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Skytrak 6036 Service Manual

Skytrak 6036
418 pages
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An Oshkosh Corporation Company
Service Manual
Models
6036, 6042, 8042,
10042 & 10054
SN 0160069719 to Present
including 0160065791, 0160065792, 0160065796,
0160065798, 0160065824, 0160065825,
0160065826, 0160069336, 0160069359,
0160069383, 0160069411, 0160069441,
0160069566, 0160069567 & 0160069568
31211015
Revised
July 31, 2017

Table of Contents

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Skytrak 6036 Specifications

General IconGeneral
Power SourceDiesel
Maximum Lift Capacity6, 000 lbs
Maximum Lift Height36 ft
Engine Power74 hp
Dimensions8 ft

Summary

Section 1 Safety Practices

1.1 Introduction

Provides general directions for service and repair procedures, emphasizing safety and reliability.

1.2 Disclaimer

States that the manual is based on the latest product information and reserves the right to make changes without notice.

1.3 Operation & Safety Manual

Outlines the requirement for mechanics to read and understand the Operation & Safety Manual before operating the machine.

1.4 Do Not Operate Tags

Instructs on the proper use of "Do Not Operate" tags and key removal before maintenance.

1.5 Safety Information

Emphasizes compliance with all safety messages and preparedness for accidents, including first-aid and emergency contacts.

1.5.1 Safety Alert System and Signal Words

Explains the meaning of DANGER, WARNING, and CAUTION signal words used in safety messages.

1.6 Safety Instructions

Provides general safety statements to consider before performing maintenance procedures on the telehandler.

1.6.1 Personal Hazards

Covers the importance of wearing appropriate personal safety gear for the job.

1.6.2 Equipment Hazards

Details hazards related to lifting equipment, supporting loads, and using hand tools.

1.6.3 General Hazards

Covers general safety practices related to solvents, housekeeping, first aid, and cleanliness.

1.6.4 Operational Hazards

Outlines hazards related to engine operation, fluid temperatures, pressure, and tire inflation.

1.7 Safety Decals

Advises checking that all safety decals are present and readable on the machine.

Section 2 General Information and Specifications

2.1 Replacement Parts and Warranty Information

Details on ordering replacement parts and information regarding warranty registration and claims.

2.2 Specifications

Provides technical data for the machine, including travel speeds and hydraulic cylinder performance.

2.2.1 Travel Speeds

Lists the travel speeds for each transmission gear for different models.

2.2.2 Hydraulic Cylinder Performance

Details the approximate times for various hydraulic cylinder functions.

2.2.3 Electrical System

Provides specifications for the machine's electrical system, including battery details.

2.2.4 Engine Performance Specifications

Lists engine specifications for different configurations, including horsepower and torque.

2.2.5 Tires

Specifies tire sizes, types, ply ratings, fill types, and pressures for various models.

2.3 Fluid Specifications

Lists recommended fluids and lubricants for various compartments and systems, including ambient temperature ranges.

2.4 Fluid and Lubricant Capacities

Provides capacities for engine oil, fuel tank, cooling system, hydraulic system, and transmission.

2.5 Service and Maintenance Schedules

Outlines maintenance tasks based on operating hours or time intervals.

2.6 Lubrication Schedules

Details lubrication points and intervals for different service hours.

2.7 Thread Locking Compound

Lists JLG part numbers, Loctite equivalents, and ND Industries descriptions for thread locking compounds.

2.8 Torque Charts

Provides torque values for SAE and Metric fasteners, considering different materials and coatings.

Section 9 Electrical System

9.1 Electrical Component Terminology

Defines common electrical components referred to in the section.

9.2 Specifications

References electrical system specifications found in Section 2.

9.3 Safety Information

Provides critical safety precautions for working with electrical systems.

9.4 Fuses and Relays

Details the location and circuits for fuses and relays in the engine compartment and cab harness.

9.4.1 Engine Compartment Fuse and Relays

Identifies fuses and relays located in the engine compartment's protective case.

9.4.2 Cab Harness Fuses and Relays

Lists fuses and relays associated with the cab harness for different models.

9.5 Electrical System Schematics

Provides diagrams of the machine's electrical systems for various configurations and options.

9.5.1 Cab Schematic

Electrical schematic specific to the operator's cab.

9.5.2 Chassis - Engine Schematic (85 hp (63 kW), 110 hp (82 kW) if equipped for ULS)

Electrical schematic for the chassis and engine, covering specific horsepower and ULS configurations.

9.5.3 Chassis - Engine Schematic (85 hp (63 kW), 110 hp (82 kW) if equipped for LS)

Electrical schematic for the chassis and engine, covering specific horsepower and LS configurations.

9.5.4 Chassis - Engine Schematic (74 hp (55 kW) if equipped)

Electrical schematic for the chassis and engine, covering the 74 hp (55 kW) configuration.

9.5.5 Cab O/R Option Schematic (10042 only)

Electrical schematic for the Cab O/R option specific to Model 10042.

9.5.6 Cab O/R Option Schematic (10054 only)

Electrical schematic for the Cab O/R option specific to Model 10054.

9.5.7 HVAC Option Schematic

Electrical schematic for the HVAC option.

9.5.8 Road Light Option Schematic

Electrical schematic for the road lighting option.

9.5.9 Worklights/Beacon Option Schematic

Electrical schematic for the worklights and beacon option.

9.5.10 Telematics Option

Electrical schematic for the telematics option.

9.6 Dielectric Grease Application

Explains the purpose and method for applying dielectric grease to electrical connectors.

9.7 Engine Start Circuit

Covers the starter motor, circuit checks, and removal/installation procedures.

9.8 Battery

Provides information on battery inspection, removal, installation, and disconnection/connection.

9.9 Charging Circuit

Details checks for the charging system, including battery cable connections and alternator.

9.10 Window Wiper/Washer Windshield Wiper Motor

Covers removal, disassembly, inspection, installation, and testing of the windshield wiper motor.

9.11 Cab Heater and Fan

Explains the removal and installation of cab heater controls and the heater/AC system.

9.12 Solenoids, Sensors and Senders

Lists and describes various solenoids, sensors, and senders used in the machine's systems.

9.12.1 Coolant Level Sensor

Details the removal, disassembly, and installation of the coolant level sensor.

9.12.2 Transmission Solenoid Valves

Explains how to check transmission solenoid valves for proper function and potential issues.

9.12.3 Transmission Temperature Sender

Covers the removal, inspection, installation, and testing of the transmission temperature sender.

9.12.4 Service Brake Switch

Provides procedures for removing, installing, and adjusting the service brake switch.

9.12.5 Boom Angle Sensor

Details the removal, disassembly, installation, and testing of the boom angle sensor.

9.12.6 Boom Extend Interlock Sensor (10054 only)

Covers the removal and installation of the boom extend interlock sensor specific to Model 10054.

9.12.7 Outrigger Pressure Switches (10054 Only)

Explains the testing, removal, and installation of outrigger pressure switches for Model 10054.

9.13 Display Monitor

Covers the removal and installation of the display monitor and its components.

9.14 Dash Switches

Details the removal, disassembly, inspection, replacement, and installation of dash switches.

9.15 Machine Data

Explains how to access machine and engine data using diagnostic tools.

9.16 Analyzer Software Accessibility

Describes access levels for the analyzer software and its diagnostic functions.

9.17 Telematics Gateway

Lists the data points available through the telematics gateway device.

9.18 Troubleshooting

Provides guidance on fault detection and offboard diagnostics.

9.19 Machine Fault Codes

Lists fault codes related to various machine systems, including engine, battery, and communications.

9.20 Engine Fault Codes

Lists engine fault codes, their SPN, FMI, and description for troubleshooting.

Section 4 Cab and Covers

4.1 Operator Cab and Covers Component Terminology

Identifies major assemblies of the machine cab and covers for understanding.

4.2 Operator Cab

Covers cab safety and the location and purpose of the serial number decal.

4.3 Cab Components

Details various components within the operator's cab, including steering wheel, pedals, and controls.

4.3.1 Steering Wheel

Provides procedures for removing and installing the steering wheel.

4.3.2 Steering Column and Steering Valve

Covers removal, installation, and testing of the steering column and valve.

4.3.3 Service Brake Pedal

Details the removal and installation procedures for the service brake pedal.

4.3.4 Throttle Pedal

Outlines the removal and installation procedures for the throttle pedal.

4.3.5 Joystick Assembly

Provides instructions for removing and installing the hydraulic joystick assembly.

4.3.6 Auxiliary/Frame Level Lever Assemblies

Covers the removal, installation, and testing of auxiliary and frame level lever assemblies.

4.3.7 Windshield Wiper Assembly

References Section 9.10 for removal and installation of the windshield wiper motor.

4.3.8 Heater System (if equipped)

Details the removal and installation of the cab heater assembly.

4.3.9 Heater and A/C System (if equipped)

Covers the removal and installation of the heater and A/C system components.

4.4 Cab Removal

Provides step-by-step instructions for removing the machine cab, including safety precautions.

4.5 Cab Installation

Details the procedures for installing the cab onto the machine frame, including alignment and connections.

Section 5 Axles, Drive Shafts, Wheels and Tires

5.1 Axle, Drive Shaft and Wheel Component Terminology

Identifies and defines components related to axles, drive shafts, wheels, and tires.

5.2 General Information

Provides general information on drive shaft assemblies, cleaning, and servicing of axles and drive shafts.

5.3 Axle Assemblies

Covers axle serial number plates, specifications, internal service, maintenance, and replacement procedures.

5.4 Axle Assembly and Drive Shaft Troubleshooting

Lists common problems with axle assemblies and drive shafts, along with their causes and remedies.

5.5 Drive Shafts

Details drive shaft inspection, maintenance, removal, and installation procedures.

5.6 Wheels and Tires

Provides guidelines for selecting replacement tires and procedures for removing and installing wheel and tire assemblies.

5.7 Brakes

Covers brake disc inspection and troubleshooting related to brake engagement and holding power.

5.8 Towing a Disabled Machine

Provides instructions and precautions for towing a disabled machine.

Section 6 Transmission

6.1 Transmission Assembly Component Terminology

Identifies major components of the transmission assembly.

6.2 Transmission Serial Number

Specifies the location of the transmission serial number plate.

6.3 Transmission Specifications and Maintenance Information

Refers to Section 2 for transmission specifications, oil, and maintenance information.

6.4 Transmission Replacement

Provides detailed procedures for transmission removal, inspection, internal repair, and installation.

6.5 Transmission Troubleshooting

Lists common transmission problems, their causes, and recommended remedies.

Section 7 Engine

7.1 Introduction

Provides a disclaimer and scope for the engine section, including guidelines for worldwide use and referencing Cummins manuals.

7.2 Engine Serial Number

States the location of the engine serial number for correspondence.

7.3 Specifications and Maintenance Information

Refers to Section 2 for engine, coolant, and oil specifications, and maintenance information.

7.4 Engine Cooling System

Covers coolant system pressure cap, thermostat replacement, and radiator/oil cooler removal/installation.

7.5 Engine Electrical System

References Section 9 for engine electrical system details, including starter and primary wiring.

7.6 Fuel System

Covers diesel fuel, fuel/hydraulic oil tank removal/installation, and DEF system components and maintenance.

7.7 Engine Exhaust System

Details procedures for removing and installing the exhaust system for different engine configurations.

7.8 Air Cleaner Assembly

Provides instructions for removing and installing the air cleaner assembly.

7.9 Engine Replacement

Outlines the procedures for engine removal and installation, including necessary tools and safety precautions.

7.10 Isolation Coupler

Details the removal and installation procedures for the isolation coupler.

Section 8 Hydraulic Section

8.1 Hydraulic Component Terminology

Identifies and defines hydraulic components referred to in the section.

8.2 Safety Information

Provides critical safety precautions for working with hydraulic systems, including fluid hazards and contamination.

8.3 Specifications

Refers to Section 2.2 for hydraulic system specifications.

8.4 Hydraulic Circuits

Covers hydraulic circuits, function pressures, and checking procedures, emphasizing electrical and hydraulic interrelationships.

8.5 Hydraulic Pressure Diagnosis

Outlines general steps for conducting pressure checks and performing adjustments on the hydraulic system.

8.6 Hydraulic Reservoir

Details procedures for hydraulic oil reservoir draining, filling, filter replacement, and replacement.

8.7 Hydraulic System Pump

Refers to internal service instructions from the authorized service distributor for pump replacement.

8.8 Valves and Manifolds

Covers the main control valve, service brake valve, steering orbitrol valve, steer select valve, secondary function manifold, and outrigger valve.

8.9 Hydraulic Cylinders

Provides general instructions, pressure checking, and torque specifications for hydraulic cylinders.

Section 10 Stabil-TRAK™ System and Boom Interlock System

10.1 Stabil-TRAK™ System Component Terminology

Identifies major assemblies of the Stabil-TRAK system for understanding the section.

10.2 Boom Extend Interlock System Component Terminology (10054 Only)

Identifies components of the boom extend interlock system specifically for Model 10054.

10.3 Stabil-TRAK™ Description

Explains the patented rear axle lock or Stabil-TRAK system and its operating modes.

10.4 Stabil-TRAK™ Operation

Describes the machine's operation in Free Pivot, Slow Pivot, and Locked modes, including conditions and effects.

10.5 Boom Extend Interlock System Description

Describes the purpose and function of the boom extend interlock system on Model 10054.

10.6 Boom Extend Interlock System Operation (10054 Only)

Details the Extend Interlock Mode and Outrigger Interlock Mode operations for Model 10054.

10.7 Stabil-TRAK™ System Test

Provides instructions for testing the Stabil-TRAK system's function and proper operation.

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

Covers electrical circuit operation and troubleshooting for the Stabil-TRAK system on specific models.

10.9 Stabil-TRAK™ and Boom Interlock Electrical Circuit Operation and Troubleshooting (10054)

Details electrical circuit operation and troubleshooting for Stabil-TRAK and boom interlock systems on Model 10054.

10.10 Boom/Outrigger Interlock System Test

Outlines the procedures for testing the boom/outrigger interlock system.

10.11 Stabil-TRAK™ Hydraulic Circuit Operation and Troubleshooting

Describes the hydraulic circuit operation and troubleshooting for various Stabil-TRAK modes and conditions.

10.12 Boom Extend System Hydraulic Circuit Operation and Troubleshooting

Details the hydraulic circuit operation and troubleshooting for the boom extend interlock system.

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