JLG Telehandler 6036 6042 8042 10042 10054 12054 Service Manual 31211953 2025

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JLG Telehandler 6036 6042 8042 10042 10054 12054 Service Manual 31211953 2025
Size: 68.65 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Telehandler
Type of Manual: Service Manual, Electrical and Hydraulic Diagrams
Model: JLG 6036, 6042, 8042, 10042, 10054, 12054 Telehandler
Part Number: 31211953
Publication Date: 2025
Number of Pages: 500 Pages

Contents:
Safety

General​

1.1.1 Disclaimer​

1.1.2 Operation & Safety Manual​

Safety Information​

1.2.1 Safety Alert System and Signal Words​

Safety Hazards (task)​

1.3.1 Personal Hazards​

1.3.2 Equipment Hazards​

1.3.3 General Hazards​

1.3.4 Operational Hazards​

Safety Decals​

Machine Verification​

General Machine Information & Specifications

Specifications​

2.1.1 Travel Speeds​

2.1.2 Hydraulic Cylinder Performance​

2.1.3 Cylinder Drift​

2.1.4 Electrical System​

2.1.5 Engine Performance Specifications​

2.1.6 Tires​

Machine Temperature Chart​

Serial Number Location​

Fluids and Lubrication​

2.4.1 General Information​

2.4.2 Hydraulic Oil​

2.4.3 Changing Hydraulic Oil​

2.4.4 Lubrication Specifications​

2.4.5 Fluids​

2.4.6 Capacities​

2.4.7 Lubrication Schedules​

Maintenance & Inspection Schedules

Machine Preparation, Inspection, and Maintenance​

3.1.1 Preparation, Inspection, and Maintenance​

3.1.2 Pre-Start Inspection​

3.1.3 Pre-Delivery Inspection​

Service and Guidelines​

3.2.1 General​

3.2.2 Safety and Workmanship​

3.2.3 Cleanliness​

3.2.4 Components Removal and Installation​

3.2.5 Component Disassembly and Reassembly​

3.2.6 Pressure-Fit Parts​

3.2.7 Bearings​

3.2.8 Gaskets​

3.2.9 Bolt Usage and Torque Application​

3.2.10 Hydraulic Lines and Electrical Wiring​

3.2.11 Hydraulic System​

3.2.12 Lubrication​

3.2.13 Battery​

3.2.14 Welding on JLG Equipment​

Preventive Maintenance and Inspection Schedule​

3.3.1 Every 10 Hours​

3.3.2 First 50 Hours​

3.3.3 Every 50 Hours​

3.3.4 First 250 Hours​

3.3.5 Every 250 Hours​

3.3.6 First 500 Hours​

3.3.7 Every 500 Hours​

3.3.8 Every 750 Hours​

3.3.9 Every 1000 Hours​

3.3.10 Every 1500 Hours​

3.3.11 Every 2000 Hours or 2 Year​

3.3.12 Every 4000 Hours or 3 Years​

3.3.13 Every 5000 Hours or 4 Years​

Pins and Composite Bearing Repair Guidelines​

3.4.1 Filament Wound Bearings​

Tires and Wheels​

3.5.1 Tire Inflation​

3.5.2 Tire Damage​

Brake Maintenance​

3.6.1 Service Brake Bleeding​

DEF Tank Inspection​

Boom Inspection and Maintenance​

3.8.1 Boom Wear Pads​

Hydraulic Filter Replacement​

Specification and Maintenance Information​

3.10.1 Axle​

3.10.2 Axle Maintenance​

3.10.3 Transmission​

Testing, Calibrations, & Special Procedures

Special Tools​

4.1.1 Multimeter​

4.1.2 Thread Locking Compound​

4.1.3 Tools Catalog​

Testing Procedures​

4.2.1 Starter​

Calibration Procedures​

4.3.1 JLG Analyzer​

Special Procedures​

4.4.1 Towing A Disabled Machine​

4.4.2 Hydraulic Reservoir​

4.4.3 Fuel Tank Cleaning and Drying​

4.4.4 Pressure Checks and Adjustments​

4.4.5 Cylinder Checking Procedure​

4.4.6 Cylinder Drift Test​

4.4.7 Hydraulic Circuits​

4.4.8 Pressure Specifications​

4.4.9 Boom Extend and Retract Chains​

4.4.10 Boom Chain Tension Adjustment (6036, 6042, 8042 & 10042)​

4.4.11 Boom Chain Tension Adjustment (10054 & 12054)​

4.4.12 Extend Chains Removal and Replacement (6036, 6042, 8042 & 10042)​

4.4.13 Retract Chain Removal and Replacement (6036, 6042, 8042 & 10042)​

4.4.14 Extend Chains Removal and Replacement (10054 & 12054)​

4.4.15 Retract Chain Removal and Replacement (10054 & 12054)​

STABIL-TRAK™ and Boom Interlock System​

4.5.1 Stabil-Trak™ System Component Terminology​

4.5.2 Boom Extend Interlock System Component Terminology (10054 & 12054 Only)​

4.5.3 Stabil-Trak™ Description​

4.5.4 Stabil-Trak™ Operation​

4.5.5 Boom Extend Interlock System Description​

4.5.6 Boom Extend Interlock System Operation (10054 & 12054 Only)​

4.5.7 Stabil-Trak™ System Test​

4.5.8 Stabil-Trak™ Electrical Circuit Operation And Troubleshooting (6042/8042/10042)​

4.5.9 Stabil-Trak™ And Boom Interlock Electrical Circuit Operation And Troubleshooting (10054 & 12054)​

4.5.10 Boom/Outrigger Interlock System Test​

4.5.11 Boom Extend System Hydraulic Circuit Operation And Troubleshooting​

4.5.12 Stabil-Trak™ Hydraulic Circuit Operation And Troubleshooting​

System Software

Analyzer​

5.1.1 Machine Data Access​

5.1.2 Hand Held Analyzer​

5.1.3 Mobile Analyzer​

5.1.4 Analyzer Software Version P4.0​

Analyzer Software Accessibility​

5.2.1 Access Level​

5.2.2 Diagnostics​

5.2.3 Machine Set-Up​

5.2.4 Personalities​

5.2.5 Calibrations​

Fault Codes

Introduction​

6.1.1 Gauge Fault Code Display​

6.1.2 Offboard Diagnostics​

Engine Fault Codes​

Machine Fault Codes​

Hydraulics

General Information and Safety​

Theories of Operation​

7.2.1 Cylinders​

7.2.2 Valves​

Hydraulic Component​

Torque Values​

7.4.1 Cylinder Torque Specifications​

Electricals

General Information​

8.1.1 Applying Silicone Dielectric Compound to Electrical Connections​

8.1.2 Dielectric Grease Application​

8.1.3 Electrical Connector Examples​

Electrical Connectors​

Electrical Component Terminology​

Harness Layouts​

Board Layouts​

8.5.1 Engine Compartment Fuse and Relays​

8.5.2 Cab Harness Fuses and Relays​

Telematics Gateway (if equipped)​

8.6.1 Telematics-Ready (TCU) Plug​

8.6.2 Component Locations​

8.6.3 Telematics Gateway Harness Breakdown​

Removal and Installation

Wheels​

9.1.1 Removing Wheel and Tire Assembly from Machine​

9.1.2 Installing Wheel and Tire Assembly onto Machine​

Drive Assembly​

9.2.1 Axle Assembly And Drive Shaft Troubleshooting​

9.2.2 Axle Serial Number​

9.2.3 Axle Replacement (6036 & 6042)​

9.2.4 Axle Replacement (8042, 10042, 10054 & 12054)​

9.2.5 Drive Shafts​

9.2.6 Outrigger Replacement (10042, 10054 & 12054 only)​

9.2.7 Transmission Components​

Boom​

9.3.1 Boom System Component Terminology​

9.3.2 Troubleshooting​

9.3.3 Boom System (6036, 6042, 8042 & 10042)​

9.3.4 Boom System (10054 & 12054)​

9.3.5 Manual Coupler​

9.3.6 Boom Prop (If Equipped)​

9.3.7 Isolation Coupler​

9.3.8 Forks​

9.3.9 Boom Angle Sensor​

9.3.10 Boom Extend Interlock Sensor (10054 & 12054 only)​

Cab​

9.4.1 Serial Number Plate​

9.4.2 Cab Removal/Installation​

9.4.3 Steering Wheel​

9.4.4 Service Brake Switch​

9.4.5 Service Brake Pedal​

9.4.6 Throttle Pedal​

9.4.7 Joystick Assembly​

9.4.8 Ignition Key Switch​

9.4.9 Dash Switches​

9.4.10 Outrigger Pressure Switches (10054 & 12054 Only)​

9.4.11 Windshield Wiper Motor​

9.4.12 Skylight Wiper Motor​

9.4.13 Windshield Washer Reservoir​

9.4.14 Heater System (if equipped)​

9.4.15 Heater and A/C System (if equipped)​

9.4.16 Cab Heater And Fan​

9.4.17 Display Monitor​

9.4.18 Steering Column and Steering Valve​

9.4.19 Auxiliary/Frame Level Lever Assemblies​

Engine​

9.5.1 Component Terminology​

9.5.2 Diesel Fuel​

9.5.3 Engine Serial Number​

9.5.4 Engine Replacement​

9.5.5 Engine Electrical System​

9.5.6 Coolant System Pressure Cap​

9.5.7 Coolant Level Sensor​

9.5.8 Thermostat Replacement​

9.5.9 Radiator/Oil Cooler and Replacement​

9.5.10 Fuel/Hydraulic Oil Tank​

9.5.11 Diesel Exhaust Fluid (DEF) Tank - if equipped with 110 hp (82 kW) ULS engine​

9.5.12 Diesel Exhaust Fluid (DEF) Header - if equipped with 110 hp (82 kW) ULS engine​

9.5.13 Diesel Exhaust Fluid (DEF) Pump Filter - if equipped with 110 hp (82 kW) ULS engine​

9.5.14 Diesel Exhaust Fluid (DEF) System Cleaning - if equipped with 110 hp (82 kW) ULS engine​

9.5.15 Exhaust System - if equipped with 110 hp (82 kW) ULS engine​

9.5.16 Exhaust System - if equipped with 74 hp (55 kW) ULS engine​

9.5.17 Exhaust System - if equipped with 110 hp (82 kW) LS engine​

9.5.18 Air Cleaner Assembly​

9.5.19 Starter​

9.5.20 Alternator​

Transmission​

9.6.1 Transmission Components​

9.6.2 Transmission Serial Number​

9.6.3 Transmission Replacement​

9.6.4 Transmission Temperature Sender​

9.6.5 Reverse Alarm​

9.6.6 Transmission Troubleshooting​

Hydraulic Cylinders​

9.7.1 General Cylinder Instructions​

9.7.2 Steering Cylinders​

Hydraulic Valves​

9.8.1 Main Control Valve​

9.8.2 Service Brake Valve​

9.8.3 Steering Orbital Valve​

9.8.4 Steer Select Valve​

9.8.5 Secondary Function Manifold​

9.8.6 Outrigger Valve (10042, 10054 & 12054 only)​

9.8.7 Extend Lockout Valve (10054 & 12054 only)​

9.8.8 Transmission Solenoid Valves​

Hydraulic Pump​

9.9.1 Hydraulic System Pump​

Electrical Components​

9.10.1 Battery​

Disassembly and Assembly

Drive Assembly​

10.1.1 Axle Assembly​

10.1.2 Transmission Assembly​

Boom​

10.2.1 Boom System - Three Boom Section (6036, 6042, 8042 & 10042)​

10.2.2 Boom System - Four Boom Section (10054 &12054)​

Cab​

Engine Components​

10.4.1 Fuel/Hydraulic Oil Tank​

Transmission​

10.5.1 Piston Pump​

Hydraulic Cylinders​

10.6.1 General Cylinder Disassembly​

10.6.2 Cylinder Cleaning Instructions​

10.6.3 Cylinder Inspection​

10.6.4 Cylinder Assembly Instructions​

10.6.5 Hydraulic Cylinder Repair Information​

Hydraulic Valves​

10.7.1 Main Control Valve​

10.7.2 Secondary Function Manifold​

10.7.3 Steer Select Valve​

10.7.4 Outrigger Valve (10042, 10054 & 12054 only)​

10.7.5 Extend Lockout Valve (10054 & 12054 only)​

Hydraulic Components​

Torque/Connection Information

Hydraulic Fittings​

11.1.1 Definitions​

11.1.2 Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections​

11.1.3 Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections​

11.1.4 Assembly Instructions for 37° (JIC) Flare Fittings​

11.1.5 Assembly Instructions for 45° SAE Flare Fittings​

11.1.6 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings​

11.1.7 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)​

11.1.8 Assembly Instructions for Bulkhead (BH) Fittings​

11.1.9 Assembly Instructions for O-Ring Boss (ORB) Fittings​

11.1.10 Assembly Instructions for Adjustable Port End Metric (MFF) Fittings​

11.1.11 Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends​

11.1.12 Assembly Instructions for Adjustable Port End (BSPP) Fittings​

11.1.13 Assembly Instructions for Flange Connections (FL61 and FL62)​

11.1.14 Double Wrench Method​

11.1.15 FFWR and TFFT Methods​

11.1.16 Adjustable Stud End Assembly​

11.1.17 O-ring Installation (Replacement)​

Torque Charts​

11.2.1 SAE​

11.2.2 Metric​

Schematics

Hydraulic Schematics​

Electrical Schematics​

12.2.1 Electrical Schematic — T4F HRC​

12.2.2 Electrical Schematic — T4F LRC​

12.2.3 Electrical Schematic — T4F 55KW​