Oshkosh Corporation JLG SkyTrak 10054 User manual

1
31200548
General Guidelines
•This repair procedure provides parts and repair
information for a specific discrepancy. It is the
responsibility of the entity performing the repairs to
determine if the discrepancy can be corrected by this
procedure.
Weld Repair Guidelines
•All welding must be in accordance with ANSI/AWS
D1.1 Standard.
•Disconnect the battery of the machine being repaired
prior to welding.
•Ground only to the component being welded. Do not
ground to any adjacent component or allow pins,
wear pads, wire ropes, bearings, gears, seals,
valves, electrical wiring, or hoses to be between the
grounding position and the area to be welded.
Tools & Equipment Required
1. Stands and lifting equipment capable of lifting/
supporting the affected components
2. Hand-held power grinder
3. Air carbon-arc equipment
4. Electric welding equipment
5. AWS 70 grade, low hydrogen rod or wire
6. Standard welder tools
7. Standard mechanic tools
8. Paint
Personnel Required
1. Qualified Equipment Mechanic
2. Certified Welder
Pivot Repair Kit:
Left Side P/N 7131633
Right Side P/N 7131643
Detailed parts list shown on Page 3.
Procedure
1. Remove components as required to facilitate repair.
2. Safely support the components to alleviate pressure
or stresses at affected repair area(s).
3. Using a portable grinder or air carbon-arc equipment,
remove the damaged slave cylinder pivot weldment
from the base boom weldment.
4. Visually inspect the welds and base metal around the
pivot weldment on both sides to ensure there are no
cracks or deformities. If any cracks or deformities
exist, repair as outlined in Step 5 or as recommended
by a certified welder.
5. Repair the cracks:
a. For weld cracks, use air carbon-arc
equipment or a portable power grinder
to remove area(s) of weld
discrepancy. Remove the weld 1 in.
beyond end(s) of weld discrepancy,
tapering to a depth of 0 in.
b. For parent metal cracks, use a
portable power drill to drill a 1/4 in.
hole at the termination point(s) at the
end(s) of each crack. Use a portable
power grinder to grind along the
crack(s) to form a 60°-90° “vee”
groove, 0 in. opening.
c. Prepare the affected areas for
welding. Using the recommended
weld material, weld the discrepancy
area(s) using the appropriate sized
fillet weld. For parent metal cracks,
weld along the crack(s) through the
drilled termination point(s).
CAUTION
Use all applicable Safety precautions while working
on, around or under any machinery.
NOTICE
Reference the Service Manual and Illustrated Parts
Manual for safe and proper disassembly/assembly
procedures.
NOTICE
Failure to comply with the above weld repair guidlines
may result in component damage.
NOTICE
Do not damage the base boom weldment during this
procedure.
SkyTrak 10054, 10042, 8042
Pivot Repair of Base Boom Weldment - Option 1
Installation Instructions
For Kits 7131633 & 7131643
B
8/09
31200548
An Oshkosh Corporation Company

2 31200548
SkyTrak 10054, 10042, 8042 Pivot Repair of Base Boom Weldment - Option For Kits 7131633 & 7131643
d. Inspect welds using the magnetic particle or dye-
penetrant inspection methods to assure there are
no cracks or deformities. If any cracks or
deformities exist, grind to remove affected area(s)
and repeat the weld and inspection procedures.
6. Dress the repair area in preparation for installing a
new pivot weldment.
7. Install the new pivot weldments. Refer to pages 3 & 4
of the Boom Pivot Replacement Kit illustrations.
8. Inspect welds using the magnetic or dye-penetrant
inspection methods to assure there are no cracks or
deformities. If any cracks or deformities exist, grind to
remove affected area(s) and repeat the weld and
inspection procedures
9. Clean, prime and paint the affected area(s).
10. Replace all damaged slave cylinder and pivot pin
components and attachment hardware.
11. Reassemble all components and prepare the
machine for operation.
12. Check hydraulic pressures per the Service Manual.
Properly set all hydraulic relief pressures found to be
out of spec.
13. Cycle the lift and telescope functions a minimum of
five times before returning the machine to service.
14. Inspect the repair areas for discrepancies. All
discrepancies must be properly corrected before
returning the machine to service.

3
31200548
SkyTrak 10054, 10042, 8042 Pivot Repair of Base Boom Weldment - Option For Kits 7131633 & 7131643
WAP0011

4 31200548
SkyTrak 10054, 10042, 8042 Pivot Repair of Base Boom Weldment - Option For Kits 7131633 & 7131643
WAP0021