary that the operator/
mechanic be familiar with the name and location of the
electrical components of the machine. The following
ts
9.1.1 General Overview
ar
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COOLANT TEMPERATURE
SENSOR
ou
ry
ALTERNATOR DASH SWITCHES
INSTRUMENT
de
CAB HEATER
PANEL
CONTROLS
or
TRANSMISSION
TEMPERATURE
to
SENDER
IGNITION
SWITCH
om
t.c
STARTER PARK BRAKE

SWITCH
en
m
ip
qu
SERVICE
BRAKE
-E
TRANSMISSION SWITCH
SOLENOID
nt
VALVES
ou
sc
ACCELERATOR DIAGNOSTIC
PEDAL LOCATION
Di
to
Go
BOOM ANGLE
BOOM EXTEND SENSOR
(FOUR SECTION BOOM SHOWN)
INTERLOCK SENSOR
(10054 & 12054)
MAE41300
6036, 6042, 8042, 10042, 10054, 12054 31211388 9-3

Electrical System
9.2 SPECIFICATIONS 9.4 FUSES AND RELAYS

Electrical system specifications are listed in Section 2,
“General Information and Specifications”.
9.4.1 Engine Compartment Fuse and Relays
Starter relay (1), one 250 amp fuse (2) two 60 amp power
9.3 SAFETY INFORMATION module fuses (3) 150 amp relay for cold start grid heater (4)
and DEF System Power Module (5) are located inside engine
compartment in protective case next to battery.
WARNING
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pa
this manual.
ur
5
yo
2
r
de
or
1
to
om
t.c
en
m
ip
qu
3
4
-E
MAQ1450
nt
ou
sc
1
R1 R2 R3
2
Di
R4 R5
to
MAQ4500
Go
No. Amp Circuit

R1 35 Amp Starter Lockout Relay
R2 35 Amp DEF Heater Suction Relay
R3 35 Amp DEF Heater Diagnostic Relay
R4 35 Amp DEF Heater Pressure Relay
R5 35 Amp DEF Heater Supply Module Relay
1 15 Amp Supply Module Heater
2 15 Amp DEF Heater
9-4 31211388 6036, 6042, 8042, 10042, 10054, 12054

Electrical System
9.4.2 Cab Harness Fuses and Relays
6036, 6042, 8042 & 10042
1 R1 R5
2
3 R2 R6
ts
4
ar
R3 R7
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5
6
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7 R4 R8
ry
8 R9
de
D1
9 16
or
22 R10
10 17
D2
11 18
to
30
om
R13 12 19 R11
D3
13 20 R12
t.c
R14
30
14 BLANK
en
m
MAQ1461
23
ip
qu
10054 &12054
-E
nt
ou
1 R1 R15
R5 24
BLANK
2
sc
3 R2 R6 R16
Di
4
to
5 R3 R7 R17
6
Go
7 R4 R8 R18
8 R9 R19
D1
9 16 25
22
10 17 R10 R20
D2
11 18
30
R13 12 19 R11 R21

D3
13 20 R12
R14
30
14 BLANK R22
23 MAQ1561
6036, 6042, 8042, 10042, 10054, 12054 31211388 9-5

Electrical System
No. Amp Circuit No. Amp Circuit

1 20 Amp Hazard Lights R19 35 Amp Right Outrigger Lock Out
2 15 Amp Outriggers/Beacon R20 35 Amp Left Outrigger Lock Out
3 7.5 Amp Work Lights Relay R21 35 Amp Park Brake Interlock
4 10 Amp Boom Switch R22 35 Amp Boom Extension Lock Out
5 7.5 Amp Park Brake Disengage/Transmission 24 7.5 Amp Outrigger 1 (Mini-Fuse)
6 10 Amp Steering/Stabilizer 25 7.5 Amp Outrigger 2 (Mini-Fuse)
7 10 Amp Gauge Cluster/Park Brake Interlock
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8 20 Amp Work Lights Relay
9 7.5 Amp AC Switch
pa
10 20 Amp Heater Blower Motor
ur
11 7.5 Amp Accessory Plug
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12 10 Amp AC Relay
13 20 Amp Horn/Heater
r
de
14 5 Amp Alternator Excite
or
15 BLANK
16 10 Amp Diagnostic Battery
17 10 Amp Diagnostic Ignition
to
om
18 5 Amp ECM Key Switch
19 10 Amp Wipers
t.c
20 40 Amp Main
en
21 BLANK
m
22 30 Amp Work Lights (if equipped)

ip
23 30 Amp Road Lights (if equipped)

qu
R1 35 Amp Boom Switch (Removed on 6036)

-E
R2 35 Amp Park Brake Switch

nt
R3 35 Amp Neutral Relay

ou
R4 35 Amp Backup Relay

R5 35 Amp Relay 2
sc
R6 35 Amp Ground Fault Relay

Di
R7 35 Amp HVAC Relay 1

to
R8 35 Amp HVAC Relay 2

Go
R9 35 Amp Lights Relay (*Diode)

Stabilizer Lock Relay (*Diode)
R10 35 Amp
(Removed on 6036)
R11 35 Amp Ignition Relay (*Diode)
R12 BLANK
R13 35 Amp Work Lights (if equipped)
R14 35 Amp Road Lights (if equipped)
R15 BLANK
R16 35 Amp Stabilizer Interlock
R17 35 Amp Stabilizer Lockup
R18 35 Amp Boom Extend Interlock
9-6 31211388 6036, 6042, 8042, 10042, 10054, 12054

9-7 31211388 6036, 6042, 8042, 10042, 10054, 12054
MAE42180I
F
B
C
A
G
H
1001166035-I
ENGINE DIAGNOSTIC
2
1
ENG_BULK3_IF
C
B
A
D
2
1
X1008
X1020
E
C
J
G
F
B
H
D
A
X335
TO X2 ON
ENGINE HARNESS
FC1002
2KA BLK (18)
TO BEACON (OPTION)
(10042 MACHINES)
IGN SWITCH
2KK BLK (18)
TO OUTRIGGER HARNESS
160 RED (12)
RL414-85
2AC BLK (16)
2MC BLK (14)
AC2 WHT (16)

SPL26 RL414-86
50 WHT/YEL (16)
51 WHT/RED (16)
26 RED (12) THERMOSTAT WHT (16) RL414

A RL414-87 HVAC RELAY 1
IGN DBL (18)
IGN DBL (18)
PWR RED (16)
0
GND BLK (16)
RED RELAY 2-30 (12)

CANL GRN (18)
52B ORG (12)

SEE X1099 & X1100, SHT7-B2)
CANH YEL (18)
X146 RL414-30
1 1 WHT (12) FLOOR HTR PWR RED (16)
1
B RL414-87a
P 2KA BLK (18)
X145 RL417-85
2 S1034 AC-1 WHT (16)
C RL417-86
RL417
FLOOR HEATER WHT (16)
(IF ROADLIGHT WORKLIGHT INSTALLED,
SW1091 RL417-87 HVAC RELAY 2

FLOOR HTR PWR RED (16)
RL417-30
RL417-87a
0 26A RED (12) 2DD BLK (18)
A RL454-85
S1074
1 3C RED (10) 12 DBL (18)

B RL454-86
P IGNSW DBL (16) 12A DBL (12) RL454
C RL454-87 LIGHTS SWITCH
S163 29 RED (12)
2 D RL454-30
E RL454-87a
2CC BLK (18)
SW IGNITION RL455-85
114B BLU/ORG (16)
RL455-86 RL455
40A BRN/BLK (16) STAB LK
RL455-87
Eliminated wire #151(B4)-Hydraulic Temp Switch
48 VIO/BLK (16)
RL455-30
47 ORG/WHT (16)
RL455-87a
2AA BLK (18)
RL456-85
10 TAN (16) RL456
RL456-86 BOOM SWITCH
28 VIO/WHT (16)
RL456-87
39 RED/GRY (16)
X148
SW604-1 RL456-30
46 WHT/ORG (16) 48 VIO/BLK (16)
1 RL456-87a
2EE BLK (18)
SW604-2 RL617-85
45B DBL/ORG (16) 107B DBL (16)
1 RL617-86 RL617
BRAKE PEDAL
113B RED (16) PARK BRAKE RELAY

RL617-87
153 GRY/WHT (16)
RL617-30
X149
153A GRY/WHT (16)

RL617-87a
2FF BLK (18)
RL458-85
112A GRY (16)
2
RL458-86 RL458
106 BLU/ORG (12) NEUTRAL START
RL458-87
111A RED (12)
RL458-30
RL458-87a
2BB BLK (18)
RL459-85
102B PNK (16)
RL459-86
31 ORG/RED (16) RL459
RL459-87 BACKUP
24A ORG/GRN (14)
8 RL459-30
2AB BLK (12) S1073
7 RL459-87a
12C DBL (16) RELAY 2-85 ORG/YEL (18)
6 RL461-85
12AA DBL (12) RELAY2-86 BLK (18)
5 RL461-86 RL461
155 GRN/RED (16) RELAY 2-87 RED (12) RELAY 2
4 RL461-87
X1004
154 BLU/WHT (16) RELAY 2-30 RED (12)

3 RL461-30
2 RL461-87a
GND FAULT BLK (18)
1 RL479-85
Go
ACC MOD GND 3 BLK (18)

RL479-86 RL479
TO ROADLIGHT HARNESS (X992)
VLV GND BLK (18) GND FLT RELAY

RL479-87
RL479-30
RL479-87a
2NN BLK (18)
RL460-85
3D VIO (18)
RL460-86 RL460
159 VIO (12)
S1007
IGNITION
RL460-87
160 RED (12)
to
RL460-30
RL460-87a
PWR2 RED (16)
FC340-1
10A
DIAGNOSTIC FUSE
PWR RED (16)
FC340-2
S1018
IGNA DBL (18)

FC338-1
10A
DIAGNOSTIC FUSE 2
3
3
IGN DBL (18)
FC338-2
34A RED (16)
5A
FC337-1 ENGINE ECM & SCR

34 RED/BLK (16)
FC337-2
12C DBL (16) HEADLIGHTS
Di
FC579-1
20A
FUSE RELAY BOX
159A VIO (12)

BUSSBAR
2LA BLK (10)

1 FC589-1
20A
52 ORG (12) HORN / HTR

FC589-2
2A BLK (10)
1
sc
51 WHT/RED (16) OPT 2

FC584-1
15A
2MA BLK (10) S1019 50 WHT/YEL (16)

1
CAB GND STUD 12 DBL (18)
2PA BLK (10) KEY IGN IND ORG (18) OPT 1
HARNESS, CAB PWR DISTRIBUTION

1 FC580-1
7.5A
S1072
39 RED/GRY (16) STAB

FC588-1
10A
ou
7 BRN (16)
S341
S491
153A GRY/WHT (16) TRANSM

FC583-1
7.5A
8 GRN/WHT (16)
11A LGN (16) 11A LGN (16) STR / STAB
1 FC587-1
10A
11B LGN (16) 46 WHT/ORG (16)

nt
2
9 GRN/BLK (16)
3
42-A TAN (16) INSTRM
4 FC582-1
10A
22 WHT (16)
5
STEER MODE
6
2JJ BLK (16) 159B VIO (14)
7 FC590-1
10A
CAB
4
4
11B LGN (16) 32 GRY/WHT (16)
-E
8 FC590-2
CLUTCH POWER RED (12)
SW615 FC490-1
7.5A
CLUTCH RED (12) CLUTCH

FC490-2
COND POWER RED (12)
FC489-1
20A
COND RED (12) COND

FC489-2
SOCKET POWER RED (12)
FC488-1
7.5A
SOCKET PWR RED (12) SOCKET

FC488-2
X330 27 RED (10)
qu
FC581-1
40A
22 WHT (16) 26 RED (12) MAIN

1 FC581-2
38CH YEL (18)
2
6CL GRN (18) 29 RED (12) LIGHTS
3 FC578-1
20A
2GG BLK (18) S203

4
S202
17 GRY (18) 15A LBL (18)

ip
5 FC702-1
5A
ALTERNATOR
15 LBL (18) EXCITATION
6 FC702-2
AC WHT (16)
7 FC411-1
10A
18 GRN (18) AC3 WHT (16) HVAC AC FUSE

8 FC411-2
201 BLU (16)
GAUGE CLUSTER
9
154 BLU/WHT (16) 3 RED (8)
10
m
155 GRN/RED (16) S1017 114A DBL (16)

11 D1-1
40B BRN/BLK (16) 114A DBL (16) DIODE 1
12 D1-2
45A DBL/ORG (16)
13 D2-1 DIODE 2
45A2 DBL/ORG (16)
14 D2-2
113C RED (16)
D3-1 DIODE 3
113A RED (16)
D3-2
en
5
5
S164
S176
t.c
X1015 X1013
2MB BLK (14)
1 1
3E RED (14)
2 2
3B VIO (14)
3 3
35 BRN/WHT (16)
4 4 S207
157 BRN (16) 7 BRN (16)
5 5
6 6
7 7
152B DBL/ORG (16)
om
8 8
107C DBL (16) 107A DBL (16)
9 9
FOR 10054 MACHINES REMOVE JUMPER

107C DBL (16) 107B DBL (16)
10 10
S185
41-A DBL/WHT (16) S331

11 11
AND CONNECT TO X1001 OF OUTRIGGER HARNESS

41C DBL/WHT (16) 41-B DBL/WHT (16)
12 12
to
S167
S212
6
6
or
S204
ORG/YEL KEY IGN 4 (18)
1 IGN PWR (7-33V)
BLK ACC MOD GND (18)
2 GROUND
PARK BK WHT (18)
3 DIGITAL INPUT 0
CAN TERMINATION X332 XMSN NEUT WHT (18)
de
4 DIGITAL INPUT 1
38H YEL (18) AIR FLT SW ORG (18)
1 5 DIGITAL INPUT 2
6L GRN (18)
2 6 DIGITAL INPUT 3
YEL TILT UP (18)
2KK BLK (18)

3 7 PWM OUTPUT 0
S482
(S ACC )
DBL TILT DOWN (18)

8 PWM OUTPUT 1
ANTISTALL WHT (18)
9 PWM OUTPUT 2
10 PWM OUTPUT 3
ENGINE LT WHT (18)
11 PWM OUTPUT 4
ry
BLK GND FAULT (18)
12 PWM OUTPUT 5
107A DBL (16)
CO556-J1
41-B DBL/WHT (16) RED 5 EXC TILT (18)
1 ANALOG +5V OUT
42-A TAN (16) WHT TILT SIG A (18)
1 2 ANALOG INPUT 0
42-B TAN (16) BLK TILT GND (18)
MACHINE CONTROLLER
2 3 ANALOG GROUND
45A2 DBL/ORG (16) VCC ORG (18)
3 4 ANALOG +5V OUT
152B DBL/ORG (16) WHT TILT SIG B (18)
4 5 ANALOG INPUT 1
ou
1 WHT (12) BLK APS GND
5 6 ANALOG GROUND
111 RED (12) APS1 WHT (18)
6 7 ANALOG INPUT 2
2HH BLK (16) APS2 WHT (18)
7 8 N/A
42-B TAN (16) YEL CAN HIGH (18)
8 9 CANBUS HIGH
7
7
GRN CAN LOW (18)
SW616 10 CANBUS LOW
PARK BREAK SWITCH S1054 WHT TX (18)
11 ANALYZER TRANSMIT
GRN RX (18)
12 ANALYZER RECEIVE
rp
CO556-J2
S560
S559
S168
S1035
S1010
ar
X557
APS1 WHT (18)
A
GND1 BLK (18)
S568
B
ts
VCC1 ORG (18)
C
VCC2 ORG (18)
D
GND2 BLK (18)
E
THROTTLE PEDAL
APS2 WHT (18)

F
BLK TILT GND (18)
S194
RED 5 EXC TILT (18)
WHT TILT SIG B (18)

WHT TILT SIG A (18)
ORG/RED KEY IGN (16)
SOCKET PWR RED (12)

1
HEST WHT (18)

GRN RX (18)
REGEN WHT (18)

2
BLK SOCKET GND (12)

WHT TX (18)
KEY IGN1 ORG (18)

KEY IGN2 ORG (18)
3
ENGINE LT WHT (18)

BLK ANALYZER GND (16)
4
ANALYZER
JOYSTICK
4
3
2
1
JS612
2PB BLK (12)

2PC BLK (12)
52A ORG (12)

AC2 WHT (16)
AC3 WHT (16)
AC-2 WHT (16)
6 GRN (18)
15 LBL (18)
38 YEL (18)
COND RED (12)
10 TAN (16)
17 GRY (18)
18 GRN (18)
104 YEL (16)

150 VIO (16)
104 YEL (16)
150 VIO (16)
158 BLK (16)
8
8
103 DBL (16)
103 DBL (16)
113 RED (16)

201 BLU (16)
112 GRY (16)

102 PNK (16)
101 BRN (16)
101 BRN (16)
7
6
5
4
3
2
1
105 GRN (16)

105 GRN (16)
27C RED (12)
CLUTCH RED (12)
27D RED (12)
102A PNK (16)

YEL TILT UP (18)
X570
X569
AC COMP WHT (16)
9 GRN/BLK (16)
MS571
2
1
1
34 RED/BLK (16)
8 GRN/WHT (16)
40 BRN/BLK (16)
28 VIO/WHT (16)
1B
1B
1A
31 ORG/RED (16)
2B
1A
2A
2B
35 BRN/WHT (16)
2A
47 ORG/WHT (16)
106 BLU/ORG (12)

DBL TILT DOWN (18)
153 GRY/WHT (16)

158 BLK (16)
24A ORG/GRN (14)

THERMOSTAT WHT (16)
2
41-A DBL/WHT (16)

2PD BLK (14)
AIR FLT SW ORG (18)

ANTISTALL WHT (18)
BLK VLV GND (18)
1
1
3
AC COMP WHT (16)
32 GRY/WHT (16)
4
2AD BLK (12)
HORN
TO X555
12B WHT (12)
1
5
ENG_BULK 4
REGEN WHT (18)
X180
1
2
3
4
5
6
7
8
9
6
10
11
12
HEST WHT (18)
1
2
3
4
5
6
7
8
9
1
1
7
TO ROADLIGHT WORKLIGHT HARNESS (X1097)
10
11
12
B5
B4
B3
B2
B1
B5
B4
B3
B2
B1
C5
C4
C3
C2
C1
C5
C4
C3
C2
C1
A5
A4
A3
A2
A1
A5
A4
A3
A2
A1
2
1
2
1
8
ENG_BULK1_15F
X187
TO HVAC HARNESS (X408)
SHIFTER CONN
ENG_BULK2_15M
IND 2
JOYSTICK
X1009
IND 1
TO WIPER HARNESS (X1012)

POWER SOCKET
HORN
B
C
A
G
H
D
Cab Schematic (85 hp (63 kW), 110 hp (82 kW) if equipped for ULS) 9.5.1
ELECTRICAL SYSTEM SCHEMATICS 9.5
Electrical System
6036, 6042, 8042, 10042, 10054, 12054 31211388 9-8
MAE42190K
F
B
C
A
G
H
1001166036-K
2
1
ENG_BULK3_IF ENGINE DIAGNOSTIC

C
B
A
D
2
1
X1008
X1020
E
C
J
G
F
B
H
D
A
X335
TO X2 ON
FC1002
ENGINE HARNESS
TO BEACON (OPTION)
2KA BLK (18)

(10042 MACHINES)
2KK BLK (18)

RL414-85
2AC BLK (16)
AC2 WHT (16)

RL414-86
2MC BLK (14)
51 WHT/RED (16)
THERMOSTAT WHT (16) RL414

RL414-87
IGN DBL (18)
IGN DBL (18)
PWR RED (16)
HVAC RELAY 1
GND BLK (16)
CANL GRN (18)
52B ORG (12)

CANH YEL (18)
50 WHT/YEL (16)
RL414-30
SEE X1099 & X1100, SHT7-B2)
1 WHT (12) FLOOR HTR PWR RED (16)

1
RL414-87a
2KA BLK (18)
S1034 RL417-85
26 RED (12) AC-1 WHT (16)
160 RED (12)
RL417-86
RL417
RL417-87 HVAC RELAY 2
SPL26 FLOOR HTR PWR RED (16)
RED RELAY 2-30 (12)
RL417-30
26A RED (12)
A RL417-87a
3C RED (10) 2DD BLK (18)
IGNITION SW
B RL454-85
S1074
IGNSW DBL (16) 12 DBL (18)

C RL454-86
12A DBL (12) RL454
D RL454-87 LIGHTS SWITCH
S163 29 RED (12)
E RL454-30
RL454-87a
2CC BLK (18)
RL455-85
114B BLU/ORG (16)
RL455-86 RL455
RL455-87
48 VIO/BLK (16)
RL455-30
47 ORG/WHT (16)
RL455-87a
2AA BLK (18)
RL456-85
10 TAN (16) RL456
28 VIO/WHT (16)
RL456-87
39 RED/GRY (16)
X148
SW604-1 RL456-30
46 WHT/ORG (16) 48 VIO/BLK (16)
1 RL456-87a
2EE BLK (18)
SW604-2 RL617-85
X149
GENERIC
GENERIC
45B DBL/ORG (16) 107B DBL (16)

1 RL617-86 RL617
113B RED (16) PARK BRAKE RELAY
RL617-87
153 GRY/WHT (16)
RL617-30
X149
153A GRY/WHT (16)

RL617-87a
2FF BLK (18)
RL458-85
112A GRY (16)
2
RL458-86 RL458
RL458-87
111A RED (12)
RL458-30
RL458-87a
2BB BLK (18)
RL459-85
102B PNK (16)
RL459-86
31 ORG/RED (16) RL459
RL459-87 BACKUP
24A ORG/GRN (14)
8 RL459-30
2AB BLK (12) S1073
7 RL459-87a
6 RL461-85
5 RL461-86 RL461
155 GRN/RED (16) RELAY 2-87 RED (12)
Go
RELAY 2
4 RL461-87
X1004
154 BLU/WHT (16) RELAY 2-30 RED (12)

3 RL461-30
2 RL461-87a
GND FAULT BLK (18)
1 RL479-85
RL479-86 RL479
RL479-87
RL479-30
RL479-87a
to
2LL BLK (12)
2NN BLK (18)

RL460-85
3D VIO (18)
RL460-86 RL460
159 VIO (12)
S1007
IGNITION
RL460-87
160 RED (12)
RL460-30
RL460-87a
PWR2 RED (16)
FC340-1
10A
DIAGNOSTIC FUSE
PWR RED (16)
FC340-2
IGNA DBL (18)
FC338-1
10A
Di
DIAGNOSTIC FUSE 2
3
IGN DBL (18)

FC338-2
34A RED (16)
5A

34 RED/BLK (16)
FC337-2
GENERIC
FC579-1
2LA BLK (10)
20A
FUSE RELAY BOX
sc
BUSSBAR
2LA BLK (10) 159A VIO (12)

1 FC589-1
15A
HORN / HTR
S1018 ACC MOD GND 4 BLK (12)
52 ORG (12)
FC589-2
2A BLK (10)
1
FC584-1
15A
2MA BLK (10) S1019 2MM BLK (12) 50 WHT/YEL (16)

1
CAB GND STUD
2MC BLK (14) 12 DBL (18)

1 FC580-1
ou
7.5A
S1072

FC588-1
10A
7 BRN (16)
S341

nt
FC583-1
7.5A
8 GRN/WHT (16)
S491

1 FC587-1
10A
11B LGN (16) 46 WHT/ORG (16)

2
9 GRN/BLK (16)
3
4 FC582-1
10A
22 WHT (16)
-E
GENERIC
6
2JJ BLK (16) 159B VIO (14)
7 FC590-1
10A
CAB
4
4
11B LGN (16) 32 GRY/WHT (16)
8 FC590-2
SW615 FC490-1
7.5A

FC490-2
COND POWER RED (12)
FC489-1
20A
COND RED (12) COND

qu
FC489-2
FC488-1
7.5A

FC488-2
27 RED (10)
X330 FC581-1
40A
22 WHT (16) 26 RED (12) MAIN

1 FC581-2
38CH YEL (18)
ip
2
3 FC578-1
20A
2GG BLK (18) S203

4
S202
17 GRY (18) 15A LBL (18)

5 FC702-1
5A
ALTERNATOR
6 FC702-2
AC WHT (16)
7 FC411-1
10A

8 FC411-2
GAUGE CLUSTER
201 BLU (16)
9
154 BLU/WHT (16) 3 RED (8)
10
155 GRN/RED (16) S1017 114A DBL (16)
11 D1-1
12 D1-2
45A DBL/ORG (16)
13 D2-1 DIODE 2
45A2 DBL/ORG (16)
14 D2-2
en
113C RED (16)

D3-1 DIODE 3
113A RED (16)
D3-2
5
5
S164
t.c
S176
X1015 X1013
2MB BLK (14)
1 1
3E RED (14)
2 2
3B VIO (14)
3 3
35 BRN/WHT (16)
4 4 S207
157 BRN (16) 7 BRN (16)
5 5
om
6 6
7 7
152B DBL/ORG (16)
8 8
107C DBL (16) 107A DBL (16)
9 9

107C DBL (16) 107B DBL (16)
10 10
S185
41-A DBL/WHT (16) S331

11 11
12 12
to
S167
S212
or
6
6
S204 ORG/YEL KEY IGN 4 (18)
1 IGN PWR (7-33V)
de
2 GROUND
PARK BK WHT (18)
3 DIGITAL INPUT 0
4 DIGITAL INPUT 1
38H YEL (18) AIR FLT SW ORG (18)
1 5 DIGITAL INPUT 2
6L GRN (18)
2 6 DIGITAL INPUT 3
YEL TILT UP (18)
3 7 PWM OUTPUT 0
S482
(S ACC)
DBL TILT DOWN (18)

8 PWM OUTPUT 1
ANTISTALL WHT (18)
9 PWM OUTPUT 2
ry
10 PWM OUTPUT 3
ENGINE LT WHT (18)
11 PWM OUTPUT 4
BLK GND FAULT (18)
12 PWM OUTPUT 5
107A DBL (16)
CO556-J1
1 ANALOG +5V OUT
1 2 ANALOG INPUT 0
MACHINE CONTROLLER

2 3 ANALOG GROUND
ou
3 4 ANALOG +5V OUT
152B DBL/ORG (16) WHT TILT SIG B (18)
4 5 ANALOG INPUT 1
5 6 ANALOG GROUND
111 RED (12) APS1 WHT (18)
6 7 ANALOG INPUT 2
7 8 N/A
42-B TAN (16)
8 9 CANBUS HIGH
7
7
SW616 10 CANBUS LOW
rp
GRN RX (18)
12 ANALYZER RECEIVE
CO556-J2
S560
S559
S168
ar
S1035
S1010
X557
APS1 WHT (18)
ts
A
12A DBL (12)

GND1 BLK (18)
S568
12AA DBL (12)

B
VCC1 ORG (18)
C
VCC2 ORG (18)
D
GND2 BLK (18)
E
THROTTLE PEDAL
APS2 WHT (18)

F
BLK TILT GND (18)
S194
RED 5 EXC TILT (18)
WHT TILT SIG B (18)

WHT TILT SIG A (18)
2KK BLK (18)

1
SOCKET PWR RED (12)

HEST WHT (18)
GRN RX (18)
REGEN WHT (18)

2
BLK SOCKET GND (12)

WHT TX (18)
KEY IGN1 ORG (18)

KEY IGN2 ORG (18)
ENGINE LT WHT (18)

3
4
ANALYZER
JOYSTICK
4
3
2
1
JS612
2PB BLK (12)

2PC BLK (12)
52A ORG (12)

AC2 WHT (16)
AC3 WHT (16)
AC-2 WHT (16)
COND RED (12)

8
8
CLUTCH RED (12)
7
6
5
4
3
2
1
AC COMP WHT (16)

YEL TILT UP (18)
X570
X569
MS571
6 GRN (18)
15 LBL (18)
38 YEL (18)
2
1
1
10 TAN (16)
17 GRY (18)
18 GRN (18)
1B
1B
1A
104 YEL (16)

150 VIO (16)
104 YEL (16)
150 VIO (16)
2B
1A
2A
158 BLK (16)

2B
2A
103 DBL (16)

103 DBL (16)
201 BLU (16)
113 RED (16)

112 GRY (16)
102 PNK (16)
101 BRN (16)
101 BRN (16)
27C RED (12)
105 GRN (16)

105 GRN (16)
DBL TILT DOWN (18)
27D RED (12)

THERMOSTAT WHT (16)
102A PNK (16)

2
2PD BLK (14)

9 GRN/BLK (16)
34 RED/BLK (16)
40 BRN/BLK (16)
8 GRN/WHT (16)
BLK VLV GND (18)
28 VIO/WHT (16)
31 ORG/RED (16)
35 BRN/WHT (16)
47 ORG/WHT (16)
1
1
3
106 BLU/ORG (12)
153 GRY/WHT (16)

24A ORG/GRN (14)
41-A DBL/WHT (16)
AC COMP WHT (16)
32 GRY/WHT (16)
AIR FLT SW ORG (18)

ANTISTALL WHT (18)
4
2AD BLK (12)

TO X555
12B DBL (12)

5
ENG_BULK 4
REGEN WHT (18)
X180
1
2
3
4
5
6
7
8
9
6

10
11
12
HEST WHT (18)
1
2
3
4
5
6
7
8
9
1
7
10
11
12
B5
B4
B3
B2
B1
B5
B4
B3
B2
B1
C5
C4
C3
C2
C1
C5
C4
C3
C2
C1
A5
A4
A3
A2
A1
A5
A4
A3
A2
A1
2
1
2
1
8
ENG_BULK1_15F
ENG_BULK2_15M
X187
IND 2
SHIFTER CONN
X1009
HORN GENERIC
IND 1

GENERIC
POWER SOCKET
F
B
C
A
G
H
D
Cab Schematic (85 hp (63 kW), 110 hp (82 kW) if equipped for LS) 9.5.2
Electrical System
9-9 31211388 6036, 6042, 8042, 10042, 10054, 12054
MAE42200H
F
B
C
A
G
H
1001199887-H
2
1
ENG_BULK3_IF ENGINE DIAGNOSTIC

C
B
A
D
2
1
X1008
X1020
E
C
J
G
F
B
H
D
A
X335
TO X2 ON
FC1002
TO BEACON (OPTION)
2KA BLK (18)

(10042 MACHINES)
ENGINE HARNESS
2KK BLK (18)

RL414-85
2AC BLK (16)
SEE X1099 & X1100, SHT7-B2)
AC2 WHT (16)

RL414-86
51 WHT/RED (16)
THERMOSTAT WHT (16)

IGN DBL (18)
IGN DBL (18)
RL414
2MC BLK (14)
GND BLK (16)
PWR RED (16)
RL414-87
CANH YEL (18)
HVAC RELAY 1
CANL GRN (18)
52B ORG (12)

50 WHT/YEL (16)
RL414-30
1 WHT (12) FLOOR HTR PWR RED (16)

1
RL414-87a
2KA BLK (18)
S1034 RL417-85
26 RED (12) AC-1 WHT (16)
160 RED (12)
RL417-86
RL417
RL417-87 HVAC RELAY 2
SPL26 FLOOR HTR PWR RED (16)
RED RELAY 2-30 (12)
RL417-30
26A RED (12)
A RL417-87a
3C RED (10) 2DD BLK (18)
IGNITION SW
B RL454-85
S1074
IGNSW DBL (16) 12 DBL (18)

C RL454-86
12A DBL (12) RL454
D RL454-87 LIGHTS SWITCH
S163 29 RED (12)
E RL454-30
RL454-87a
2CC BLK (18)
RL455-85
114B BLU/ORG (16)
RL455-86 RL455
RL455-87
48 VIO/BLK (16)
RL455-30
47 ORG/WHT (16)
RL455-87a
2AA BLK (18)
RL456-85
10 TAN (16) RL456
28 VIO/WHT (16)
RL456-87
39 RED/GRY (16)
SW604-1 RL456-30
46 WHT/ORG (16) 48 VIO/BLK (16)
1 RL456-87a
2EE BLK (18)
SW604-2 RL617-85
GENERIC
GENERIC
45B DBL/ORG (16) 107B DBL (16)

1 RL617-86 RL617
113B RED (16)
BRAKE PEDAL SW
PARK BRAKE RELAY

RL617-87
153 GRY/WHT (16)
RL617-30
153A GRY/WHT (16)
RL617-87a
2FF BLK (18)
RL458-85
112A GRY (16)
2
RL458-86 RL458
RL458-87
111A RED (12)
RL458-30
RL458-87a
2BB BLK (18)
RL459-85
102B PNK (16)
RL459-86
31 ORG/RED (16) RL459
RL459-87 BACKUP
24A ORG/GRN (14)
8 RL459-30
2AB BLK (12) S1073
7 RL459-87a
6 RL461-85
5 RL461-86 RL461
155 GRN/RED (16) RELAY 2-87 RED (12) RELAY 2
4 RL461-87
X1004
154 BLU/WHT (16) RELAY 2-30 RED (12)

3 RL461-30
2 RL461-87a
GND FAULT BLK (18)
Go
1 RL479-85
RL479-86
RL479
RL479-87
RL479-30
RL479-87a
2NN BLK (18)
RL460-85
3D VIO (18)
RL460-86 RL460
159 VIO (12)
S1007
IGNITION
RL460-87
to
160 RED (12)

RL460-30
RL460-87a
PWR2 RED (16)
FC340-1
10A
DIAGNOSTIC FUSE
PWR RED (16)
FC340-2
S1018
IGNA DBL (18)

FC338-1
10A
DIAGNOSTIC FUSE 2
3
3
IGN DBL (18)
FC338-2
34A RED (16)
5A

34 RED/BLK (16)
Di
FC337-2
GENERIC
FC579-1
20A
FUSE RELAY BOX
BUSSBAR
2LA BLK (10) 159A VIO (12)

1 FC589-1
15A
52 ORG (12) HORN / HTR

FC589-2
sc
2A BLK (10)
1
FC584-1
15A
2MA BLK (10) S1019 50 WHT/YEL (16)

1
CAB GND STUD

12 DBL (18)

1 FC580-1
7.5A
S1072
ou

FC588-1
10A
7 BRN (16)
S341
S491

FC583-1
7.5A
8 GRN/WHT (16)
nt

1 FC587-1
10A
11B LGN (16) 46 WHT/ORG (16)

2
9 GRN/BLK (16)
3
4 FC582-1
10A
22 WHT (16)
5
GENERIC
6
-E
2JJ BLK (16) 159B VIO (14)

7 FC590-1
15A
CAB
4
4
11B LGN (16) 32 GRY/WHT (16)
8 FC590-2
SW615 FC490-1
7.5A

FC490-2
COND POWER RED (12)
FC489-1
7.5A
COND RED (12) COND

FC489-2
qu
FC488-1
7.5A

FC488-2
27 RED (10)
X330 FC581-1
40A
22 WHT (16) 26 RED (12) MAIN

1 FC581-2
38CH YEL (18)
2
ip
3 FC578-1
40A
2GG BLK (18) S203

4
S202
17 GRY (18) 15A LBL (18)
5 FC702-1
5A
ALTERNATOR
6 FC702-2
AC WHT (16)
7 FC411-1
10A

m
8 FC411-2
GAUGE CLUSTER
201 BLU (16)
9
154 BLU/WHT (16) 3 RED (8)
10
155 GRN/RED (16) S1017 114A DBL (16)
11 D1-1
12 D1-2
45A DBL/ORG (16)
13 D2-1 DIODE 2
45A2 DBL/ORG (16)
14 D2-2
en
113C RED (16)

D3-1 DIODE 3
113A RED (16)
D3-2
5
5
S164
t.c
S176
X1015 X1013
2MB BLK (14)
1 1
3E RED (14)
2 2
3B VIO (14)
3 3
35 BRN/WHT (16)
4 4 S207
157 BRN (16)
om
7 BRN (16)
5 5
6 6
7 7
8 8
107C DBL (16) 107A DBL (16)
9 9

107C DBL (16) 107B DBL (16)
10 10
S185
41-A DBL/WHT (16) S331

11 11
to
12 12
S167
S212
or
6
6
S204
de
ORG/YEL KEY IGN 4 (18)
1 IGN PWR (7-33V)
r
2 GROUND
PARK BK WHT (18)
3 DIGITAL INPUT 0
4 DIGITAL INPUT 1
38H YEL (18)
1 5 DIGITAL INPUT 2
6L GRN (18)
2 6 DIGITAL INPUT 3
YEL TILT UP (18)
3 7 PWM OUTPUT 0
S482
(S ACC)
DBL TILT DOWN (18)

8 PWM OUTPUT 1
ANTISTALL WHT (18)
9 PWM OUTPUT 2
COLNT VLV WHT (18)
10 PWM OUTPUT 3
yo
ENGINE LT WHT (18)
11 PWM OUTPUT 4
BLK GND FAULT (18)
12 PWM OUTPUT 5
107A DBL (16)
CO556-J1
1 ANALOG +5V OUT
1 2 ANALOG INPUT 0
MACHINE CONTROLLER
ur
2 3 ANALOG GROUND
3 4 ANALOG +5V OUT
WHT TILT SIG B (18)
4 5 ANALOG INPUT 1
5 6 ANALOG GROUND
111 RED (12) APS1 WHT (18)
6 7 ANALOG INPUT 2
7 8 N/A
42-B TAN (16) YEL CAN HIGH (18)
7
8
7
9 CANBUS HIGH
GRN CAN LOW (18)
SW616 10 CANBUS LOW
pa
GRN RX (18)
12 ANALYZER RECEIVE
CO556-J2
S560
S559
S168
COLNT VLV WHT (18)
1 Future use
S1035
S1010
rts
X561
X557
APS1 WHT (18)
A
GND1 BLK (18)
S568
B
VCC1 ORG (18)
C
VCC2 ORG (18)
D
GND2 BLK (18)
E
THROTTLE PEDAL
APS2 WHT (18)

F
BLK TILT GND (18)
S194
RED 5 EXC TILT (18)
WHT TILT SIG B (18)

WHT TILT SIG A (18)
2KK BLK (18)

1
GRN RX (18)
HEST WHT (18)

2
REGEN WHT (18)
SOCKET PWR RED (12)

BLK SOCKET GND (12)
WHT TX (18)
KEY IGN1 ORG (18)

KEY IGN2 ORG (18)
3
ENGINE LT WHT (18)

4
ANALYZER
JOYSTICK
4
3
2
1
JS612
2PB BLK (12)

2PC BLK (12)
52A ORG (12)

AC2 WHT (16)
AC3 WHT (16)
AC-2 WHT (16)
COND RED (12)

8
8
CLUTCH RED (12)
7
6
5
4
3
2
1
AC COMP WHT (16)

YEL TILT UP (18)
X570
X569
MS571
2
1
1
1B
1B
1A
2B
1A
2A
2B
2A
DBL TILT DOWN (18)
6 GRN (18)
THERMOSTAT WHT (16)
15 LBL (18)
38 YEL (18)
10 TAN (16)
17 GRY (18)
2
18 GRN (18)
2PD BLK (14)
104 YEL (16)

150 VIO (16)
104 YEL (16)
150 VIO (16)
158 BLK (16)
103 DBL (16)

103 DBL (16)
201 BLU (16)
113 RED (16)

112 GRY (16)
102 PNK (16)
101 BRN (16)
101 BRN (16)
27C RED (12)
105 GRN (16)

105 GRN (16)
27D RED (12)
BLK VLV GND (18)
102A PNK (16)

1
1
3
9 GRN/BLK (16)
34 RED/BLK (16)
40 BRN/BLK (16)
32 GRY/WHT (16)
8 GRN/WHT (16)
28 VIO/WHT (16)
AC COMP WHT (16)
31 ORG/RED (16)
35 BRN/WHT (16)
KEY IGN ORG (16)

47 ORG/WHT (16)
106 BLU/ORG (12)

4
12B DBL (12)
153 GRY/WHT (16)

24A ORG/GRN (14)
2AD BLK (12)
41-A DBL/WHT (16)
ANTISTALL WHT (18)

TO X555
5
ENG_BULK 4
REGEN WHT (18)
X180
1
2
3
4
5
6
7
8
9
6

10
11
12
HEST WHT (18)
1
2
3
4
5
6
7
8
9
1
7
10
11
12
B5
B4
B3
B2
B1
B5
B4
B3
B2
B1
C5
C4
C3
C2
C1
C5
C4
C3
C2
C1
A5
A4
A3
A2
A1
A5
A4
A3
A2
A1
2
1
2
1
8
ENG_BULK1_15F
ENG_BULK2_15M
X187
IND 2
SHIFTER CONN GENERIC
X1009
HORN
IND 1

GENERIC
POWER SOCKET
F
B
C
A
G
H
D
Cab Schematic (74 hp (55 kW) if equipped) 9.5.3
Electrical System
9-10
9.5.4
1 2 3 4 5 6 7 8
NSF = 30A
BOOM ANGLE BOOM EXTEND SF = 30A
GRID HTR RLY ENGINE
STEER MODE VALVE STABILTRAK VALVES START RELAY
ENGINE
SFV TELEMATICS
M
STM_CR STM_4 ALTERNATOR
1
2
3
4
X1087
250A BUSSBAR
87
30
86
85
BACK UP ALARM
12B-2F
12A-2F
4A-2F
4B-2F
H H
LOCK_2F
TO LOGIC HARNESS
X462
TRANS TEMP SW
TRANS GND
A
B
B
A
B
A
1
1
A
B
A
B
A
B
B
A
A
B
A
B
A
B
A
B
C
B
A
A
B
C
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
X4
X325
HV111
SN112
AH330
EC291
X52
X54
X55
X56
X53
T316
X324
T312
T298
T299
X602
EC302
EC291-B-
RL478
EC291-B+
HV313
C
A
RL109-85
RL109-87
RL109-30
RL109-86
RL478-B+
2U BLK (18)
23 ORG (16)
24A BLK (16)

5 YEL/RED (18)
RL478_2
49 RED (16)
8 GRN (16)
41 WHT (16)
5 YEL (16)
161 RED (10)
2M BLK (18)
2E BLK (18)
2L BLK (18)
18 GRN (16)
2X BLK (16)
2B BLK (16)
2T BLK (16)
2C BLK (16)
47A WHT (18)
2G BLK (16)
2N BLK (18)
2P BLK (18)
158 WHT (16)
9 GRN (16)
BUSSBAR
31 ORG (16)
28B WHT (18)

28A WHT (18)
47B WHT (18)

STRT ORG (16)
161 RED (10)
2Y BLK (16)
40 BLK (18)
35 BRN (16)
10 TAN (16)
GRID HTR PWR RED (2)
ALT PWR RED (4)
EXTEND/RETRACT PWR RED (12)
HARNESS
ALT PWR RED (4)
HTR PWR RED (2)

HTR PWR RED (2)
STRT GND BLK (2/0)
BAT POS RED (10)
BLACK WIRE BLK (16)

WHITE WIRE WHT (16)
GREEN WIRE GRN (16)

BOOM EXTEND
STRT PWR RED (2/0)
5A
S 28
EXTEND/RETRACT PWR RED (12)
IAH REL SIG WHT (18)

OUTPUT RTN 2 BLK (18)
IP1088
X74
Go
40 BLK (18) S 20D 120 OHM
X601
A1
A
B
C
41 WHT (16) IP1062
A2
A
B
C
47 ORG (16) 200A
S1076
A3
A4 S 47 S1067
158 WHT (16)
A5 6
SN113
18 GRN (16)
G B1 5 G
24A BLK (16)
B2 4
28 WHT (16) 104B(S1) YEL (18)
B3 1
to
49 RED (16)
Electrical System
23 ORG (16)
35 BRN (16) S 104 12OB(S2) PNK (18)
B4 2
2R BLK (16)
38 YEL (16) 103B(S3) BLU (18)
B5 IP1069 3
6 GRN (16) 2J BLK (18)
C1 7
ENG_BULK1_15M
8 GRN (16) GND
C2 X300
9 GRN (16)
C3
UPPER
10 TAN (16)
C4 3
ANTISTALL WHT (16) S 102
C5 2
S 103
1
105B(S5) GRN (18)
4
101B(S5) BRN (18)
5
Di
S 101 150B(S6) VIO (18)
TRANSMISSION
S 20B 6
ANTISTALL WHT (16) 2H BLK (18)
LOWER
GND
S1068
1 7
ANTISTAL GND BLK (16)
2 X301
S 20
S 20A
HV551 S 105
S 150
ANTISTALL
sc
150A(S6) VIO (18)
A
105A(S4) GRN (16)
B
104A YEL (16)
C
2A BLK (16)
FUEL SENDER 1 D
VP2
F 1 T88 E F
2D BLK (16)
2 17 GRY (16) F
1
SN574 D304
ou
T87
103A BLU (16)
A
101A BRN (16)
B

Eliminated X327 (wire151) - 102 PNK (16)
C
VP1
D
Hydraulic Temp Switch E
2DD BLK (16)
F
nt
X73 D305
5 YEL (16)
A1 T351
17 GRY (16) BLOCK GND BLK (10)
A2 1 ENG BLOCK
A3 CASE GND BLK (10)
27C RED (12) T284 GND
A4
-E
ECM GND 5 BLK (12)
31 ORG (16) 1
A5
34 ORG (18)
B1
106 DBL (12)
B2 1 T58
150(S6) VIO (16)
B3 S1071 FRAME GND BLK (2/0)
ELEVATE IDLE YEL (16) 1
B4
27D RED (12) FRAME GND BLK (2/0) FRAME GND
B5 1
101(S5) BRN (16)
C1
qu
E 102(S2) PNK (16) E
C2 STRT GND BLK (2/0)
ENG_BULK2_15F
103(S3) BLU (16) 1
C3
104(S1) YEL (16) BLOCK GND BLK (10)
C4 1 1
105(S4) GRN (16)
C5 T352 BT512-
ip
S445
RED ECM BATT -
12V BATTERY
HV550 SENS RET WHT (18) 1

VLV GND BLK (16) 4 4
2 CIT WHT (18) BT512+
TILT UP YEL (16) 3 3
TILT UP
1 5V SUP WHT (18) STRT PWR RED (2/0)
2 2
m 1
34 ORG (18)
AAP WHT (18)
1 1
X346 X347
TBAP SENSOR S RTN
27D RED (12)
HV549 1 T61
VLV GND BLK (16) 27F RED (12)
TILT VALVES
2
S520
TILT DOWN VIO (16) 27B RED (12) 60A
1 1 T1036
TILT DOWN
27C RED (12)
1
160 RED (12) PFM
T328
31211388
AC COMP WHT (16) 60A
1 T444
en
RELAY2-30 RED (12)
PWR BUSS
X442 1
N/A
8 1
D HEST WHT (18) DEF SM SNSR 5V WHT (18) D
7 2
REGEN WHT (18) DEF PRESS SNSR SIG WHT (18)
6 3
DEF PRES SNSR RET WHT (18)
5 4
AC COMP WHT (16) SM HR WHT (16)
4 5
VLV GND BLK (16) BAT NEG BLK (18)
3 6
t.c
TILT DOWN VIO (16) N/A
2 7
TILT UP YEL (16) DEF PUMP RET WHT (18)
1 8
TO CAB HARNESS
DEF PUMP SPLY WHT (18)
X555 9
DEF SM TEMP WHT (18)
10
SUPPLY MODULE
DEF VLV SIG WHT (18)

11
EC292 DEF VLV RET WHT (18)
12
COLNT LVL RTN BLK (18)
om
C X495
COLNT LVL SIG WHT (18)
B
COLNT LVL SPLY ORG (18)
A
S527 S2
COOLANT LEVEL
27B RED (12)
4
S1 27F RED (12)
3
RELAY2-30 RED (12)
2
DEF QUALITY KEY IGN ORG (18) S528 160 RED (12)
4 1
S501
BAT NEG BLK (18)

3 X2
/LEVEL CAN4 HI YEL (18) S1057
2 S511
to
S507
C CAN4 LO GRN (18) S1056 CAN4 LO GRN (18) C

TO CAB HARNESS
1
ENG_BULK3_IN
/TEMP S510
X519
BAT NEG BLK (18) S509

4
CAN4 HI YEL (18)
3 S525
SCR NOx CAN 4 LO GRN (18)
2
KEY IGN ORG (18)
1
X522
S502
S499
KEY IGN ORG (18)

or
4
CAN4 HI YEL (18)
3
SCR TEMP CAN 4 LO GRN (18)
2
BAT NEG BLK (18)
1
X523
S526
S 117
S GND
BAT NEG BLK (18)
de
WHT DEDF HTR CRT MNTR -
HTR DIAG 1 WHT (16)
HTR DIAG 2 WHT (16)
DEF HTR3 SUCT WHT (16)
4
CAN4 HI YEL (18)
3
CAN 4 LO GRN (18)
DRT NOx 2
KEY IGN ORG (18)
1
r
S508
X524
3
1
2
1
2
1
2
EC513
EC514
EC515
DEF TANK H VLV

DEF HTR REL WHT (16)
106 DBL (12)
B 2 B
HTR PWR RED (10)
HTR PWR RED (16)
BAT POS RED (10)
HEATER RED (16)
HEATER RED (16)
DEF SM HTR RLY WHT (16)
SM HR WHT (16)
HEATER RED (16)
HTR PWR RED (16)
HTR DIAG WHT (16)
HTR PWR RED (16)
HTR PWR RED (16)
HTR DIAG WHT (16)
HTR PWR RED (16)
HTR PWR RED (16)
HTR PWR RED (16)
STRT LKO REL WHT (18)
STRT ORG (16)
DEF VLV RET WHT (18)

4
DEF TANK H VLV WHT (18)
1
EC516
RED ECM BATT -
DEF DOS INJ VLV

ECM BATT RED (12)
X554
3
4
8
1
2
9
6
DEF DOS VLV HI WHT (18)

yo
46
42
45
41
24
15
16
23
20
12
11
34
25
26
33
30
22
13
14
21
18
10
1
DEF DOS VLV LO WHT (18)
2
EC517 85 86 87 30 87a 85 86 87 30 87a 85 86 87 30 87a 85 86 87 30 87a 85 86 87 30 87a
WIF RET WHT (18)

B
A
2
FC1070
F2 F1
WIF SENSOR WIF SIG WHT (18)
1
X349 R5 R4 R3 R2 R1
30A FUSE RELAY MODULE

S518
X1055
ur
ECM PWR
CAN TERMINATION C
Chassis - Engine Schematic (85 hp (63 kW), 110 hp (82 kW) if equipped for ULS)
B CAN4 LO GRN (18)

A CAN4 HI YEL (18)
34 ORG (18)
CAN4 LO GRN (18)

STRT LKO REL WHT (18)
IAH REL RTN WHT (18)
23
WIF RET WHT (18)
COLNT LVL SIG WHT (18)
REGEN WHT (18)

BAT POS 5 RED (16)
DEF DOS VLV LO WHT (18)
DEF PUMP RET WHT (18)
BAT NEG 5 BLK (16)
DEF DOS VLV HI WHT (18)
DEF PUMP SPLY WHT (18)
DEF VLV SIG WHT (18)
DEF TANK H VLV WHT (18)
HEST WHT (18)
COLNT LVL RTN BLK (18)

24 WAY OEM CAN4 HI YEL (18)
BAT NEG 2 BLK (16)
BAT POS 2 RED (16)
BAT POS 1 RED (16)

CASE GND BLK (10)
BAT POS 4 RED (16)

22
BAT POS 3 RED (16)

ELEVATE IDLE YEL (16)
BAT NEG 3 BLK (16)
BAT NEG 1 BLK (16)

BAT NEG 4 BLK (16)
CAN1 H YEL (18)

DEF VLV RET WHT (18)
DEF PRES SNSR RET WHT (18)
CAN1 LO GRN (18)

pa
X548
DEF SM TEMP WHT (18)

DEF SM SNSR 5V WHT (18)
COLNT LVL SPLY ORG (18)
WIF SIG WHT (18)
DEF PRESS SNSR SIG WHT (18)

DEF SM HTR RLY WHT (16)
DEF HTR1 PRESS WHT (18)
DEF HTR2 BFL WHT (18)
DEF HTER CRT MNTR WHT (18)
DEF HTR CRT MNTR WHT (18)
A A
X44
T350
X329
1
2
3
4
5
6
7
8
9
1
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
CAN TERMINATION C
CANL1 GRN (18)
B ECM CASE GND
CANH1 YEL (18)
A
CM2350 96 PIN CONN (J2)
KEY IGN
KEY IGN
rts
1001166035-I
1 2 3 4 5 6 7 8
MAQ1600I
6036, 6042, 8042, 10042, 10054, 12054

1 2 3 4 5 6
NSF = 30A
7 8 9.5.5
STARTER
BOOM ANGLE BOOM EXTEND SF = 30A
GRID HTR GRID HTR RLY ENGINE
STEER MODE VALVE STABILTRAK VALVES START RELAY
ENGINE
SFV
M
STM_CR STM_4
ALTERNATOR
TELEMATICS
BE_3F
1
2
3
4
250A BUSSBAR
BOOM_3F
87
30
86
85
BACK UP ALARM
12B-2F
12A-2F
4A-2F
4B-2F
X1093
LOCK_2F
TO LOGIC HARNESS
X462
TRANS TEMP SW
TRANS GND
A
B
B
A
B
A
1
1
A
B
A
B
A
B
B
A
A
B
A
B
A
B
A
B
C
B
A
A
B
C
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
H H
X4
X325
AH330
X52
X54
X55
X56
X53
T316
T319
X324
T312
T298
T299
X602
EC302
RL478
EC291-B+
HV313
HV111
SN112
EC291
RL478-Y
RL109-85
RL109-87
RL109-30
RL109-86
EC291-B-
RL478-B+
C
A RL478-R
49 RED (16)
RL478_2
23 ORN (16)
5 YEL (16)
Go
2U BLK (18)
9 GRN (16)
8 GRN (16)
161 RED (10)
2B BLK (16)
40 BLK (16)
2L BLK (16)
2P BLK (16)
2C BLK (16)
2K BLK (16)
2E BLK (16)
2G BLK (16)
BUSSBAR
2N BLK (16)
18 GRN (16)
2M BLK (16)
5 YEL/RED (18)
41 WHT (16)
47B BLK (16)
47A BLK (16)

2Y BLK (16)
28B BLK (16)

28A BLK (16)
2T BLK (16)
2X BLK (16)
10 TAN (16)
ALT PWR RED (4)
35 BRN (16)
31 ORN (16)
24A BLK (16)

158 WHT (16)
BATT POS BLK (14)
ALT PWR RED (4)
HTR PWR RED (2)

HTR PWR RED (2)
HARNESS
STRT GND BLK (Feb-00)
161 RED (10)

STRT PWR RED (Feb-00)
BLACK WIRE BLK (16)

STRT (87A) ORG (16)
WHITE WIRE WHT (16)
GREEN WIRE GRN (16)

BOOM EXTEND
S 28
BATT POS RED (10)
X74 S1102
to
40 BLK (16) 2K BLK (16) S 20D 5 YEL (16) 120 OHM 5 YEL (16)
X601
A1
A
B
C
41 WHT (16) 2AA ORN (16) IP1062
A2
A
B
C
47 ORN (16) 200A
A3
201 BLU LRC ENABLE (16)
A4 S 47 6
SN113
158 WHT (16) S1067 S1068
A5 5
18 GRN (16)
B1 4
24A BLK (16) 104B(S1) YEL (18)
B2 5A 1
G 28 WHT (16) 12OB(S2) PNK (18) G
B3 2
49 RED (16)
IP1069
23 ORN (16)
35 BRN (16) IP1094 103B(S3) BLU (18)
B4 3
6036, 6042, 8042, 10042, 10054, 12054

2R BLK (16)
38 YEL (16) 2J BLK (18)
B5 7
Di
6 GRN (16) S 104
C1 X300
8 GRN (16)
C2
9 GRN (16)
ENG_BULK1_15M
C3
10 TAN (16)
C4 3
UPPER
20D BLK (12)

ANTISTALL WHT (16) S 102
sc
C5 2
S 103
1
105B(S5) GRN (18)
4

Manual de Serviço - Skytrak

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Manual de Serviço - Skytrak

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Service Manual

January 21, 2020 - Rev A

An Oshkosh Corporation Company

DATE REVISION DESCRIPTION

6036, 6042, 8042, 10042, 10054, 12054 31211388 i

XXXhp (XXkW) @ XXXX RPM 2

ii 31211388 6036, 6042, 8042, 10042, 10054, 12054

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

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

3.5 Boom System - Four Section (10054 & 12054). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3.6 Boom Assembly Maintenance (10054 & 12054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3.7 Boom Extend and Retract Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

3.9 Quick Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

3.10 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

Cab ....................................................................... 4-1

6036, 6042, 8042, 10042, 10054, 12054 31211388 I

7.4 Engine Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

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

7.7 Engine Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

7.10 Isolation Coupler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

Hydraulic Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

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

8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

8.5 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

II 31211388 6036, 6042, 8042, 10042, 10054, 12054

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

10.1 Stabil-TRAK™ System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

10.3 Stabil-TRAK™ Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5

10.4 Stabil-TRAK™ Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

10.7 Stabil-TRAK™ System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12

10.8 Stabil-TRAK™ Electrical Circuit Operation and Troubleshooting (6042/8042/10042) . . . . . . . . . 10-15

Troubleshooting (10054 & 12054) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19

10.10 Boom/Outrigger Interlock System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24

6036, 6042, 8042, 10042, 10054, 12054 31211388 III

PARAGRAPH TITLE PAGE

6036, 6042, 8042, 10042, 10054, 12054 31211388 1-1

1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS

Supplementary information is available from JLG in the form

of Service Bulletins, Service Campaigns, Service Training

Schools, the manufacturer website, other literature, and

1.2 DISCLAIMER WARNING indicates a potentially hazardous situation which,

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

information available at the time of publication. The

manufacturer reserves the right to make changes and

improvements to its products, and to discontinue the

1.3 OPERATION & SAFETY MANUAL

1-2 31211388 6036, 6042, 8042, 10042, 10054, 12054

1.6 SAFETY INSTRUCTIONS 1.6.3 General Hazards

equipment could fall or tip.

equipment. Always support equipment with the proper

capacity blocks or stands properly rated for the load.

service tools only as recommended.

6036, 6042, 8042, 10042, 10054, 12054 31211388 1-3

unless specific training has been completed. Refer to the

engine manufacturers’ manual for specific details

before jump-starting or connecting a battery charger.

residual pressure before removing any part or component.

machine. Refer to the Operation & Safety Manual supplied

proper torque. Capture fluid in an appropriate container and

dispose of in accordance with prevailing environmental