Skytrak 6042 Service Manual manuals

Skytrak 6042 Service Manual User Manual (544 pages)

Brand: Skytrak | Category: Special machinery | Size: 32.56 MB |

English

Table of contents

SECTION CONTENTS

3

Section Subject Page

4

Section 1

7

1.1 INTRODUCTION

8

1.2 OWNERS/OPERATORS MANUAL

8

1.3 TRAINING MECHANICS AS

9

OPERATORS

9

1.4 SAFETY INFORMATION

9

DANGER:

10

WARNING:

10

CAUTION:

10

1.6 SAFETY INSTRUCTIONS

11

Safety Practices

12

1.6.3 General Hazards

12

1.6.4 Operational Hazards

12

1.8 HAZARD/EMERGENCY

13

INFORMATION DECALS

13

Domestic: 1-888-872-5123

13

International: 1-262-268-8958

13

Section 2

15

2.2 INTRODUCTION

18

2.2.4 Disclaimer

19

2.3 TORQUES

20

to the torque

23

2.4 METRIC CONVERSION FACTORS

26

2.4.2 Approximate Metric to

27

American Conversions

27

2.5 SPECIFICATIONS

28

MA10,0670

29

2.5.2 Vehicle Weights

30

2.5.3 Attachment Weights

31

2.5.6 Electrical System

33

2.5.9 Hydraulic System

36

2.5.10 Tires

36

2.6 FLUIDS, LUBRICANTS AND

37

CAPACITIES

37

2.6.2 Axle Wheel Ends

38

2.6.3 Transmission

38

2.6.5 Hydraulic System

39

2.6.6 Engine

39

2.6.7 Drive Shaft Splines

40

2.6.8 General Anti-Corrosion

40

2.6.9 Electrical

40

2.7 CLEANING

41

2.8 REPLACEMENT

42

2.9 HOSES AND TUBES

42

2.10 BEARINGS

42

2.11 PRESSURE TESTING AND

43

ADJUSTMENT

43

2.12.8 After Engine Service

45

2.12.9 After Boom Service

45

2.12.10 After Axle Service

45

Section 3

47

3.1 BOOM SYSTEM COMPONENT

48

3.2 BOOM SYSTEM

49

3.3 BOOM ASSEMBLY MAINTENANCE

49

3.3.1 Inner Boom Removal

50

Figure 3-12 Retract Chain

53

End Pin Removal

54

Save the

55

Right Side Wear Pads

56

3.3.3 Outer Boom Removal

61

Figure 3-41 Boom Sensor

64

Figure 3-45 Rubber Bumper

65

Figure 3-47 Angle Indicator

66

3.3.4 Outer Boom Installation

67

Cylinder Bearings

68

Figure 3-54 Rubber Bumper

69

Tube Assemblies

72

Attachment Tilt Tube Clamps

73

of the

74

Figure 3-70 Side Wear Pads

77

3.3.6 Inner Boom Installation

81

Clamps Inside Inner Boom

82

Figure 3-82 Extend Chains

84

Hydraulic Hoses

86

Hydraulic Hoses and Tubes

87

Figure 3-88 Retract Chain

87

Figure 3-92 Quick Attach

89

3.4 BOOM CHAINS

92

3.4.2 Chain Lubrication

100

Model 6042 Legacy Origin 7/02

101

Removal and Replacement

104

3.5 BOOM WEAR PADS

111

3.6 QUICK ATTACH ASSEMBLY

114

3.6.3 Quick Attach Removal

115

Figure 3-155 Quick Attach

116

3.7 TROUBLESHOOTING

117

Problem Cause Remedy

117

Section 4

121

Cab and Covers

121

COMPONENT TERMINOLOGY

122

4.2 OPERATOR’S CAB

123

4.3 OPEN CAB COMPONENTS

124

4.3.4 Brake Pedal and Valve

130

Assembly Replacement

136

4.3.9 Electrical Components

138

4.4 ENCLOSED CAB (OPTIONAL)

140

COMPONENTS

140

4.4.5 Door and Latches

144

4.4.6 Windows

145

4.5 CAB REMOVAL

146

4.6 CAB INSTALLATION

149

4.7 ACCESS PANELS AND COVERS

152

Section 5

153

5.2 GENERAL INFORMATION

155

5.3 AXLE ASSEMBLIES

155

5.3.4 Axle Specifications

156

5.3.5 Axle Maintenance

156

5.3.6 Axle Replacement

157

Troubleshooting

166

5.4 DRIVE SHAFTS

167

5.4.2 Drive Shaft Maintenance

168

5.4.3 Drive Shaft Removal

168

5.4.4 Drive Shaft Disassembly

169

5.4.6 Drive Shaft Assembly

171

5.5 WHEELS AND TIRES

173

WARNING: Damaged, modified

175

Section 6

179

Transmission: ZF 4 WG-98 TC

179

6.1 TRANSMISSION ASSEMBLY

180

6.2 TRANSMISSION DESCRIPTION

181

6.3 TRANSMISSION OPERATION

181

6.6 TRANSMISSION MAINTENANCE

182

6.7 TRANSMISSION REPLACEMENT

184

6.8 TOWING A DISABLED VEHICLE

191

6.9 TROUBLESHOOTING

192

Section 7

195

Engine: Cummins 4BT3.9

195

7.1 INTRODUCTION

196

7.2 SAFETY INFORMATION

198

7.3 ENGINE SERIAL NUMBER

200

7.4 SPECIFICATIONS AND

200

MAINTENANCE INFORMATION

200

7.5 STANDARD PRACTICES

200

7.6 ENGINE COOLING SYSTEM

201

Heater Replacement

204

7.7 ENGINE ELECTRICAL SYSTEM

208

7.8 FUEL SYSTEM

209

7.8.1 Diesel Fuel

210

7.9 ENGINE EXHAUST SYSTEM

217

7.10 AIR CLEANER ASSEMBLY

218

7.11 ENGINE REPLACEMENT

219

Back-up Alarm Location

220

7.11.3 Engine Installation

224

Wires to the Starter

228

7.12 ENGINE STORAGE

231

7.13 TROUBLESHOOTING

232

Section 8

233

Hydraulic System

233

8.1 HYDRAULIC COMPONENT

235

TERMINOLOGY

235

8.2 SAFETY INFORMATION

236

8.3 SPECIFICATIONS

237

8.4 HYDRAULIC FLUID

237

Replacement

238

8.7 HYDRAULIC SYSTEM TESTING

242

8.8 HYDRAULIC CIRCUITS AND

245

TROUBLESHOOTING

245

Load Sense

252

Pressure

252

3. Air in the lines

257

Description

284

PROCEDURE

290

8.10 HYDRAULIC RESERVOIR

292

8.11 HYDRAULIC SYSTEM PUMP

293

8.11.2 Pump Replacement

294

1/4 INCH

294

8.12 VALVES AND MANIFOLDS

300

8.12.2 Main Control Valve

302

8.12.4 Service Brake Valve

319

8.12.5 Shuttle Valve

323

8.12.6 Power Steering Valve

324

8.12.7 Steer Select Valve

326

8.13 HYDRAULIC CYLINDERS

330

8.13.5 Slave Cylinders

335

8.13.7 Lift/Lower Cylinder

344

8.13.8 Frame Sway Cylinder

348

8.13.9 Stabilizer Cylinder

353

8.13.12 Steering Cylinders

370

Section 9

371

Electrical System

371

9.2 SERVICE WARNINGS

376

9.3 SPECIFICATIONS

376

9.5 WIRING HARNESSES

377

9.5.3 Cleaning and Drying

378

9.5.4 Inspection and Repair

378

9.5.5 Installation

378

9.5.6 Wire Code and Color

378

9.7 ELECTRICAL SYSTEM

381

IGNITION

393

CONSOLE/STABILIZER

395

(See page 9.20)

395

Figure 9-16 Charging Circuit

400

SOLENOID COIL

402

Figure 9-23 Heater Circuit

414

Not OKIf OK

448

9.10 ENGINE START CIRCUIT

450

9.11 CHARGING CIRCUIT

452

9.11.2 Battery

455

9.12 ELECTRICAL SYSTEM

459

9.12.2 Back-up Alarm

460

9.12.3 Instrument Cluster

461

9.13.2 Windshield Wiper Motor

466

9.13.3 Roof Wiper Switch

468

9.13.4 Roof Wiper Motor

469

9.14.1 Cab Heater Controls

472

9.15 SWITCHES AND SOLENOIDS

474

9.15.2 Fuel Shut-off Solenoid

477

9.15.4 Park Brake Switch

480

9.15.7 Steering

490

9.15.8 Steer Select Switches

492

9.15.9 Steer Select Valve

493

9.15.13 Engine Block Heater

497

Fuel Level Sender

500

9.15.15 Hourmeter

502

9.15.17 Service Brake Switch

504

Section 10

507

Stabil-TRAK™ System

507

10.1 STABIL-TRAK™ SYSTEM

508

10.2 STABIL-TRAK™ DESCRIPTION

509

10.3 STABIL-TRAK™ OPERATION

510

Stabil-TRAK™ System

511

10.3.3 Relay Testing

513

Ignition “ON”

515

PB & SB Released

515

Boom Below 40°

515

Transmission in Fwd. or Rev

515

Boom Retracted

515

Boom Above 40°

516

Boom Extended

516

PB & SB Applied

517

Transmission in Neutral

517

STABIL-TRAK

520

MANIFOLD

520

Locked Mode, Frame Sway Right

528

Locked Mode, Frame Sway Left

530

10.6 STABIL-TRAK™ SYSTEM TEST

533

Section 11

535

Accident Prevention Tags

541

8990403 Origin 5/00

542

More products and manuals for Special machinery Skytrak

Models	Document Type
8042 Service Manual	User Manual SkyTrak 8042 Service Manual User Manual, 906 pages
6036 Service Manual	User Manual SkyTrak 6036 Service Manual User Manual, 460 pages
10054	User Manual SkyTrak 10054 User Manual, 412 pages
3606 Operation Manual	User Manual SkyTrak 3606 Operation Manual User Manual, 168 pages
3606 Parts Manual	User Manual SkyTrak 3606 Parts Manual User Manual, 238 pages
3606 Service Manual	User Manual SkyTrak 3606 Service Manual User Manual, 412 pages
6036 Service Manual	User Manual SkyTrak 6036 Service Manual User Manual, 280 pages
6036 Parts Manual	User Manual SkyTrak 6036 Parts Manual User Manual, 300 pages
6036 Operation Manual	User Manual SkyTrak 6036 Operation Manual User Manual, 110 pages
10054 Operation Manual	User Manual SkyTrak 10054 Operation Manual User Manual, 170 pages
6036 Service Manual	User Manual SkyTrak 6036 Service Manual User Manual, 342 pages
10054 Operation Manual	User Manual SkyTrak 10054 Operation Manual Manuel d'utilisation, 176 pages
10054 Operation Manual	User Manual SkyTrak 10054 Operation Manual Manual del usuario, 176 pages
8042 Operation Manual	User Manual SkyTrak 8042 Operation Manual User Manual, 190 pages
10042 Operation Manual	User Manual SkyTrak 10042 Operation Manual User Manual, 196 pages
10054 Operation Manual	User Manual SkyTrak 10054 Operation Manual User Manual, 200 pages
10054 Operation Manual	User Manual SkyTrak 10054 Operation Manual User Manual, 208 pages
6036 Operation Manual	User Manual SkyTrak 6036 Operation Manual User Manual, 154 pages
6036 Operation Manual	User Manual SkyTrak 6036 Operation Manual Manual del usuario, 156 pages
6036 Operation Manual	User Manual SkyTrak 6036 Operation Manual User Manual, 180 pages

Skytrak devices

Special machinery